Modium voltage products 1, Your safety first ~ at all times! 2, Summary 2.4 Introduction 2.2 General 2,3 Standards and specifications 2.4 Operating conditions. 3, Technical data 3.1 Electrical data 3.2 Resistance to internal arc faults 3.4 Dimensions and weights: 4. Panel design and equipment 4.1 Basic structure and variants 4,2 Enclosure and partitioning. 4.3 Compartments in the panels 4.4 Interlockiprotection against incorrect operation 4.5 Plug connector coding 4.6 th Limiters 5. Dispatch and storage 5.1 Condition on delivery 5.2 Packing 3 Transport 4 Delivery 6.5 Intermediate storage. 5,6 Handling 6. Assembly of the switchgear at site 6.1 General 6.2 Foundations. 6.3 Assembly of the switchgear panels 6.4 Procedure for setting-up the doors 6.5 Installation of tne bushing 6.6 Fixing of the panels 6,7 Installation of the busbars, 6.8 Installation of the top-mounted boxes 6.9 Pressure relief ducts 6.10 Cable connection 6.11 Earthing the switchgear, 6.12 Installation of interconnecting bundles 6.18 Final erection work 7. Operation of the switehgear 7.1 Switching operations 7.2 Test procedure 4 7.3 Service trucks 8, Commissioning 8.1 Preparatory work 8.2 Measurements and teste 8. Maintenance 9.1 Maintenance strategies 9.2 Preventive maintenance 9.3 Inspection 9.4 Servicing 9.5 Repairs 9.8 Risk-Based maintenance 9.7 Spare parts, auxillary materials and lubricants. 9.8 Operating accessories 10, Product quality and environmental protection 97 99 2199 100 101 101 101 102 108 108 109 109 110 an1. Your safety first — at all times! That is why our instruction manual begins with the following recommendations: Only install switchgear in closed rooms suitable for electrical equipment. Ensure that installation, operation and maintenance is only carried out by qualified competent electricians. Fully comply with the legally recognized standards (IEC or local), the connection conditions of the local electrical utility and the relevant safety at work regulations. Observe the relevant information in the instruction manual for all actions involving switchgear. A DANGER! Pay special attention to the hazard notes in the Instruction manual marked with this warning symbol. + Make sure that the specified criteria are not exceeded under switchgear operating conditions. + Ensure the Instruction manual is accessible to all personnel involved in installation, operation and maintenance. + The user's personnel must act responsibly in all matters relating to safety at work and correct handling of the switchgear. A WARNING + Always follow the instruction manual and respect the rules of good engineering practice! + Hazardous voltage can cause electrical shocks and burns. + Disconnect power, then earth and shortcirci before proceeding with any ‘work on. this equipment Ay WARNING Using ‘of safety clothes like safety gloves according to EN 388 Blade cut resistance class 5, long sleeved work jacket or safety sleeves, safety shoes is recommended during all activities done with the switchgear. If you have any further questions about this instruction manual, ABB's field service team will be pleased to provide the required information, We reserve all rights to this publication. Misuse, including in particular, duplication and making this, manual - or extracts theraof available to third parties is prohibited, We do not accept any responsibility for the information provided, which is subject to change,2. Summary 2.1 Introduction The instructions in this publication refer to UniGear Z81 medium voltage switchgear with either withdrawable apparatus or switeh-disconnector, For correct use of the apparatus, please read the manual carefully. Thanks to the advanced design of ABB switchgear, UniGear ZS1 is suitable not only for many different applications, but also allows for further technical and construction modifications to suit any installation requirements. Consequently, this manual may not include some specific instructions concerning special apparatus configurations. In these cases, it is therefore strongly recommended to consult both this, manual and the latest technical documentation (circuit ané wiring diagrams, foundation plans and any protection selectivity siudies) 2.2 General UniGear $1 is three-phase, metal-enclosed, air- insulated, LSC-2B switchgear and all the panels are factory-assembled, type-tested and suitable for indoor applications up to 24 kV. The panels are designed as, withdrawable modules and are fitted with a single busbar system. The withdrawable parts are equipped with circuit-breakers and contactors. Details of the technical design and configuration of individual switchgear, such as the technical data, detailed equipment lists for the individual panels and comprehensive circuit documentation etc., can be found in the relevant order documents 2.3 Standards and specifications UniGear switchgear panels comply with the standards and specifications for factory-assembled, metal- enclosed and type tested high voltage switchgear to IEC publications 62271-200 (2011) and 62271-1 (2007). In addition, in accordance with IEC 80529, the switchgear panels have the following degrees of protection: IP 4X for the enclosure and IP 2X for the partitions. All other corresponding IEC publications, national or local safety at work regulations and safety regulations for production materials must be followed during erection and operation of these systems. Above and beyond this, the order-related data from ABB must be taken into account, 2.4 Operating conditions 2.4.1. Normal operating conditions The ‘switchgear is basically suitable for normal operating conditions for indoor switchgear in accordance with IEC 62271-200. Among other considerations, the following lim ting values apply: Ambient temperature: Maximum Tae Maximum 24h average T35e Minimum {according to "Alnus 5 daor Sassy =5°e Ambient humidity: Maximum 24 n average of relative hamielty ORE, Maximum 24 h average of walor vapour pressure | 2.2 KPa Maximum monhtly average of relative humisity 30% RE Maximum monhtly average of water vapour pressure | 1.8 KPa The normal operational altitude is up to 1000 m above sea level. The indoor ambient conditions are free of significant pollution, such as dust, smoke, corrosive and/or flammable gases, vapors or salt, etc.2.4.2. Special operating conditions The switchgear is suitable for operation in the WDa type of climate according to IEC 60721-2-1. Special operating conditions must be discussed with ABB in advance, For example: + Atsite altitudes above 1000 m, the effects of the reduction in dielectric strength of the air on the insulation level must be taken into account (Figura A. + Increased ambient temperatures must be compensated in the design of the busbars and branch conductors, otherwise the current carrying capacity will be limited Note on special climatic operating conditions: When switchgear is operated in areas with high humidity and/ or major rapid temperature fluctuations, there is a risk of dow deposits which must be excluded under normal operating conditions for indoor switchgear. Preventive action (e.g. suitable ventilation and proper air conditioning of the building or housing, use of dehumidifying equipment, etc.) must be taken into consideration with ABB to avoid this condensation phenomenon and any resulting corrosion or other adverse effects. Figure 1: Curve for detarmining the altitude factor k in falation to the altitude H,3. Technical data 3.1 Electrical data Main parameters for panels with cireult breakers Rated voliaga: TE TZ Te ZT Raled power (roquoncy withstand vollage! TRV 4 mind 287 30 50 Rated lightning impulse withstand vollage Tv} 7S 35 135 Rated frequency 7 50/60 | 80/60 | 801 60 Main busbar rated curren! AL 78000 | 4000 3750 Circuit-breaker raled currant Al 4000 4000 3160 Peak current TkAT 2125 125 28 Tnternal are wihatand current TATE) 50 50 35 Rated short time withstand current [KAS 8} 50 50 315 (2) a2 ev (GBIDL) ° Main parameters for UniGear 17.5 kV with VD4G UniGear 251 wih] UniGear 251 wih | UniGear 257 wih Vo4G-25 VosG-40 'Vo4G-50 Rated vokage Te 17.5 Maximum service vollage tev 5 Test vollage (50/60 He) Tv 4 mia 38 Tmpulse withstand voltage Tv 96 Rated frequency eal 50760 Rated shori-time withstand current [KAS a] a 0 30 ‘Symmoirical short-cireult eurront ethane as (al 16 25 50 ‘Symeeirical short-circuit current 7 a 7 Isog Class G2 [kal 6 25 x Peak withstand current Teal Bae Tis ia Tnernal are withetand current TAT 25 40 30) Rated current af the main busbare Tal 4000 4000 4000 Feeders rated current with natural tay 4250 2000 ventilation 3180 3150 eedare ated current wih Toroed mw ao00 000 GnsGear 25] panel wih VOAG crcur-breaker can be coupled wih Randard Main parameters for panels with switch-disconnector NALF Rated voliage: TT 7212 ad 2 Rated power Fewuoncy wi aay 4 min me ce 30 ales Tantaing puss winwiane mv 7s 7. we Rated frequency Tal 50760 30760 30760 Rated current of busbare Al 4000 4000 3750 Rated current of branches AL 630 330 530 Rated breaking current of awileh= 5 disconnector (power factor = 0.7) AL 520 30 520 Rated short time wihstand currant of switch-disconnector 1s {kal 28 28 28 Rated short circuit making Curent Tear a co 3 Rated peak withstand current tral 52.5 32.5 53 ‘Auxillary voltage DC VBA Tae TiO aa [BAT ae OT ae | AT AB TIO RO ‘Auxiliary voltage AC vr 1107 230, 1101230 1707 230,Main parameters for panels with vacuum contactor vsc7iP. vsct2ie Rated voltage: wT Tz 72 Rated insulation vollage ie Tz, 7 Raled power (requeney wihatand vollage Te 1 mind 20% 2a°7 Rated lightning impulse withstand vallage eV] 80 78 Raed trequency Fal 507 6 307 60 Rated short time winetand current” eA] 50) 3 Peak current eA) 215 125 Tnternal are winstane eurrent™™ TAT 31 50) 30) Maximum rated current of the contactor Al 400 00 Hy Limes by the fuser, {2) The interval are withstand values are guaranteed inthe compartments on the supply side ofthe fuses (busbars and apparatus) by the (3) VSC7IPG for 32 #v power Wequency withstand vellage and VSCI2I°G for 42 KV power tea 3.2 Resistance to internal arc faults The fault withstand capacity Is as follows: + 12kV-50KA1S 17.5kV-50kKA1S 24 kV 31.5 kA 18 The switchgear panels have been tested according to IEC 62271-200 standard (Annex A, accessibility type A, IAC classification FLR) and also to PEHLA recommendation no. 4. In individual cases, depending fon the configuration of the switchgear panels and/or the switchroom conditions (e.g. low ceiling height), additional measures may be necessary to ensure compliance with criterion 53.3 Dimensions and weights Dimensions of 12 / 17.5 kV panels Dimension Til Teight a 2200 1 2595) Width: = Feeder pandls up 1 1250 AL S315 KA oso = Feeder panels up to 1250 A (= 31.5 KA) 8 ao = Feeder panels 7600 - 7000 A B00" = Feeder panels above 2000 A 7000 Dept 1 =p to 25008, 315 KA 340 TaIS0 AAO KA ot 7385, = 400A 0-KA 1390) = 3150.80 KA 7390 = 4000 A 50-kA 1455) a 2400 Height of the basic part of panel 2 7100 (2) 1000 mm on request (0) Deeper unite are available on request Dimensions of 24 kV panels (4) Fascers equipped with the VSC contactor ars 650 rim wies up to the 80 kA shortime currant ane vp to 12 Dimension Taal Feight 2506 1 27a wit: a = Feeder pancla up to 12508 B00 = Feeder panels above 1250 0 7008 Depth Too" 3 2200 eight of the basic part of panel 2 aa THT Fargnt of Wa Tow vollage compartment @ 7051 TOT A (2) 1000 mm on request Weight of the pane! including withdrawable clrcult-breaker part Rated current ARIAT) TOR e1290 A 300 = 850 ke 7000 = 1050 ke TaD A. 350 - 900 Kg 7200 kg) 2000.0 (850-900 kg 7200 kg) 2500.8 7200 ka 71200 kg) TiSDA, 7200-kg 7300 ka, 4000.8 7400 ka x Dimensions of panel with the switch-disconnector Dimension | 121 47.5 kV 2a KV Height mm a Ba007 25957 | B75 1 27207 Width ~ Oulgoing and ineering aanalas—immi 3 300 7000 Depth nl ¢ 7340) Too o 2400 2200 Height of the basic part of panel mm) : Ta38 fe20 (1) Haight of law vole (2) 1660 mm depth version avaliable on request (2) 430 A (max, currant of suiten-siaconnacter panel linited By coordinated fuses)< n - Le OBE 7 Figure 2: Dimensions of UniGear 251 panel4. Panel design and equipment 4.1 Basic structure and variants The basis for the UniGear panel is the incoming / outgoing feeder panel with SF6 or vacuum circuit- breaker using insertion technology. It is divided into busbar compartment |., circuit breaker compartment IL, cable compartment II and low voltage compartment IV. for the secondary equipment. Apart from this, there are variants for all operating needs For busbar sectionalising, two panels are necessary. the coupling panel with the withdrawable circuit breaker part and a bus riser panel (optional with busbar metering and earthing). In equipment without busbar sectionalising, a direct bar connection between the busbars will be established. The UniGear switchgear also includes the variant of incoming / outgoing panel with the NALF switch- disconnector with the stationary mounting of the switch-disconnector. The panel is divided into busbar compartment A, switch-disconnector compartment including cables’ 8 and low voltage compartment for the secondary equipment D. Further details about installation and switchgear equipment can be obtained from the relevant order documents. 