Safesix: ABB Switchgear

Safesix
12 kV switchgear manual
ABB Switchgear
Instruction 1VES 580901-902

Edition 97-11
CONTENTS
Page
0. Access zones....................................................................................................................................................................................1
1. General description ................................................................................................................................................................1
1.1.
Standards ................................................................................................................................................................................................3
1.2.
Cubicle design ................................................................................................................................................................................4
1.2.1. Personnel safety ..............................................................................................................................................................................5
1.2.2. Dimensions and weights.....................................................................................................................................................7
1.2.3. Busbars and downleads .....................................................................................................................................................8
1.2.4. PC intermediate wall with shields .........................................................................................................................8
1.2.5. Earthing.........................................................................................................................................................................................................8
1.2.6. Running gear and interlock system....................................................................................................................9
1.2.7. Temperature indicators.....................................................................................................................................................11
1.3.
Power circuit breaker cubicle ..........................................................................................................................12
1.4.
Load disconnector cubicle SFL .....................................................................................................................13
1.5.
Load disconnector cubicle NAL/NALF ..............................................................................................14
1.6.
Disconnector cubicle ......................................................................................................................................................15
1.7.
Metering cubicle ......................................................................................................................................................................16
1.8
Sectioning cubicle ................................................................................................................................................................17
1.9
Contactor cubicle ..................................................................................................................................................................18
2. Contactor cubicle .....................................................................................................................................................................19
2.1.
Erection requirements ...................................................................................................................................................19
2.1.1. Lift truck ...................................................................................................................................................................................................19
2.2.
Floor..............................................................................................................................................................................................................20
2.2.1. Space requirements...............................................................................................................................................................21
2.3.
Unloading ............................................................................................................................................................................................23
2.4.
Moving in ..............................................................................................................................................................................................23
2.5.
Setting up ............................................................................................................................................................................................24
2.6.
Fitting busbars ............................................................................................................................................................................27
2.6.1. Fitting busbars, light series .........................................................................................................................................27
2.6.2. Fitting busbars, heavy series ...................................................................................................................................28
2.7.
Cubicle and system earthing..............................................................................................................................30
2.8.
Fitting roof panels .................................................................................................................................................................31
2.9.
Connecting power cables........................................................................................................................................31
2.10. Connecting control cables .....................................................................................................................................35
2.11. Post-tightening ..........................................................................................................................................................................37
3. Post-tightening ............................................................................................................................................................................38
4. Post-tightening ............................................................................................................................................................................41
4.1.
Commissioning new switchgear ................................................................................................................41
4.2.
Commissioning after stoppage for repair or other action .............................41
4.3.
Commissioning after stoppage......................................................................................................................41
5. Operating instructions....................................................................................................................................................42
5.1.
Circuit breakers HPA and HA ............................................................................................................................42
5.1.1 Circuit breaker shift ................................................................................................................................................................43
5.1.2. Circuit breaker shift to operating position ............................................................................................44
5.1.3. Circuit breaker shift to disconnected position ...............................................................................45
5.2.
Load disconnector SFL ..............................................................................................................................................47
5.2.1. Safesix SFL interlock chain ......................................................................................................................................47
5.2.2. Shifting load disconnector SFL ............................................................................................................................48
5.2.3. Shifting load disconnector SFL to operating position ......................................................48
5.2.4. Switching load disconnector on ........................................................................................................................49
5.2.5. Shifting load disconnector SFL to disconnected position .........................................49
5.2.6. Switching load disconnector off .........................................................................................................................49
5.3.
Load disconnectors NAL 12/630, NALF 12/630 ..................................................................50
5.3.1. Operating NAL/NALF ...........................................................................................................................................................52
6. Maintenance rules ................................................................................................................................................................54
6.1.
Switchgear cubicle maintenance ...............................................................................................................55
6.2.
Lubricants ...........................................................................................................................................................................................57
6.3.
Cleaning agents ........................................................................................................................................................................57
7. Accessories, spares and ancillary equipment ............................................................................58
8. Documentation references ......................................................................................................................................60
Safesix 12 kV switchgear
0
Access zones
Switchgear is not intended to be accessible to the general
population. The access zone for operators is the service entrance at the front of the switchgear. Only servicing personnel
are allowed to open switchgear doors. All operation of a withdrawable switching or connecting unit must be with the doors
closed.
1
General description
ABB's Safesix switchgear series is divided into compartments
and intended for indoor locations. It is available in three different
voltage versions of 12, 17.5 and 24 kV. This documentation is
for the 12 kV version. The cubicles are sized for operating
currents of up to 3150 A and maximum 4000 A on the busbars
and a short-circuit current of up to 40 kA.
Safesix 12 kV switchgear is available in two forms:
Light series
Max. rated current 1600 A.
Max. short-circuit current 31.5 kA.
Heavy series
Max. rated current 4000 A.
Max. short-circuit current 40 kA.
The range comprises the following cubicles:

Circuit breaker cubicle, with SF6-breaker
Switch disconnector cubicle, with SF6-or air-insulated

switch disconnector
Disconnector cubicle, with drawer-mounted disconnector
Metering cubicle, with measuring transformers
Sectioning cubicle, with withdrawable switching or connecting unit
Interconnection cubicle
Contactor cubicle with vacuum contactor (max. 7.2 kV)
The withdrawable switching and connecting units have the following functions:
Circuit breaker
Can make, carry and break operating
current and short-circuit current
Switch disconnector
Mechanical electrical switch operated manually. Can make, carry and
break normal operating current. Can

carry short-circuit current for a specified period. Can close against shortcircuit current and can be provided
with fuses and short-circuit protection. NAL and NALF have visible
break points. SFL has mechanical
indication. Type of switch used preferably where both switching density
and current are low.
Disconnector
Operated manually and has visible

disconnection distance. Cannot connect current but can carry operating
and short-circuit current. Safesix has
a disconnector of drawer-mounted
design that can be interlocked so that
it cannot be shifted when energised.
Contactor
Electrical switch that is operated electrically and has an electrical or mechanical latch. Can make, carry and break
normal operating current and carry
short-circuit current for a specified
period. Can be supplied with fuses as
short-circuit protection. Type of switch
used preferably where switching
density is high and current low.
Circuit breaker
cubicle
Sectioning cubicle
31.5 kA 630 - 1600 A
Sectioning cubicle
40 kA 800 - 3150 A
Disconnector
cubicle
Metering
cubicle
Switch disconnector
cubicle
Inter connection
cubicle
Contactor
cubicle
Fig. 1. Examples of cubicle types in ABB Safesix range.
1.1.
Standards
Standards complied with:

SS-IEC 298.
Electrical requirements complied with:
Rated voltage:
12 kV SS-IEC 298
Test voltage:
Impulse withstand voltage 75 kV
1.2/50 s.
Power frequency voltage 28 kV 50
Hz, 1 min.
All voltage levels apply to earth and between phases (max.
1000 m above sea level).
Rated current:
Busbars: 630, 800, 1250 and 1600 A
for light series.
1250, 2000, 2500, 3150 and 4000 A
for heavy series.
Circuit breakers and cubicles: 630,
800, 1250 and 1600 A for light
series.
800, 1250, 2000, 2500 and 3150 A
for heavy series.
The above current values apply with
enclosure IP3X, max. temperature
rise as per SS-IEC 298 table V at
max. average ambient temperature
35C and max. short-time temperature 40C.
Rated short-time
current:
25, 31.5 and 40 kA in one second.
25 and 31.5 kA in 3 seconds (option).
Rated impulse current
peak value:
2.5 x rated short-time current.
Mechanical requirements complied with:
Enclosure:
Outer enclosure IP3X according to
SS-IEC 298. Partitions IP2X as seen
from withdrawable switching or
connecting unit compartment.
Environmental requirements complied with:
Ambient temperature: As per SS-IEC 298, -5C to +40C.
Switchgear can be equipped to cope
with difficult environments.
1.2.
Cubicle
design
Cubicle frames and rear panels made of spot-welded 2 mm