4.2 Enclosure and partitioning The enclosure and internal partitions of the panels are of 2 mm thick high quality galvanized steel sheets. The three high voltage compartments (busbar compartment, circuit-breaker compartment and cable connection compartment) are equipped with top mounted and secured pressure relief flaps. These open in the case of overpressure due to an internal arc fault. The front of the panel is closed off by pressure resistant doors which open to an angle of ie Cable and circuit-breaker compartments have their own doors, both compartments can be equipped with inspection’ windows made of security glass. Neighbouring panels are partitioned from one another by the side walls of each panel and, as a resull of the design, the air cushion remains between these walls when the panels are jointed together. The enclosure is completed on the roof by top- mounted pressure relief flaps which, according to the rated branch conductor current, are made of sheet steel or expanded metal and at the base by means of floor-covering 18 (Fiaure 3}, made of Al sheet, The pressure-relief flaps are secured with steel screws on one longitudinal side and on the other longitudinal sige with plastic screws. In the case of internal overpressure, the plastic screws are the rupture point Arc fault current limitation can be achieved by undelayed circuitbreaker release, carried out by auxiliary switches operated by the pressure wave. The switchgear can be equipped with Ith limiter: the auxiliary switches (Figure 28) are operated by the pressure relief flaps. The necessary safety measures to counteract the effects of an internal arc fault must be ensured in relation to the ceiling height. In individual cases, this may require additional operator protection measures on the switchgear panels. These measures include: 1. Mounting a pressure relief duct 1 (Figure 124) on the top of the switchgear, with further channels leading out of the switchgear room in a form appropriate for the design of the building. The shock wave and are discharge are channelled off in ducts, 2. Mounting a pressure relief duct with blow-out apertures located above the duct at the ends of the switchgear and pointing towards the centre of the switchgear (diverter duct). The shock wave and are discharge then emerge in an extremely attenuated form and in a location which is not critical for the operating personnel The rear wall of the busbar compartment 12. (Figure, 3), intermediate wall 19, mounting plate 13 with shutters 20/24 and horizontal partition 29, form part of the internal partitioning . The internal partitioning makes safe access to the circuit-breaker and cable compartments possible even when the busbars are live, The low voltage compartment for the secondary equipment is completely protected from the high voltage area thanks to its stee!-sheet casing On the end sides, cover plates ensure a good appearance and aré mechanically and thermally arc fault proof should such an event occur in the end panel Doors and cover plates are thoroughly cleaned and treated against corrosion before receiving a high quality double coating of paint. The finishing coat is in the standard RAL 7035 color (special colors by agreement). Stoving completes the procedure and provides considerable resistance to impact and corrosion. The circuit-breaker compartment and cable connection compartment doors are pressure resistant and can either be fitted with screws or manual closing systems (central handle).Ventilation of the panels Openings in the outer enclosure are needed for ventilation in the case of certain rated currents in the busbars and branch bars. For incoming air to the circuit-breaker compartment, the horizontal partition is provided with air-vents 28 IP4x degree of protection and safety in the case of any release of hot gas due to an arc fault is provided Instruction for switching of cooling fans Incomer, 12 / 17.5 kV, 3600 A by flap 27 in the horizontal partition 29. For outgoing air, the pressure relief flaps 8 incorporate vents which provide the IP4X degree of protection (Figure 3), In cases of higher ambient temperature (> 40 °C) it is necessary to apply derating of rated current. It is necessary to use forced fan ventilation in 3600 A and 4000 A panels for 12 / 17.5 kV rated vollage and in 3150 A panels for 24 kV rated voltage. Current {ambient ] Current (ambient | Current {amblont | Current ambient [FANT FANE lomporature max. | temperature max, | temperature max. | tomperature max. | circuit | Current Note soc) ‘asrc) 50°C) 55°C) Breaker | transformers = 3200 A = 30708 = 2040.8 = 28008 No - as = 3200 A 230708 2 29408 = 2600 A Yee - Sree Incomer, 12/ 47.5 RV, 4000 A Current (ambient | Current ambient | Current ambient] Current ambient [FANT FANE temperature max, | temperature mox, | temperature max, | temperature mex. | creat [current Nate 20°C) 25°C) 50°C) 55°C), Sreaker_| transtormers = 2200 A =3070 8 = 29808 = 2800 No No em ans Bath fans > 9200 = 2070 220404 > 2800 A ves Yes start operation Incomer, 24 KV, 2500 A Current {ambient ] Current (ambient | Current (ambient | Gurren: ambient [FANT FANE temperature mex | temperature mex. | temperature max. | temperature max- | —circat [Current Nove 43°C) 50 55°C), Breaker | wanstormors 020 920 ‘ee starts Incomer, 26 KV. 3150 A Current {ambient | Current (ambien? | Current {ambient | Gurrent ambient [FANT FANE temperature mar, | temperature mex, | temperature max, | temperature mex, [—circat |Current Note s0°c) as'c) 50°C) 56°C) Sroaker_| wanstormers = 2700 A = 2580 A = 2400 A = 2360 No - fan 00 580 80 360 weeaes 22700 = 2590 A 224808 27360 ves - {ar startsir = Tr Figure 3: UniGear feeder panel 17.5 kV, 34.5 kA. Buspar compartment Circult-breaker compartment Gable compartment Low valtage compartment coer Spindle mechanism Spigot on spindle Hole in spindle for insertion lever vi ing mechanism thing switen Slice Pressure relief flap Enclosure Branch conductor Busbar Partition °: 10 Mounting plate Isolating bushing Earthing switch Current vansfarmer Voltage transformer Floor cover ~ split Partition = removable Top shutter Control wiring plug connector Control witing duct Lower shutter Ventilation grid Back fl Horizontal partition, removable Control Cabl Main earthing bar2 : i} 40 ” 19 rs | 2 2 : ] 3 a ! ls ; : | 2 i 25 + Pili: ad 7 27 Figure 4: UniGear Digital panel (voltage matering in cable compartment). A Busbar compartment 12 Mounting plate. 8 feult-breaker compartment 13, Isolating Bushing © Gable compartment 14 Earthing switen D Low voltage compartment 15 Voltage sensor in cable compartment 18 Floor cover ~ split Spincte mechanism 17 Partition = removable Spigot on spindle 18 Top shutter Hole in spindle for Insertion lever 19 Control 9 plug connector 1 2 3 4 20 Control 5 2 8 22 7 23 3 Enclosure 28 9 Branen conductor 25 10 Busbar 28 1 Partition 2Figure 5: UniGear Digital panel (voltage mot coer 12 Buspar compartment Ciroult-breaker compariment Cable compartment Low valtage compartment Spindie mechanism Spigot on spindle Hole in spindle for insertion tev Earthing switch operating mechanism fling shalt for earthing swtiteh Proseur Enclosure Branch conductor Busbar Partition roliet flap ring In busbar compartment). Mounting plate Isolating bushing Earthing switch Voltage sensor in cable compartment Floor cover ~ split Partition = removable Top shutter wiring plug connector Control witing duct Lower shut Withdrawable part Current sensor Horizontal partition, removable Cable sealing ona Cable clamp. Main earthing bar8 okL Re | I a3 ANS Figure 6: Panel with 12 / 17.5 kV awitch-disconnactor with fuses and earthing switch, Busbar compartment Switch-disconnecto’ and cable compartment Cow voltage compartment Pressure relief tlaps Brancn conductor Bushing Earthing switen Swileh-disconnector Cable clamp Position indicator of switen-aisconnector Operating mechanism of switchsisconnecter Postion indeatar of earthing switch Operating mechanism of earthing switen she 134.3 Compartments in the panels There are six types of electronic instrument transformers for UniGear Digital: + KEVA 17,582x - voltage sensor with ratio 10000:1 + KECA 800104 — current sensor with ratio 150mV@B0A + KECA 800165 - current sensor with ratio 150mV@80A (for nominal voltage up to 17,5kV) + KEVA 24B2x ~ voltage sensor with ratio 10000:1 + KECA 80C184 — current sensor with ratio 150mV@s0A + KECA 800216 - current sensor with ratio 150mV@B0A (for nominal voltage 24kV) 4.3.4 Busbar compartment The busbars have a flat cross-section made of copper and are laid in sections from panel to panel. For higher rated currents (3150, 3600 and 4000 A), the busbars have a open D-shaped cross-section. According to the current rating, either single or double configuration is used. They are held in place by the flat branch conductor and, if installed, by busbar bushings (chapter 6.5). No special connection clamps are needed. Busbars and branch conductors for 17.5 and 24 kV are insulated by means of shrink-on sleeves. The bolt connections in the 17,5 and 24 kV busbar system are covered by insulating covers (chapter_6.7). The busbars for 12 kV panels up to 2500 A do nol have shrink-on sleeves. Open D-shaped busbars 3150, 3600 and 4000 A are insulated and the connections are covered By means of bushing plates and busbar bushings chapter 6.5), partitions can be created between panels. These partitions are necessary for higher rated short-time currents, see table below. Ua Te Partitions Every lateral panel; from 12 panels additional partiton in 25s | thomiddlo; trom 2" panels one ‘adeitional partition in each 1247.5 kV third of the switeng: Every lateral panel and every 31.5 kA third panel FOSOKR Every panel Every lateral panel; from 12 panels additional partiton in 25kA | the middle: from 27 panels one adgitional partition in eacn third of the switehgear zany SEERA Every panel WarinelSeremie All ratings Every panel According to customer requirements, this separation into individual panels by means of busbar bushings and bushing plates (chapter 8,5) can also be provided in switchgear panels where it is not_ technically necessary. Top-mounted boxes with busbar earthing switches, or busbar voltage transformers can be placed above the panels. 144.3.2 Circuit-breaker compartment The circuit-breaker compartment contains all_ the necessary equipment for reciprocal operation of the withdrawable part and the panel. Like the busbar compartment, it is metallically partitioned on all sides. The tulip isolating contacts 4 (F.qure 165), together with the fixed isolating contacts, are located in mounting plate 13 (Figure 3). The metal shutters 2/4 Figure 8), covering the insertion openings, are also Included. The shutters are opened by the actuating bars of the withdrawable circult-breaker part, using the lever when inserting into the service position, and are closed when the latter is removed. In the test / disconnected position of the withdrawable part, partitioning by separation is established in the main current circuit. Gonnection of the control wiring, required for test purposes, need not be interrupted when in the test / disconnected position. In the test / disconnected position, the withdrawable part is still completely inside the panel with the door closed. The ON / OFF pushbutton located on the circuit-preaker, and the mechanical indicators for ON / OFF and CHARGED / DISCHARGED can be observed through an inspection window. If the circuit breaker is in service position. The switching operations are carried out with the doors closed. Installation of an additional mechanical switching device for manual operation of the circuit» breaker in the service position is also possible (Figure 41). The socket 1 (Figure 9) for the control wiring Is ‘mounted in the circuit-breaker compartment. Withdrawable part with VD4 type clroult-bre pole side. Figure 9: View into the circult-breaker compartment, Control wiring socket Top shutter Duet cover, top right Lower shutter Right-nard travel rail Figure 10: Cireuit-breaker compartment, open. Withdrawable test part in position, control wiring plug connecter oper 1 ‘Contral wiring plug 2 wither part a Square spigotFigure 11: Push button for mechanical ON/OFF broake operation with the door closed (on request) If the withdrawable part isin the service position, operation is carried out weing the knob which swings a push rod extension out 4 Mocharical pushbutton 2 Turning knob Figure 12: View of the push rod extension swung out by the knob at the front, with the withdrawable circuit-b part in service position and the door open 1 ‘Swivelling push ros Figure 13: Current sensors KECA 80C165 mounted In the clreult breaker compartment in UniGear Digital. Figure 14: Current sensors KECA 806104 mounted in the clrcult breaker compartment in UniGear Digit4.3.3 Withdrawable parts 4. Withdrawable circuit-breakers The withdrawable circuit-breaker forms @ complete module consisting of the vacuum circuit-breakers type VD4 or VM1, SF6 circuit-breaker type HD4 the withdrawable assembly 1 (Figure 15), isolated contact arm 3 with contact system 2 (Figure 165) and control wiring plug 1 (Figure 10) The withdrawable assembly and the circuit-breaker are coupled via a multi-pole control wiring plug connector. The withdrawable assembly _ establishes the mechanical connection between the panel and the circuit-breaker. The fixed part is connected to the panel by a forked connection, which is form coded on both sides. The moving part with the circuit-breaker is moved either manually or by a motor by means of a spindle, between the service or test _/ disconnected positions with the front doors closod. Service and test I disconnected positions are set precisely by means of auxiliary switches, which register the final position reached and the angular position of the spindle, The earthing connection between the withdrawable part and the panel Is established by its rollers and travel rails 5 (Figure 2), which are bolted onto the panel Withdrawable parts of the same design and clectrical parameters are interchangeable. In the case where the withdrawable parts have the same dimensions, but different electrical parameters, the control wiring plug coding prevents any incorrect connections between the withdrawable part and the panel. 2. Other withdrawable parts The withdrawable part can also be fitted with the following trucks: + Metering voltage transformers truck with fuses. + Earthing truck without making capacity (for main busbar system and power cables). + Earthing truck with making capacity (for busbar system and power cables). Power cable testing truck, Isolation truck, Isolation truck with fuses. ‘Shutter lifting truck. 3, Withdrawable contactors In place of the circuit-breaker type, the withdrawable part can also be fitted with the VSC type vacuum contactor, VSC is fitted with MV fuses 1 (Figure 157) and can be used for rated voltage up to 12 kV. All the data stated in this chapter for circuit-breakers also applies to the contactors. Figure 18: Withdrawable part with circult-breaker, type ‘VD4, operating mechanism sido, 1 Withdrawable assembly Figure 16: Withdrawable assembly for circuits auxiliary switches. 1 ‘Tost position indicator 2 Sorviee position indicator 5 Square spigot 74.3.4 Cable connection compartment The cable compartment contains current transformers 16 (Figure 3), fixed and withdrawable voltage transformers 17, and earthing switch 15, according to individual operating requirements in each case. The cable compartment is constructed for installation of three current transformers. Should all three current transformers not be required, dummies will be installed in their place, using the same installation and connection procedures, The fixed voltage transformers are connected on the primary side with flexible, fully- Insulated cables which are connected to the transformers. The removable voltage transformers are fitted with HRC fuses. The earthing switch can be used with either a manual or motor-operated mechanism. Its switching position will be indicated both mechanically by indication on the shaft and electrically by means of the auxiliary switch. Three fixed surge arrestors can be mounted instead of one position of single-core cables. fe 17: Voltage sensors KEVA 117-5820 mounted in the ‘compartment in UniGear Digital Cable connection of 12 / 17.5 kV panels: In the 650 mm wide panel, up to three parallel plastic cables can be connected with single-core cable protection and push on gealing ends with a maximum cross-section of 630 mm*. In the 800 or 1000 mm wide panel, up to six parallel plastic cables can be connected with single-care cable protection and push- fon gealing ends with a maximum cross-section of 630, Customer requests regarding connections to bars, three-core cables, special cables or sealing ends of different typos must be considered during the ordor- planning stage. Cable connection of 24 kV panels: In the 800 mm wide panel, up to three parallel plastic cables can be connected with single-core cable protection and push on sealing ends with a maximum cross-section of 500 mm’, In the 1000 mm wide panel, up to six parallel plastic cables can be connected with single-core cable protection and pushon sealing ends with a maximum cross-section of 500 mm*. For more information regarding cable connection (chapter 6.10. 4.3.5 Low voltage compartment The height of the low voltage compartment Is 705 / 1400 mm (chapter 3.3), If the secondary devices are not intended for door installation, they are mounted on DIN RAILS that enable any subsequent changes to the wiring. In the lower part of the low voltage compartment, there are three rows of DIN RAILS on the swivelling DIN RAILS holder and. below these, 18 there is an easily accessible auxiliary switch for the control wiring plug. Secondary wiring inside the panel is in a duct on the ight side of the panel. The left side of the panel is for the external wiring. The ducts are covered witn steel shoot 2, 4 (Figuro 73). There are holes for sliding in the ring conductors ai the side of the low vollage ‘compartment. 4.3.6 Switch-disconnector and cable compartment in the panel with switch-disconnector The switch-disconnector and cable compartment is merged. The stationary switch-disconnector is connected to busbars, The interconnection to the busbar compartment is carried out by bushings, which secures the separation of busbar compartment from all other switchgear compartments. The — switch disconnector and cable compartment is also separated from other compartments by metal partitions. The switchedisconnector can optionally contain an integrated earthing switch. The switching positions of the integrated earthing switch type E can be indicated by an auxiliary switch. The closing and opening of the switch-disconnector is performed manually by a lever with the door closed. On request, the device can be also mounted for the motor operation of the switch- disconnector, The switchdisconnector can therefore be operated both locally and remotely. The earthing switch is always operated locally by the operating lever The switchgear is constructed for the use of single- core cables as standard. The cable compartment usually contains supporting insulators forthe fastening of cables. On request the cable compartment can contain the instrument current transformers instead of the supporting insulators. If all three current transformers are not required, the relevant insulators are installed instead of them Cable connection in the panels for 12 kV, 17.5 kV and 24 kV: In the panel with switch-disconnector plastic Single-core cable can be connected on each phase with a cross-section up to 240 mm? as standard. Important note. In the case of any non standard cable connections an agreement must be reached between the customer and ABB during tho technical proparation stage of the order.4.4 Interlock/protection against incorrect operation 4.4.1 Panel internal interlocking To prevent hazardous situations and _ incorrect operation, there is a series of interlocks to protect both personnel and equipment: + The withdrawable part can only be moved from the test / disconnected position (and back) when the circuit-breaker and earthing switch are off (1,8, the switch must be off before hand.) In the intermediate position, the switch is mechanically interlocked. When the circult-breakers have an electrical release, the interlock is also electrical. ‘+ The circuit-breaker can only be switched on when the withdrawable part is in the test or sorvice position, In the intermediate position, the switch is mechanically interlocked. When the circuit- breakers have an electrical release, the interlock ig also electrical ‘+ If required, prevention of malfunction of the switch can also be achieved by means of the control terminal (i.e. Relion®) + In the service or test positions, the circuit-breaker can only be switched off manually when no control voltage is applied and it cannot be closed (electromechanical interlock) = Connecting and disconnecting the control wiring plug 2 (Figure 142) is only possible in the test / disconnected position of the withdrawable part. + The earthing switch 15 (Figure 3) ean only be switched on if the withdrawable part is in the test / disconnected position or outside of the panel (mechanical interlock). + If the earthing switch is on, the withdrawable part cannot be moved from the test / disconnected position to the service position (mechanical interlock). ‘+ Optionally there can be interlocking on shutters to prevent manual opening. If it is applied then a shutter device must be specified + Details of other possible interlocks, ¢.9._ in connection with a locking magnet’ on | the withdrawable part and / or earthing switch drive, can be obtained from the relevant order documents. 4.4.2 Door Interlocking The panels are equipped with the following interlock: + Tho apparatus (circuil-breaker or contactor) can hot be racked-in if the apparatus compartment door is open + The apparatus compartment door cannot be opened if the apparatus (circuit-breaker or contactor) Is in service or in an undefined position + The earthing switch cannot be operated if the cable compartment door is open. + The cable compartment door cannot be opened if the earthing switch is open - please see warning about door's handle in section 4.4.4 Locking devices. Note: When the interlocking for circuit-breaker is used then itis necessary to use the OFF push button on the door to provide emergency switching OFF. ‘A) Closed position of door's han: position of door's hand By Not 4.4.3 Intorlocks between panels + The busbar earthing switch can only be closed when all the withdrawable parts in the relative busbar section are in the test / disconnected position (electromechanical interlock). + When the busbar earthing switch is closed, the withdrawable parts in the earthed busbar section cannot be moved from the test / disconnected Position to the service position (electromechanical interlock), 4.4.4 Locking devices + The shutters 2/4 (Figure 9) can be secured independently of each other with padlocks when the withdrawable circuit-breaker part has been removed. + Access to the operating-shaft 30 (Figure 3) of the earthing switch can be restricted with a padlock + Access to the circuit-breaker racking slol can be restricted with a padlock, + Access to the circuit-breaker compartment and the cable compartment can be restricted with a padlock AX veoune + The locking magnet is not installed in the case of a motor operator; busbar earthing switche: or the withdrawable parts are electrically locked. The manual emergency switch Is not locked! + This Interlock Is not available for motoroperated withdrawable apparatus as a mechanical devics 19BY sanunc + The door’s handle which is an integral part of doors has to be push to its final close position = see of closed and not closed position of door's handle. + In case the door's handle Is not In its final close position the doors are not closed yet. In this case the interlock function cannot be ensured. 