Aluzink sheetsteel. Doors of 2.5 mm painted sheet steel.
Cubicles may either be backed up against a wall or placed
with sufficient clearance to leave the rear accessible. They
may also be ordered with exhaust channels designed for
minimum roof height 2650 mm.
Each cubicle is divided into a number of compartments:
Busbar compartment
Low-voltage compartment, with contents varying from installation to installation. A detailed description of this compartment appears in the documentation specific to each
order
Withdrawable switching or connecting unit compartment
Cable compartment
All HV compartments (busbar compartment, cable compartment and withdrawable switching or connecting unit compartment) have individual upward pressure relief ducts with top
covers that opens by any overpressure in the respective compartment.
Lead-in duct for

external LV cables
Low voltage box door and
Combiflex framework
Busbar compartment
LV compartment
Instrument space
Upper door
Racking mechanism
Lower door
Air intake for cubicles with
rated current 1600 A
Fig. 2a. Safesix cubicle space distribution.
Compartment for
withdrawable switching
or connecting unit
PC partitions
Partition wall for
compartment division
Cable compartment
The front of cubicles for 1600 A or over is provided at the

bottom with a cooling air intake to create sufficient ventilation. This intake is provided with a patented check valve.
On 3150 A circuit breaker cubicles the lower door is also
provided with ventilation apertures.
Each cubicle is provided with lighting. The incandescent
bulb can be replaced from the LV compartment and is
situated outside the compartment rear wall.
1.2.1.
Personnel
safety
Personnel safety
High voltages and currents can cause serious injuries, so the
Safesix range is designed for maximum elimination of
accident risks.
Contact safety
As it is vitally important for servicing personnel to be protected
from inadvertent contact with energised parts, Safesix cubicles
are divided into compartments. Among other advantages, this
prevents access to energised busbars when disconnected
circuit breakers are being inspected. The walls between
compartments are partly transparent. The advantages of this
include being able to view the disconnection distance through
the window in the LV compartment.
CAUTION! There is no contact protection inside the lower
door. The cable side has to be de-energised and be earthed
by means of the earthing switch before opening the door.
Unauthorised access can be prevented by padlocking the
handles of both the upper and lower doors.
Arcing safety
The outer enclosure has been arc-tested to SS-IEC 298.
The front, rear and sides withstand the pressure caused by
arcing faults. Safesix cubicles have also been successfully
tested to SS-IEC 298 with breaker doors open.
Damage caused by arcing faults is extensive and costly,
so their causes need to be eliminated despite the high
degree of personnel safety built into Safesix switchgear. The
following are possible causes of flashover:
Small animals, most commonly rats or mice, that make

their way into HV spaces
Overheating due to bad threaded connections, oxidised
contacts or overload
High overvoltages, e.g. during thunderstorms
Objects such as tools inadvertently left behind
Faulty or severely fouled components or cable terminations
The Safesix design incorporates the following measures to

improve the prevention of arcing:
Holes in outer enclosure too small for even small animals

to make their way into HV spaces
Erection instructions give torques for correct tightening of

threaded connections
Spring washers used in threaded connections of primary

conductors to control prestress forces even after a
number of temperature cycles and sagging of material
Busbar monitoring by SafeGuard (option)
Overvoltage limitation by surge arrestor (option)
Arcing fault prevention by arc monitor (option) to trip the

breaker when it indicates a powerful arc combined with
high current. This involves the development of pressure
waves that reach their maximum in a hundredth of a
second
Exhaust gas channels (option)

For gathering and leading overpressure and flue gases away so
as not to affect switching operations. As the channels lead to
outdoor outlets, the switchgear room is not pressurised or polluted by toxic arc gases.
Voltage indicator (option)
Earthing medium-voltage switchgear is a safety risk. To
minimise it, the earthing should be effected inside closed
doors by means of earthing switches. Each cubicle is provided with an interlock system to prevent incorrect operation. It may also be provided with voltage indicators that
display 1, 2 or 3 if the corresponding phase is energized.
Fig. 2b. Voltage indicator
SafeGuard (option)
SafeGuard is a monitoring system covering, among other
things, the temperatures of busbar joints and contacts in the
main circuit. The continuous information thus provided helps
to eliminate the risk of arcing faults.
Temporary earthing
Safesix switchgear is equipped with a patented earthing
switch that has the following features:
It can be operated when the doors are closed
It has making capacity up to 40 kA rms
The window in the lower door makes it possible to see