4.4.5 Internal interlocking of panel with switch- disconnector To prevent hazardous situations and _ incorrect operation, there is a series of interlocks to protect both personnel and equipment: + The switch-disconnector can only be switched on if the earthing switch Is off. The earthing switch can only be switched on if the switch-disconnector is off. The switch-disconnector and earthing switch are mutually mechanically interlocked. + The door of the lower KV cable part of the panel can only be opened if the earthing switch is on, During the closing of the earthing switch the insulating plate 26 is automatically inserted in the isolating distance of switch disconnector, which increases safely. This plate is automatically removed again during the opening of the earthing switch. + The earthing switch can only be operated if the cable compariment door is closed. + Ifthe control voltage is nat connected, the switch- disconnector can be open and closed only manually. The manual operation of switch- disconnector and earthing switch can be prevented if the slides 10 and 14 of the operating openings are locked up. + In panels with digital control techniques the protection against incorrect operation is basically carried out by the panel software. But the earthing switch is operated locally by the operating lever 1 The mechanical interlocking between the switch-disconnector and earthing switch is still in operation. + Details of other possible interlocks, e.g. in connection with a locking magnet on the switch- disconnector, can be obtained from the relevant order documents, AX vanune The door of the upper HV part of the panel can only be opened if the off-circu iteh- disconnector is verified, This means that the off- circuit condition must be unconditionally verified both on the upper and lower contacts of the switeh-disconnector. 20 Figure 18: Switch-disconnect position. Insulating plate in the Isolating distance of Switeh-disconnector. Position indicator of switch-disconnector Switeh-disconnector Movable insulation plate Insulation partition wall, Figure 20: Preparation for the operation of earthing switch in panel with the switch-disconnector. (Operating lover prepared for the OFF operation : Operating leverTypes of interlocks Standard safety interlocks (mandatory) Type | Description: Condition to be fulfied 1 |B] Apparatus racking-invout ‘Apparatus in OFF position B | Apparatus closing Defines tuck pasition | Apparatus racking@ia ‘Apparatus muli-contact plug plugged B | Apparatus mulli-contaci plug unplugging Truck i test position > LA [earthing switch closing Truckin test position 5 | Roparaias racking-in Farthing switch in OFF pasion 7 [A [Apparatus compartment door opening “Truck in test position * [5 [apparatus recking-in ‘Apparatus compartment door closee 7 [A [Reeder compariment door opening arthing switeh in ON position & | Earining swith epening Cable comparirient door closed Keys (on request) e ‘Apparaive racking-in lock Gan only be removed wilh the [rusk in ihe racked-out position 7 Earthing switch closing lock Can only be removed with the earthing ewiteh open 8 Earthing éwitch opening lock Can only be remaved wilh the earthing closed ° Thsortion of the apparatus raking-inlout crank lover | Can alwaye be removed To [ [Insertion of the earthing switch operating lever Gan always be removed Padlocks 11 |__| Apparatus compartment door opening 12 |__| Cable compartment door opening 13 |_| Trsertion of the apparatus raking-in/out crank lever 14 |__| Ineertion of the earthing ewiteh operating lever 15 |__| Shutters opening or closing Locking magnets (on request) 76 [_[ Apparatus racking-invout Magnet energized 17 |_[Earthing switch ON/OFF Magnet energizes Accessory devices “The device locks the shutlen Ta the closed position whan tha apparatus ls removed from The 18 | | shutters tailsate compartment. The operator cannot open the shutters manually. The shutters can only be operated by the apparatus truck or the service trucks, Apparatus-awitengeat The apparatus mulli-contact plug and relative ewilehgear unll soekel are equipped with & mechanical matrix, hat disables apparatus racking-in into 2 swilehgoar un t with an appropriate rated current 13 |_| unit compatibinty matrix Circuit-breaker 20 | | mechanical operating mechanism The apparatus compariment ie equipped wiih @ mechanical dovico, thal enables circull-breaker closing and/or opening directly by moans of tho front opera‘ing mechanism pushbuttons, keoping the door clased, The contrals can be operated with the cireull-breaxers in the operation and racked-out position, 24Fig 22: Cireult-breaker truck enabling slot (A) Figure 28: Circult-breaker compartment door locking device (8). 22Figure 25: Cable compar yent door enabling slot and earthing switch enabling pin. Figure 26: Cables compartment door locking pin (0). 234.5 Plug connector coding The control wiring plug connector coding allows withdrawable parts for switching devices to be assigned to particular panels. This ensures, for example, that withdrawable parts with different rated currents or differant control wiring circuits can only be Used In the panels they are Intended for. Coding pins are fitted in the control wiring sockets (Fiaure 10) or control wiring plugs and engage with the corresponding bores of the relevant plug 1 (Figure 10 or socket 3 when the two parts are connected. The plug connector coding is order-related, and is noted in the relevant wiring documentation. Figure 27: Control wiring plug connector coding, shown, for a 58-pole connector, 1 Bore for actuating pin of the control wiring plug for controlling the auxiliary switeh 24 Centering striking tabs 3 Control wieing socket Coding: The corresponding coding designation for the control wiring plug is given in brackets. The coding pins can be fitted in the control wiring socket 3 (Figure 27) and/or in the control wiring plug. Basic design: The number of sockets is optional, but the basic assignment is 1, 8, 10, 20, 21, 31, 33 and 40. Sockets and pins can be mixed ‘as required in the control wiring socket 3 and control wiring plug. 244.6 Ith Limiters Itis additional safety feature on the top of each panel The microswitch generates an immediate fault signal when the overpressure flap is opened. Reaction time is less than 15 ms. The signal from the microswitch can be sent directly to trigger the circuit-breaker OFF. Figure 50: Valld for microswitch of type Crouzet. 1 Ith Himiter 2 Prossure tap wuxiliary Ith limiter swite! ‘auxiliary switches int elts have be itm ‘essary their service position removed. Itis necessary to adjust the centre of the switch knob of the auxiliary switch to the centre of the pressure relief flap's hole. Correct value of the adjustment of the auxiliary switches’ height in the pressed position according to the particular type of the switch is Indicated in following pictures. for microswitch of type M18 6610. 2 Proseute fap Figure 29: Valid for mi joswitch of type LXW37. 255. Dispatch and storage 5.1 Condition on delivery At the time of dispatch, the UniGear panels are factory assembled, the withdrawable parts are in the test position and the doors are closed. The factory- assembled panels are checked for completeness in terms of the order and simultaneously subjected to routine testing (normally without AC voltage testing of the busbars) to IEC publication 62271-200, and are therefore tested for correct structure and function, The busbars are not assembled. The busbar material fasteners and accessories are packed separately. 5.2 Packing Available packing methods + Polythene foil - storage time 1/2 year in clean and dry environment, + OSB boards - storage time 1/2 year in outdoor environment according to IEC. + Wood boxes - storage time 1 year in outdoor environment according to IEC. According to the kind of transport and country of destination, the panels remain unpacked or are packed in’ seaworthy crates. A drying agent is provided to protect them against moisture + Panels with basic packing or without packing * Panels with seaworthy or similar packing (including packing for containerised shipments): -Sealed in polyethylene sheeting. -Transport drying agent bags included. 5.3 Transport The transport units normally comprise individual panels and, in exceptional cases, small groups of Panels. The panels are each fitted with four lifting eyebolts, Transport panels upright. Take the high centre of gravity into account. Only ever carry out loading operations when it has been ensured that all precautionary measures to protect personnel and materials have been taken and use the following: + Crane + Fork-lift truck and/or manual trolley jack Loading by crane + Fit lifting ropes of appropriate load capacity with spring catches (eyebolt diameter: 30 mm) + Keep an angle of at least 60° from the horizontal for the ropes leading to the crane hook + Suspend the unit using ALL four eyebolts! For detailed information on please refer to (chapter 5.6) switchgear handling, 26 020 60° co oS Figure 32: Handling by crane 5.4 Delivery ‘The responsibilities of the customer when the switchgear arrives at site include, but are not limited to, the following, * Checking the delivery for completeness and damage (e.g. also for moisture and its detrimental effects). In case of doubt, the packing must be ‘opened and then properly resealed, inserting new drying agent bags, when intermediate storage is necessary. + Hany quantities are short, or defects or transport damage are noted, these must be documented on the respective shipping document and notified to the relevant carrier or forwarding agent immediately in accordance with the relative liability regulations, Note: Always take photographs to document any major damage,5.5 Intermediate storage Optimum intermediate storage, where this is necessary, without any negative consequences depends on compliance with a number of minimum conditions for the panels and assembly materials. 1, Panels with basle packing or without packing: +A dry well-ventilated store room with a climate in accordance with IEC 6271-1 The room temperature must not fall below -§ °C, There must not be any other negative environmental influences. ‘+ Store the panels upright and do not stack panels. + Panels with basic packing - Open the packing, at least partially + Panels without packing = loosely cover with protective sheeting, ~ ensure thal there is sufficient air circulation. + Check regularly for any condensation until installation is started, 2. Panels with seaworthy or similar packing with internal protective sheeting: + Store the transport panels: ~ protected from the weather. - ina dry place ~ safe from any damage. ‘+ Check the packing for damage. + Check the drying agent (chapter 5.2 “on arrival of the delivery. - subsequently at regular intervals. © When the maximum storage period, starting from the date of packing, has been exceeded. ~ the protective function of the packing can no longer be guaranteed, - take suitable action if intermediate storage is to continue. BS ssane Do not walk on the roof of the panels (rupture points in pressure relief devices!). The pressure Tolief devices. and/or Ith Limiters could be damage 5.6 Handling 5.6.1 Switchgear The switchgear sections are usually fixed to wooden Handling should be carried out by overhead or cranes. Otherwise, use rollers or fork lift trucks, Weights and dimensions of each section are listed ‘in the shipping documents and in the plant drawings. 5.6.1.1 Handling with overhead crane or mobile crane and unpacking - Handling the switchgear in the wood packing. The switchgear must be lifted by crane and circular slings. The slings must be inserted according to the lifting symbols marked on the crate. Weight and lifting opening angle must be taken into account when choosing the circular slings. Unpacking -Remove the nails and crate lid and sides. -Open the compartment door and loosen the bolts fixing the switchgear to the pallet. Lift the cubicles by the crane the instructions below. -Remove the pallet. -Position the unloading shims. -Put the switchgear on the loading shims using the crane. following After unpacking, lift the panel groups by crane (Figure 32), Use the eyebolts and the safety ropes. Aller installation of the panels, remove the eyebolts used for lifting, AX sroune + Only use a suitable balanced lifting system + Should an accidental fault cause a leakage of SF6, ventilate the room and carefully follow the safety procedures prescribed in the IEC 1634 Standards. Figure 33: Handling the switehgear in the wooden crate. 275.6.1.2 Handling by rollers Lift the switchgear section by overhead or mobile crane or using jacks; remove the wooden pallet loosening the screws fixing it to the switchgear section base. Put a sturdy metal sheet between the rollers and the panel base and place the switchgear ‘on the sliding rollers. A sinvwe Only use rollers on a level floor. Move the switchgear section avoiding any possible tilting. fe 34: Handling by rollers. 1 Sliding rotters 2 Metal she: : Lifting switchgear packed in a wooden crat 28 5.6.1.3 Handling by transpallet or fork lift trucks To guarantee stability, the switchgear must not be lifted too high, Check the alignment of the forks, Only use transpallets or fork lift trucks on a level floor. Move the switchgear section avolding any tilting. TEE TD Figure 35: Switching handling. 5.6.2 Apparatus The apparatus can be handled by cranes, fork lift trucks or using the truck provided by ABB. For each piece of apparatus follow the instructions below. BY sasnne * While handling do not put any stress on the insulating parts and on the apparatus terminals. + Before handling the apparatus, make sure that the operating mechanism springs are discharged and that the apparatus Is In the ‘open position.5.6.2.1 Handling by crane Circuit-breaker Hook the lifting bolts to the relevant supports (Figure 37), While handling, pay the utmost attention not to but any stress on the insulating parts or on the circuit breaker terminals (Figure 38). Before putting into service, remove all the lifting eyebolts. Contactor To lift the contactor use removable support shown on Figure 39) OO Figure 37: Correct handling, Figure 38: Mounsing the tttin 5.6.2.2 Handling by fork-lift trucks Handling by fork-lift trucks can be carried out only after the apparatus has been positioned on a sturdy Support. While handling, pay the utmost attention not to put any siross on the insulating parts or on the circuit-breaker terminals. BX nnn Do not insert the truck forks st the apparatus but put the appa support, ight underneath jtus on a sturdy Figure 38: Wrong handling. —__~ Figure 40: Handling by fork-lift trucks. 295.6.2.3 Handling by service truck For handling and inserting the apparatus into the switchgear, use the service truck (Figure 43) In order to handle the circuit-breaker with the relevant truck, follow the instructions bolow. + Hook the lifting bolts to the circu supports and align it above the truck (1) + Press the handles (2) towards the circuit-breaker centre (*) to Insert the horizontal check pins (3). + Put the circuit-breaker on the truck, + Push the circuit-breaker towards the circult- breaker compartment and insert the truck into the guides until the handles (2) are released (**) outwards and the horizontal locking pins go into the slots (4), locking the circuit-breaker. A WARNING * Do not use the service truck for any purpose other than handling ABB's apparatus. + Fix the circuit-breaker to the truck before moving i breaker 30 Further warnings When moving the switchgear on cylinders always put the cylinders collinear (in parallel) with the front side of the switchgear and always keep the switchgear in the vertical position! Do not try to open the cable or the circuit-breaker compartment doors, close the earthing switch or withdraw the circuit breaker if an auxiliary voltage is not connected to the switchgear! Do not step on the pressure relief flaps! ure 44:_(*) Handling direction for horizontal locking pin sntry, (7) Handling direction for exit of the horizontal, locking pins.6. Assembly of the switchgear at site To carry out the optimum installation sequence and ensure nigh quality standards, site installation of the switchgear should only be carried out by specially trained and skilled personnel, or at least by personnel supervised and monitored by responsible people. In case higher IP is needed please follow the structions described in manual 1VLG100101 - available on request. 6.1 General ‘On commencement of installation on site, the switch room must be completely finished, provided with lighting and the electricity supply, lockable, dry and with facilities for ventilation, AM the necessary preparations, such as wall openings, ducts, etc., for laying the power and control cables up to” the switchgear must already be complete. Where switchgear panels have top-mounted structures for earthing switches or instrument transformers, it must be ensured thal the ceiling height is sufficient for the opening travel of the pressure relief plates. The ceiling must be high enough to allow the assembly of the pressure relief duct and/or top mouted VT box and earting switch box. See table in (chapter 6.7), 2. Further structural data guidelines given provide a rough calculation of the space required and the plan for designing the room for a switchgear Project. If seismic resistance is not required, it is not necessary to attach each switchgear panel to the floor or frame, but it suffices to fix outside panels in each row of switchgear only. If seismic resistance is required, it is necessary to attach each switchgear panel to the floor or frame. To achieve seismic resistance the special fixing system is used. This system preferably uses a steel floor frame with *C" profile shape but moreover with an addition special fixing element - please contact ABB for details When the final building construction documents are drawn up, the binding data supplied by ABB for a particular case must always be taken into account! Dimension chart of structural ta = panels 12 17.5 kV Compliance with the conditions for indoor switchgear according to IEC 62271~ the indoor temperature class must be ensured. 6.2 Foundations Tho following three basic switchgear in the switchroom are identified: Method A — installation on C profile for concrete floor As standard, it is recommended to switchgear on “C* profile base concrete floor of the switchroom, panels are fastened using the special bolt blocks (ABB delivers these on request). Method 8 — installation on anchoring bolts Installation directly on the makes much higher demands on the floor levelling which must, in this case, fulfil the same tolerances as the base irons during method A installation. Fastening s carried out by anchoring bolts in the concrete floor. Method C — installation on bolts for raised floor In this case, fastening of the panels is carried out by welding outside panels to the steel floor frame in the places where the frame is larger than the base of the switchgear, i.e. on the outside lateral walls of the panel row. This method of installation is not recommended if seismic resistance is required Generally, the following procedure for switchgear anchoring can be recommended for any of the nstallation methods mentioned: 1. The switchgear panels are bolted together in the front and rear part to make one unit Paneth FT TPB 80 | 7068 ite with Tm [ Free rane 1500 Sutchavar7=om door tm | 50 | t000 [1200 Including the eondtions for Swengpar Tm Teer See Ee opening nosing i wanaporeg tough of wth tm Teo [Tan 76 eth trim] [Tana rsn0- 1500 methods of installing | Ceiling load Tkaim7 [ 1200 | 1400 [7400 Dimension chart of structural data = panels 244 anata F ta 55006 tal tne PSEIERETE-S (aa ed to install the [ Syrcigea’ room door wath trent 1000-1200 ong set Into. the [Swieigear rom doer hig tent aes [ae opening ncetnng transported through oo wt Tem Touo [a0 Tenth ten] [1900 [1900 Tevelled concrete ‘oor [Ceting Tad are s00 380 Ty Miinnum aimerslors. Pay atlonion to appropriate national (2) Appliae 1 low voltage compartments of standard neigh! (3) Approximate nu Ing on the typeof panels. 316.2.1 Method of installation A - Installation on profile for concrete floor The general foundation drawing is given in following figures according to the parameters of the panels. + The "C* shaped base irons can be supplied by ABB. together with the switchgear. Their installation is usually carried out by personnel on site and should, if possible, be performed under supervision of an ABB specialist, The base irons must be installed in the slab before finishing the floor + Rest the irons in the specified position on the conerete flor as shown in the relevant foundation drawing and mark out the places for drilling the holes. Then drill the holes for anchoring bolts, i.e. for plugs for fixing the base irons in the floor. Then put the plugs in the holes and attach the base irons to the floor loosely with bolts, without final tightening so that any required’ levelling is possible, + Carefully level the base irons both longitudinally and transversally over the entire length and to the correct height by putting strips of suitable thickness under them and using a levelling instrument. Tolerances for laying the floor frame are: - Evenness tolerance + 1 mm over a measuring length of tm = Straightness tolerance 1 mm per 1m, but not more than 3 mm over the entire length of the frame. + After levelling the base irons, tighten bolts 13. The adjusted position of the base irons on the concrete floor must not be changed during this operation! Check again and, if necessary, correct any deviations, + Weld Individual parts of the base irons together Inside the "C* profile at the seams so that there is ‘a mutual conductive connection + Take any necessary measures for perfect earthing of the base irons with galvanized steel strips with minimum dimensions of 30 x 4 mm. Two earthing connections are recommended for a panel row longer than approx. 5 panols. + When the floor top covering is applied, carefully backfill the floor frame, leaving no gaps. The top edge of the floor frame should be 2 mm above the finished floor surface; the tolerance of this value is, within the limits of 0 to 5 mm. This facilitates erection and alignment of the switchgear panels. In some cases, this means that the material thickness of an additional floor covering to be fitted later must be taken into account separately + The base irons must not be subjected to any harmful impact or pressure, particularly during the installation phase. If these conditions are not respected, problems during assembly of the switchgear and possibly with movement of the withdrawable parts, as well as opening and closing of the doors cannot be ruled out. Attachment of the panels to the “C The switchgear is attached to the base irons by special bolt blocks, which can be supplied on request. + Place the individual panels of the switchgear in sequence onto correctly levelled and installed base irons and level them according to the relevant foundation drawings. shape base 32 + Level the panels and then bolt them together in the front ang rear part + To attach them to the base irons, insert specially prepared bolt blocks in the fixing holes in the bottom of the panels and tighten them. Figure 45: Fixing to the proiile for eonrete floor or = Mathod A - Installation on ¢6.2.2 Method of installation B — Installation on anchoring bolts The general foundation drawing is given according to the parameters of the units. n following Clean the switchgear installation area carefully On the slab, visibly trace the perimeter of all the units making up the switchgear according to the relevant drawing, taking the minimum wall and obstacle clearances into account + Level the floor both longitudinally and transversally, evenness tolerance is + 1mm over a measuring length of 1 m + Drill the floor at the intended fixing points, referring to the slab drilling drawings. To make the holes, use a hammer drill with a bit according to the steel plugs used + Insert the plugs in the holes and put the individual panels on the traced perimeters of the units to create the switchgear ‘+ Level the units and then bolt them together in the front and rear part + Fix the units with bolts with special washers (the coupling material is supplied on request) + In the case of a metal floor, use the attachment according to the figure. To make the holes, use a drill with a suitable bit for the type of fixing to be made (through or threaded hole) 6.2.3 Method of installation — Install bolts for raised floor The general foundation drawing is given in (Figure 48), + (Figure 72) according to the parameters of the panels. In most cases, the floating floor is created by a steol structure in which the welded steel frame is installed. A frame produced using suitable steel profiles is used, ABB does not supply this frame. ~ Evenness tolerance + 1 mm over a measuring length oft m, + Straightness tolerance + mm per 1 m + Clean the installation area + After installation of the frame, take any necessary measures for perfect earthing of the frame with galvanized steel strips with min, dimensions 30 x 4mm. Two earthing connections are recommended for a panel row longer than approx. 5 panels. + Place the panels on the frame according to the relevant foundation drawings, taking the minimum wall and obstacle clearances into account, + Level the panels and then bolt them together in the front and rear part, + Carry out attachment by welding the outside panels to the steel floor frame in the place where the frame juts out from the switchgear bottom, i.e. on the outside lateral walls of the unit row. This method of installation is not recommended if seismic resistance is required. + In the case of a metal floor, use attachment according to the figure. To make the holes, use a drill with a suitable bit for the type of fixing to be made (through or threaded hole) Figure 46: Fixing to the floor - Meth: anchoring bolts. B - Installation on Figure 47: Fixing to the floor - Method C - Install bolts for raised floor. 33Draufsicht 100 foo 600 100{700 480 ce rea Section AA ea 8 Figure 48: Unc on concrete flo 42 / 17.5 KV up to the nominal current of T-offs 2500 A. Guideline structur. it I not valld for the panel with switeh-disconnector data for foundation frame © Typical pans! depth C = 1340 mm ~ however always consider annotation 2) GS ——_ With of operating aisle (chapter 6.2 FT Panel width (chaptor 6.2 TB Door width = FT + 200 mm TH Door height = panel height + 200 mm 1 Rear cover 2 3 3 5 1) Minimum gimensions: recommenced space 500 mm. 2) Dimension must be verified In documentation of the relevant order, 34A Draufsicht Figure 49: Uni: foundation frame on cone! Section A-A pa 12 47.5 KV for the nomin ‘Moor. Its not v current of T-offs 3150 / 4000 A and/or 50 kA. Guldeline structural data fo Id for the panel with switch-disconnactor. ‘Typical pane! depth C = 1290 mm — however always consider annotation 2) Width of operating aisle (chapter 6.2 Panel wigth (chapter 6.2 Door width = FT + 200 mm Door height = panel height + 200 mm Roar cover Door ‘Side end cover Screw Steel dowel Minimum dimensions: recommendes space $00 mm, Dimension must be verified in documentation of the relevant order 35A Draufsicht él = a carol I ' ofA f is a Ty S é $ | ! ' & g a ' roo" fA ~ ™ }| ody w “ " | I Ht 800 hochoa 600 | 600 hed i 7 \ W100 g ! ° 1a TH Seaton AA s ot 100 | L, LLLLL ALLA NC LA 4 fll roe_| ae |) Figure 50: UniGear 24 kV. Guidelin nel with switeh-disconnector ructural data for foundation c 6 FT Panel width (chapter 6.2 TB Door width = FT + 200 mm TH Door height = panel height + 200 mm 1 Rear cover 2 Door 3 fond cover 4 5 1) Minimum eimensions: recommenced space 500 mm. 2) Dimension must be verified in documentation of the relevant order. 36A praufsicht 100” Seaton A is Y = L ra 1: UniGoar 12/ 17.5 kV with NAL switch onnector. Guldeline structural data for foundation frame on concrete © Typical panel depth ¢ = 1340 mm — however always consider annotation 2) G Width of operating aisle (chapter 6.2) FT — Panel wicth (chapter 6.2 TB Door width = FT + 200 mm TH Door height = panel height + 200 mm 1 Roar cover 2 Door 3 Side end cover 4 Screw 5 Stet ‘sowel 1) Minimum dimensions: recommendes space $00 mm, 2) Dimension must be vorifed in documentation of the relevant order. 37Draufsicht a : fe cca 20) = a pe =) Tho 300, 8] iso oo 8 ' J oil vo. y Hl gies Hl | g 8 i ty i . \ / 1 100” xT Lo} met] ° SectionAA at gee 20 1 Ife Fh q 7 SOT floor. Figure 52: UniGear 24 kV with NAL switeh-disconnector. Guideline structural data for foundation frame on concrat © Typical pans! depth C = 1700 mm - however always consider annotation 2) G With of operating aisle (chapter 6.2 FT Panel width (chaptor 6.2 TB Door width = FT + 200 mm TH Door heigh = panel height + 200 mm 1 Rear cover 2 Door 3 Side ond cover 4 5 1) Minimum dimensions: recommenced space $00 mm. 2) Dimension must be verified in documentation of the relevant order. 38Figure 53: Example of 12 / 17.5 kV switchg: ga duct A Y T4600 ] WH 2793 2595 ve 1190) 2080 \ W/L F for 2500 A on foundation frame on conerete floor, Panel with examples of "a chimneys or pressure relief to the outside, Typical pane! depth A = 1340 mim - howor F always consider annotation 2) Minimum dimensions; recommendes space $00 mm Dimension must be verified according to documentation of the relevant order a Li ZE Uff. Y wf res00 )) 3 7 4 7 ‘ ] i 4 44 UV g a ee a8 da gaa8 ds 7 3 y q TD Yi Uididllld Figure $4: Example of 12 / 17.5 kV switchgear for 3150 / 4000 A on foundation frame on concrete floor. Panel with mol = duet Including chimneys or pressure ri ‘Typical pane! depth B = 1340 mm — howe to the outeld F always onsider annotation 2) Minimum dimensions; recammandaé space 500 mm Dimension must be varified according to documentation of the relevant ord: 39Z 0" 8 Freso0 WOOT 2505 110 200 2100 200 2200 (LV 705) he! Z] “ Villa Figure 58: Example of 12 / 17.5 kV, 40 1 50 kA switchgear on foun: ‘gae duct including chimneys or pressure relief to the outside, jon frame on concrete floor. Panel with examples of © Typlcal panel depth © = 1380 mm ~ however always consider annotation 2) 1) Minimum aimensions: recommenced space 500 mm. 3} Bimonsion mest be verti sccordingte documentation ofthe relevant order. reece ee nnn g 7 a | | ae g yn \4 y sa 8 | 7 s a8 5 ui Z 4 8 7 7 3 | 7 Z yj Y Z| TH YH LL Wh WH Figure 56: Example of 24 kV, 25 kA switch on foundation frame on concrate floor, Panel with examples of gas duct ingluding chimneys or prossur jo the outsid Typical pane! depth D = 1560 mm - howaver always consider annotation 2) 1) Minimum gimensions; recommenced space 600 mm. 2) Dimension must be ing ta documentation of the relevant order. 40Figure 87: Example of 24 kV, 31.5 kA switch; Including chimneys or press e y 100! AS He WOON 2200 He270@ve 1100) 2325 VC 705) waco \ Li to the outside. ‘Typical pan —lnowever always consider annotation 2). Minimum dimensions; recommandac space 600 mm. Dimension must be verified according to documentation of the relevant order jepth E = 1700 mm (For short-time current up to 25 KA a 1560 mm depth version is aA Draufsicht B Figure 58: Guideline structural data for a raised false floor. A Larger dimension is valid for the cubicle with circuit breaker HDA including combination with them, In other cases smaller dimensions are valid ~ however always consider annotation 2). Width of operating aisle Fr Panel width TB Door wigth'= FT + 200 mm TH Door height = panel height + 200 mm 1) Min, dimensions, x) Max. dimensions. 2) Dimension must be verified in documentation of the relevant order. 5) In ease of rear acess of inspection window on the rear cover min, recommended distance from the wall is 500 mm. Structural date for a raised false floor Un [kV] Panel depin AT z eT TETAS up to 2500K 7340 7 1500 Tae Tas F215 - 31501 4000 K 739077350 1235 7 TZLi7.8 - 407 50 KA 7390 125 785 2a TOOT 15607 7825 7500 | 1480 140 42104 8 A ia B) 1 1 S E L B go b f E a a Figure $9: 12/17.5 KV up to 40 KA = 650 1800/1000 mm wide panels =A) Anchoring bolts 8) C profile for conerete fl Anchoring bots txinu system Fr wtath ne aT Sar] sot ia ai Ae ow gE g F é zg ele 5 B Figure 60: 12/ 17.5 kV, 50 kA, 1250-2000 A, 800 mm wide panels - A) Anchoring bolts B) C profile for concrete floor. 43A 18 70 y ls Peoria eee Figure 61: 1217.5 kV, 60 kA, 2800-2600 A, 1000 mm wide panels - A) Anchoring bolts B) C profile for concrete floor. 4) 106 0 a 05 a A) Anchoring bolts B) C pr fo 82: 121 17.5 kV, 50 kA, 4000 A, 1000 mm wide pa 44A wo Pa Figure 63: 24 KV, 25 kA, 800 mm wi ‘A) Anchoring bolts B) C profile for concrete floor. Ap Bf Figure 64: 24 KV, 25 KA, 1000 mm wide panels - A) Anchoring bolts B) C profile for concrete floor. 45eee m ig EE P k BE EDs B iB Figure 68: 24 KV, 31.5 kA ~ 800 mm wide p: ) Anchoring bolts B) C profile for concrete floor. A 8) Figure 66: 24 KV, 31.5 kA ~ 1000 mm wide panels - A) Anchoring bolts 8) ¢ profile for concrete floor, 48iti 22 mm 4 eee E is ke z i } ‘8 0 Figure 67: 12/ 17.5 kV cublele with switch-disconnsctor - A) Anchoring bolts B) C profile for concrste floor. A) aj ___sor____ a. Figure 68: 24 kV — cubicle with Switch-disconnector - A) Anchoring belts B) C profile for concrete floor. 47S \Y M12 Je6.3 Assembly of the switchgear panels Use screws of tensile class 8.8. The maximum recommended tightening torques based on each type of connection are given in the following tables: Tightening torques for copper bars or combined busbar connections Max. recommonded tightening torque Nar Thread! [Without (n-0.14) [Oil of aroase (0.40) mer 25 5 Mam 70 3 ME 25; 20) mio 50) 20) Mie 35, 3, Mi 200 170 Tight. torques for copper bar connections combined with epoxy insulators. Max, recommended tightening toraue Nm Thread! Wiheut (n=0.14) | Oil of grease (n=0,10) co 75 72, MAT 3 2 Mie a5, 3 Mie 110 3 Mz0 220 7380 Tight. torques for coppor bar connections combined with ABB CTs a) Max: recommended ahtentng torque Nam Thread! 14) [Oi of grease (n=0. 10) wie 57 Tight. torques for copper bar or cable connections combined with ABB VTs ‘Max. recommanded tightening torque Nm Thread Without (n=0.14) | Oil of grease (n=0.10) Mai 20) 16 Tightsning torques for copper contact pins inside epoxy spout Max, recommanded tightening torque Nm Tnvead! Without (n=0.14) | Ollof grease (n=0.10) wai a6 ld M20 250 200 (1) The facommanged maximum tightening torques are based on 2 Seetticient af sresion forthe tread o° 0.14 (without lubrication) oF (2) The Hattening torques ate recommended for screws 150 40% Scie ane 180 4752 (tonslle class 8.8). I Using other typoe Of 5 (0) Applicable anly for fixing of rubsidiary covers or terminal Any tightening torques that deviate from those in the general tables (e.g. for contact systems or device terminals) must be taken into account as stated in the detailed technical documentation. It is recommended that the threads and head contact surfaces of bolts should be lightly oiled or greased to achieve the precise tightening torque (column Oil or grease in table) The preparation work for installation is as follows: * Remove withdrawable parts 1 (Figure 145) from the switchgear panels and store them with sultable protection, + Dismantle lifting eyebolts. + Transport the switchgear panels to the prepared installation point following the sequence shown on the switchgear plan. + Remove covers 2 and 4 (Figure 73) from the vertical control wiring ducts at the front left of the panel Figure 73: View into the high voltage area at the front. Blocking adjustable pin 2 Duet cover for external control cables 3 Horizontal partition, removable 4 Duet caver far external control cables 496.4 Procedure for setting-up the doors Instructions from the standpoint of the safety at work: The relevant work and adjustments must be carried out by trained specialists familiar with the installation, taking into account all relevant safety regulations according to IEC and other relevant professional bodies, and other local and works regulations and Instructions. The switchgear doors are always mounted and set up at the factory. It is always necessary to reset these doors on site and to do this before commissioning the switchgear. During setting-up, the switching station must be connected to the control voltage, otherwise it will not be possible to operate the withdrawable part with circuit-breaker / contactor and carthing switch The working method: a) The circuit-breaker compartment door: + Loosen (but do not dismantle) 2 lock screws M6 Figure 74) on the lateral side of the door - this Feleases the blocking stop and it is possible to open the door. + Withdraw the withdrawable part with circuit breaker / contactor from the circuit-breaker compartment onto the service truck and move it outside of the switchgear. © Dismount the left lateral cables (Figure 75 + Withdraw the left lateral cover of the control cables from the circuit-breaker compartment outside of the switchgear (Figure 76 + Loosen (but do not dismantle) all M8 screws at all hinges (Figure 77) + The setting-up of the door position is based on rotating the door in the opening on an axis of the middle hinge (the second hinge from the bottom edge of doar in the case of a door with 4 hinges), + Set up the door in the position in which its upper edge is parallel with the gap between the circuit cover of the control breaker compartment and the low voltage compartment (Figure 78) + Tighten the upper hinge and check the correct function of the door including the insertion of blocking lever in the door slot with the blocking stop. + If the door closes correctly, tighten all screws a all hinges to a torque of 20 Nm. + Set up the blocking stop so that its lower edge is in the range of 29.8-30.3 mm above the level of the lower edge of the slot in the door draw bar when the door handle is in the closed position Figure 79) (Figure 80), The required position of the stop can be set up by insertion of the jig OCAQ071, drw.No. 1VL7611226P0101 + Check that the door closes correctly. 50 + Mount the left lateral cover of the contro! cables The screw tightening torque must not exceed 2,5 Nm + Insert the withdrawable part with circuit-breaker / contactor in the circuit-breaker compartment and leave in the test / disconnected position. * Close the door and verify the door blocking function by operation with the withdrawable part b) The cable compartment door: + Loosen (but do not dismantle) 2 M6 lock screws Figure 74) on the lateral side of the door - this releases the blocking stop and it is possible to open the door. * Withdraw the withdrawable part with measuring voltage transformers (if the switchgear is equipped with them) from the cable compartment outside of the switchgear (Fioure 8% + Dismount the left lateral cables (Figure 82) + Withdraw the left lateral cover of the control cables from the cable compartment outside of the switchgear (=iaure 83 + Loosen (but do not dismantie) all M8 screws at all hinges (Figure 77 + The setting up of the door position is based on rotating the door in the opening on an axis of tho middle hinge (the second hinge from the bottom ‘edge of door in the case of a door with 4 hinges). + Set up the door in the position in which its upper edge of door will be parallel with the upper edge of the separating cover (Figure 84) + Tighten the upper hinge and check the correct cover of the control door function including the insertion of the blocking lever in the door slot with the blocking stop + If the door closes correctly, tighten all screws at all hinges to a torque of 20 Nm + Set up the blocking stop so that its lower edge is in the range of 29.8-30.3 mm above the level of the lower edge of the slot in the door draw bar when the door handle is closed (Figure 79 Figure 80). The required stop position can be set up by insertion of the jig OCAOO71, drw.No. 1VL7811226P0101 + Check that the door closes correctly. * Mount the left lateral cover of the contro! cables The screw tightening torque must not exceed 2.5 Nm + Insert the withdrawable part with measuring voltage transformers (if the switchgear is equipped with them) in the cable compartment. * Close the door and verify the door blocking function by operation with the earthing switchi Figure 74: Serows on lateral side of door. Figure 76: CB compartment without lateral cover. Figure 77: MB screws.fon BE i i Figure 78: Correct position of CB compartment door. Figure 80: Setting up right position. 52 Figure 79: Setting up right position. Withdrawable part with6.5 Installation of the bushing Before fixing the panels side by side (according to the general drawings) bushings (12 + 24 kV) must be fixed (for switchgear with busbar partitioning only), 6.5.1 Bushing of 12/ 17.5 kV panels Lower bus-tie system Insert bushing 1 for the lower rear bus-tie into bushing plate § from the right side in contrast to the procedure for the other two bushings. Figure 88: 12 /17,5 kV panels - fixing bushings, 4 ne. 4 bushing 2 8 8x30 screws 5 8 M8 we 4 hr. 3 Rubber partition (busbar support) Figure 86: 12 /17.5 kV pat ne. 1 bushing fir 8 Bx30 seraws: nr 8 Me fir 8 Rubber partition (busbar support) ne 12 MB nut fir 1 bushing plate 54 6.5.2 Bushing of 24 kV panels Assembly procedure for bushings — main busbar system: Insert bushing 1 for the lower busbar into bushing plate § from the right side, and for the middle and upper busbar from the left side. (upper) Lower bus-tie system: Insert bushing 1 for the lower rear bus-tie into bushing plate 5 from the right side in contrast to the procedure for the other two bushings. C“— 1 BU 2 Figure a7: 1 2 3 5 é 24 KV panel - fixing bushings. nr. 7 bushing nr. 8 10x28 screws nr 8 M10 washer nr 12 M10 nut nr. 7 bushing plate nr. 7 bushing nt. 8 40x25 sor ni 8 M10 wash 3 Rubber partition (busbar support) nr 12 M30 nut nr. 7 bushing plate6.6 Fixing of the panels BS ssn Bofore fixing the panels side by side be sure that the bushings are fixed according to (chapter 6.5), Fit and screw down the side covers. Align the switchgear panels on the floor frame for correct positioning and vertical alignment (deviations of the panel edges from the vertical must not exceed 2 mm, especially at the front) and bolt the panels together (Figure 89). It is advisable to start from the centre when assembling switchgear with more than 10 panels. The junction points where the panels should be fix are as follows + Nr6 in the front side + Nr4 in the middle part + Nr.5 in the rear side The nuts are already fixed on the right side of the panel (except in the midcle part); on the left side there Js the an the screws are to be jure 89: View of the fixing points. 556.7 Installation of the busbars 6.7.1 Proparation of the material + Clean the insulation on the busbar sections with a soft, dry cloth, and check for any insulation damage. Remove greasy or adhesive dirt. © Busbar connections: = The silver-plated surfaces of the connections must be cleaned with a metal-free non-woven cleaning clath and thinly and evenly coated with SYN-setral-EK 339 grease = The non silver-plated surfaces of the connections are either orushed with a wire brush, preserving the grease film, or cleaned with a metal-free non-woven cleaning cloth and ovenly greased with a thin coat of SYN-setral-EK 339 + Prepare insulating covers 2 (Figure 90) and lids 3 to suit the relevant busbar connections and pull them on the busbar. (For insulated busbars only) fon at the busbar en Figure 90: 1217.5 kV panels, instalation of the busbars, The lower picture shows the inst Busbar bushing Insulating cover Us Support for cover (al end panels only) 1S0 7080 25 mm diameter 56\ @ 1011 12 Figure 91: 24 KV panels » Arrangement of the busbar and branch conducto: the connections are similar, but without th insulating cover and lid to fit the cross at the busbar ends. In continuous busbars, id holder and without the spacer plate. During assembly, cut out the fetion of the feeder Figure 92: 24 KV panels, 1250 A branch currant and 1600 or 2500 A busbar current - Arrangement of the busbar and In continuous busbars, the connections are similar, but without the lid holder 2 and without the spacer plato 13. tk 21270 1 «3 8 Figure 93: 24 kV panels 2500 A branch and b1 1.7 Lid for insulating cover 2° Lid holder 3,4 TOmm spring wash: 8 8 Insulating cover Brancn conductor 8 Busbar section 9) Washer 150 7089 10 M10 hexagon sackst head screw 1 Mt0nut 12. Washer 25 mm diameter 13 Spacer plate (only for 2500 A branch and busbar current). 576.7.2 Busbar compartment access Access to the busbar compartment is possible either from the top of the panel after dismounting the pressure relief plate @ (Figure 3) before the mounting of the gas duct, or from the front of the circuit-breaker compartment. Aller circuit-breaker has been withdrawn from the Panel, it is possible to dismount the horizontal partition 1 (Figure 95) by unscrewing 4 screws holding the partition from the inside, After that, the partition can be dismantled and taken out of the panel, which makes access to busbars from the circuit-breaker compartment possible, fe 98: Accessing busbar compartment 1 Horizontal partition 23 Cov 586.7.3 Busbars installation ‘+ Install the busbars panel by panel according to the rating of the switchgear. Screw on the individual busbar elements one above the other (depending fon the system layout) and in line with the flat branch conductor. For the tightening torque please refer to the (chapter 6.3), Use tightening material supplied by ABB. + Bolt one holder to each end of the busbars to Support insulating cover. The screws for holder must be tightened with a lower torque (for insulated busbars only). + Position insulating covers and lids over the relevant bolted joint, and slide the lid onto the cover until it clicks into place (for insulated busbars only). Note: Busbar connection is carried out with “stabilized connections”, This means that the quality of the copper busbar connections does not deteriorate according to the operating time and therefore it is not necessary to inspect tightness of busbar connections regularly, But this is on condition that correct assembly is carried out as described above and especially that all connections are tightened with the prescribed torque according to the table. We recommend only checking tightness of busbar connections during inspections (chapter 9.3 Note: In case that busbars insertion seems to be difficult then can be exceptionally used appropriate amount of the DOW CORNING TORAY DC4 silicone grease compound applied on the busbar insulation. After insertion busbars the rest of DC4 silicone grease compound on the insulation surface has to be properly cleaned up by soft dry cloth. The usage of any other types of grease for insertion of busbars through the busbar partitioning bushing & rubber partition is strictly forbidden! Figui 97: Washer after tightening 59Busbars for 12 / 17.5 kV panels Busbars are made of copper and have a flat cross- section for rated current up to 2500 A. For 3150, 3600 ‘and 4000 A, the busbars have a double D-shaped cross-section. Branch conductors always have a flat cross-section. 12 1 17.5 kV bushings are made of epoxy resin castings and are arranged as a single casting for all three phases, For bustie panels the bushings are single and are arranged in the lower part of the panel, Bushings are held in bushing plates. For 12 kV, the busbars are bare (without insulation) and without insulating covers up to 2500 A. 3150, 3600 and 4000 A open D-shaped busbars are insulated by shrink fitting sheaths and are fitted with insulating covers. For 17.5 kV, the busbars are insulated and fitted with covers over the whole current range. - T-off 630 -1250 A, busbars 1250 A, 1 ne. 4 10x28 screws 2 fir 8 KT wasne: 4 fr 4 RO mute 12,147.5 kV par ne. 4 10x60 screws fir 8 M10 washers fr 4 RO mute fr 1 spacer (15mm) 60 T-off 630 -1260 A, busbars 1600, 2000, 2500 A.Figure 101: 121 17.5 KV panals - T-off 630, 1250 A, busbars 3150, 3600, 4000 A, open D. 1 fr. 10x60 serows 2 nf, BMIO washers 3 onl M10 nuts 4 nts 1 spacer (15mm) 61nr 4 R10 mute 0 Figure 103: 12/ 17.5 kV panols - T-off 1600 - 4000 A, busbare 3150, 3600, 4000 A. 1 re. 4 10x60 serows 2 fr. 8 M10 washers 3 fir 1 spacer (ama) 4 fe & RTO nuts 62Figure 104: 121 17.5 kV pa rr, 4 10x60 serowe fr 8 M10 washers hr 1 spacer (5mm) fr & M10 mule Busbars for 24 kV panels Busbars and branches are made of copper and both have a flat cross-section. The bushings are different from the 12 / 17.5 kV versions. They are single for each phase and have an electrode inside, which must OO Figure 108: 24 KV panels - T-off 1250 A, busbars 1250 A. 1 fr 4 10x38 serews 2 nn @M10 washers 3 oan A MIO nate 0 Le += Teoff 630, 1250 A, busbars 3150, 3600, 4000 A, open D. be connected to the busbar. Busbars for 24 kV panels, are insulated by means of shrink fitting sheaths and the connection points are covered by insulating covers. 63Figure 106: 24 KV panels - Tooff 1250 A, busbars 2500 A. 1 n.d 10x60 serous 2 hr’ M10 washers : \ : et ECO- 2 Zi Q @ LLL i = X pee Gea Figure 107: 24 KV panels - Toff 2500 A, busbars 2500 A 4 rd 10%60 screws 2 8 M10 washers 3 firé M10 huts 64Figure 108: 24 KV panels - T-off 3150 A, busbars 3150 A. 1 ni 10x60 serows. 2 ni.8 M10 washers 3 nia MIO nue The contact springs must be inserted during the installation of busbars. These contact springs make the connection between the busbar and the metal tube and prevent damage caused by partial discharges inside the bushing on live busbars . | note: Always check that there Is good contact between the metal tube In the bushing and the busbars via contact spring. Ensure that the contact spring is in the correct position! Figure 109: 24 KV panel: sectional view Contact spring jotall of the busbar bushing, 656.8 Installation of the top-mounted boxes For ease of transportation top mounted boxes are delivered separate from the panel in pre-assembled sections, 6.8.1 Voltage transformer for busbar metering © Top-mounted box 1 (Figure 115) with screw fixing material in the set of bags "Top-mounted box for metering” must be mounted on the busbar compartment, In panels without busbar bushing plate § (Fiqure 87), the partition between the busbar compartment and the topmounted box is necessary. They are installed at the factory in the top-mounted box As far as equipment with busbar partitioning is concerned (ie. with bushing plate 5), the space between the busbar compartment and the top- mounted box must remain open for pressure reliof + Connecting bars 1 with branch conductors 5 at the junction point must be screwed together according Figure 110: Panels 12// 17.5 kV - Bar connection to the top-mounting box. Th busbar ends. 66 to (Figure 11%) (Figure 113). However, if, necessary, the addilional spacer plate 2 (Figure 111) and threaded plate 9 (Figure 113), as well as the screw fixing material from the “top-mounted box for metering” set of bags must be used. Insulating cover 2 (Figurc 87) must be placed into position as is described in (chapter 6.5) Intermediate box (Figure 115) (Figure 116) with the screw fixing material from the “top-mounted box for metering” set of bags must be mounted on the low voltage compartment. Conduction tube must be positioned and inserted in reducer rings. Secondary circuits from the voltage transformers. must be led to the terminal strips and connected according to the cable core markings and circuit diagram,igure 111: Panels 12 / 17.5 kV - Bar connection to the top-mounting box. The figure shows the arrangement in panels the jusbar ends. Figure 112: Panels 12 /17.5 kV - Bar connection to the top-mounted box,Figure 113: Panets 24 kv busbar joint for busbars the connection is 7 but without the 1 Connection bar 5 6 4 7 8 8 8 3 Threades plate 7 40 Insulating cover 11 Cylinder screw Figure 114: Panels 24 kV - Bar connection to the top-mounted box. 6a Washer 3 mm M0 hexagon socket head screw 40 mm spr Spacer plat 40 mm thick oy © ‘end. In continuous ne Detailed view: ee oeFigure 115: Panels 12 / 17.5 kV - Top-mounted box with voltage transformers for busbar metering. The figui arrangement in panels without the busbar bushings plate, shows the ‘Top mounted box with vollage transformer Conductor tube Partitioning Reducer ring Intermediate box: Figure 116: 24 kV panels - Arrangement of the busbar and branch conductors at the bu: the connections are similar, but without the lid holder and without the spacer pl ends. In continuous busbar Top-mounted box Conductor tube Reducer ring Intermediate box Pressure relief flap Connection bar Bushing plate 6970 .2 Earthing switch for busbar earthing Top-mounted box 1 (Ficure 117) with screw fixing material from the “top-mounted box for earthing” set of bags must be mounted on the busbar compartment, Operating mechanism box 3 with screw fixing material from the “top-mounted box for earthing” set of bags must be mounted on the low voltage compartment, Pro-mounted single parts of hexagonal shaft 2 must be removed, Please pay attention to the sequence and angling of the parts! The hexagonal shaft from the operating mechanism box must be pushed through into the bevel gear of the earthing switch. The sequence and angles of the part must be restored! Connecting bars 4 (Figure 119) with the branch conductors at the junction point must be screwed together according to (Figure 111), (Figure 113) However, if necessary, additional spacer plate 2 Figure 111) and threaded plate 9 (Figure 113), as well as the screw fixing material from the “top- mounted box for earthing” set of bags must be used Insulating cover 10 (Figure 113) must be brought into position as described in (chapter 6.7) Note: The auxiliary switches for the earthing switch are adjusted at the factory. Correct operation is only guaranteed if the working elements on the hexagonal shaft are correctly mounted. During final installation of the earthing switch and operating mechanism on site, it may be necessary to make precise adjustment of the auxiliary switches. In this case, the following is important + The auxiliary switch OFF 1 (Fioure 118) must be operated before slide 3 has uncovered half of the ‘opening in front of the hexagonal shaft and before the lower edge of the slide has touched the anchor of locking magnet 4 + The auxiliary switch ON 2 must be operated before the toggle spring of the earthing switch has reached its dead centre point + The push-rod of the auxiliary switch must still have about 0.5 mm to go to the end position in the operated position eS ° j © 147: Busbar earthing switch, Top-mounted box Conductor tube Operating mechanism boxSU ra cich rh ch = Be Figure 118: Panels 12 /17.5 kV - Top-mounted box with earthing switch for busbar earthing. Auxiliary switch OFF ‘Auailiary switeh ON. Slide Locking magnet Figure 118: Panels 24 kV = Topsmounted box with earthing switch for busbar earthing. the arrangement Is the same as the figure above. ‘Top-mounted box Condvetor tube Operating mochanism box Connection bar n6.8.3 Ultra fast earthing switch UFES For more information see document 1VLG100128 Manual for installation of UFES into UniGear 281 Figure 120: Top-mounted box with UFES. ures ‘Top-mounted box Conductor tube Reducer ring Intermediate box 6.8.4 Anti-ferroresonant resistor for transformers open delta connection When using a ferroresonance resistor for VTs open delta connection is necesary to adjust the position of this resistor during site installation. The ferroresonance resistor Is placed on the top of switchgear on the CB relief flap for the transportation Figure 121). When moving the resistor from relief flap to LV compartment (LVC) please follow pictogram Figure 122) on the top of LVG, The resistor has to be fixed by means of screws on the top of the LVC Figure 123) Assemble resistor prior to instalation of preassure relict gas duct. Pay attontion to the resistor's wires whilst installing gas duct. voltage Figure 121: Transport position of anti-terroresonant resistor. 72The pressure relief duct is supplied dismantled in single components. The rear and front wall correspond, as far as length is concerned, with the appropriate panel width. The screw fixing material is contained in the “pressure relief duct’ set of bags. Rivet nuts are already provided in the metal sheets. Detailed instructions for gas exhaust duct assembly are described in document Assembly manual 41VLMo00034 Note: The rear pressure relief flap must be mounted according to (Figure 124). Details regarding Connection to the wall and @ discharge grating for pressure relief outside the switchroom will be agreed fon with the customer Figure 124: Schematic diagram of the pressure rellef duct. 1 Pressure relief duct 2) If the switchgear is equipped with a pressure relief uct, the pressure ‘reliet tlap for the cable. connection Compartmont is fixed to the rear side of the panel and will open fo the frant (into the duct) In cage of an are fault 6.9.1 Gas duct with outlet Once the panels are bolted up, and busbars are installed, it is possible to start fixing the gas duct on the top of the switchgear. Every panel has three fixing points in the front part (Fiaure 125) and three fixing points on the rear part (Figure 126) Figure 128: Fixing points on the front Figure 127: Assembly of p duct. ove flaps without gas Not This side of the preassure relief flaps has to be fixed by plastic screws, The marked screws must be plastic. Figure 128: Assembly of pressure r duct. lave flaps with g Note: Ifa gas duct is used turn off the cable compartment flap according to figure. The marked screws must be plastic. 736.9.2 Gas duct with top chimneys In order to mount the gas duct with top chimneys please follow the appropriate instructions, The difference between the two solutions Is that in this case there are no side exits, but the gas generated from an internal the arc exits from the duct through the lop chimneys located on the top part of the gas duct on each panel. On the top of the gas duct there are two openings Figure 130); for each opening the perforated metal plate must be fixed with 6 spacers (Figure 131 pr Net and spacers of top chimneys, ‘Top cover of top chimneys 74 Note: For UniGear ZS1 24 kV: 31,5 kA with gas duct with top chimneys for a duct height of 500 mm it is necessary to use a deflector. Insert the deflector onto gus duct - open side in direction of LVC. For fixation use connecting parts included in gas duct assembly Deflector is designed to divert hot gas away of rear part of panel to shield a staff behind the panel. It is not necessary to aply the deflector in case of placing panels directly to wall, No access from rear side.6.10 Cable connection 6.10.1 Power cables The standard method for entry of power cables in the switchgear is shown in (Figure 135). The cables are conveyed from below through floor covering 2, which Is divided at the cable entry point The cables go through rubber reducer rings 3, which can be adapted to the required cable diameter in a range from 27 to 62 mm. Cables are fastened in the panel by means of cable clamps mounted on cable strips, which are part of the panel floor covering The clamps make it possible to fasten cables with 1 2 3 4 jure 133: Partial view of the cable compartment, here for connection of triple cables. Earthing connection pin Cable termination kits are mounted on the cable cores according to the manufacturer's instructions. It Is possible to use cable termination kits from different manufacturers (e.g. Prysmian, Raychem ete.), but it is necessary to keep the same length of the cable ends, including cable termination kits, which is given by the distance of cable connecting bars (Figure 133) from the panel floor covering These bars have different versions, which differ in their number of parallel cables and the values of rated and short-circuit currents The bars are equipped with holes for M16 screws. The earthing of cable screens is carried out on the strip- holding cable clamps. The cable strip is connected to the earth potential Itis also possible to place the removable arrangement of voltage transformers in the cable compartment. These can be fitted with HV fuses similar to those in the measuring panel Three fixed mounted surge arresters can also be Installed here, In both cases the number of parallel cables that can be installed Is reduced - (see table), Earthing switch position indicator Cable connection bar Gable clamp Reducer ring Floor cover, split AV operant note: The cable connection bars are equipped with holes for M16 screws, 75