whether the earthing switch is closed or open
Illicit operation is prevented by interlocking by means of a

blocking disc that closes the operating hole when the
breaker is in operating position or being shifted
Training
It is very important that operators and servicing personnel be
trained in handling the equipment.
1.2.2.
Dimensions
and weights
Weights
A 12 kV switchgear cubicle (without circuit breaker) normally
weighs 400 to 600 kg depending on equipment, e.g. an 800 A
circuit breaker cubicle weights 400 kg.
A circuit breaker weighs between 180 and 235 kg, depending
on its rated current.
Max
Series
current A
Dimensions mm
H
W
D
1600
2500
3150
2160
2160
2160
Light
Heavy
Heavy
700
700
700
1200
1300
1600
Fig. 3. Dimensions of 12 kV switchgear cubicle.
1.2.3.
Busbars and
droppers
Busbars and droppers are normally supplied uninsulated but

can be supplied with insulation to order. Busbars are made
of copper with cross-section suited to the rated current.
1.2.4.
PC-partition
with shutters
The switchgear is of the drawer-mounted type. The withdrawable units can be cranked into and out of the
compartments. The withdrawable unit compartment and the
busbar compartment are separated by a partition of
polycarbonate to prevent inadvertent contact with live parts
when the unit is removed. This partition incorporates six
shutters that are opened by the connecting bars when the
unit reaches operating position.
The PC partition and the shutters provide IP3X as degree
of protection.
Earthing switch shaft

with position symbol
PC partitions
Shutters
Box with earthing
switch auxiliary contacts
and interlock magnets
Fig. 4. PC partitions with shutters (racking mechanism removed).
1.2.5.
Earthing
Fixed earth paths, system earthing

Safesix has two alternative earthing arrangements.
The first is for each cubicle to be earthed separately, with
terminals for connecting external earth conductors to the
earth bar in each cubicle.
The other alternative has an earth bar running through the
whole switchgear, with terminals for connecting external
earth conductors to the earth bar in each cubicle. The only

earth connections of the station are in the outer cubicles.
Equipment items incorporated are earthed to the frame,
except for the earthing switch and the voltage transformers,
which have earthing wires to the earth bar of the cubicle.
Temporary earthing
A standard fitting for temporary earthing of cable is an
earthing switch permanently fitted in the cubicle. Any busbar
earthing switch fitted will be on the righthand end cover. An
option available is to equip the earthing switch with voltage
indicators that display on the cubicle front.
The earthing switch is operated from the cubicle front by
means of a crank. On earthing switch operation see section
5.1.1, Shifting withdrawable units.
1.2.6.
Each withdrawable unit is provided with wheels that run
Racking mechanism
and interlocking system along channel sections on the sides of the cubicle. The unit
can be pulled out onto the door. A stop mounted on the door
prevents its being pulled too far out. For instructions on
shifting withdrawable units, see section 5.1.1. The racking
mechanism has interlocks to prevent incorrect operation.
Torsion disc
Selector cam
Selector
Stop
Racking
mechanism
operating hole
Earthing switch
operating hole
Fig. 5. Interlock system.
The interlock system has active interlocks (preventing access

to operating holes) that mechanically make it impossible to:
1. shift a closed circuit breaker (blocking disc covers racking
mechanism operating hole, selector rotation breaks control
circuit)
2. shift a closed circuit breaker from test position to service
position (blocking device on righthand side of circuit breaker
hits the stop)
3. close the circuit breaker while it is being shifted (during
which it has no control voltage)
4. shift the circuit breaker from disconnected position to service position if the earthing switch is closed (blocking disc
covers racking mechanism operating hole)
5. connect the earthing switch if the circuit breaker is in
service position or being shifted (blocking disc covers
earthing switch operating hole)
6. push the circuit breaker in from disconnected position if the
racking mechanism is in the wrong position when the circuit
breaker is run in from the door (blocking devices on selector
shaft and torsion disc stop the circuit breaker)
7. place the selector in shift position if the circuit breaker is
closed (blocking device in circuit breaker prevents selector
movement)
8. place the selector in service position if the circuit breaker
is not fully run in to service position (selector cam cannot
enter recess in torsion disc)
9. run a withdrawable unit into a cubicle intended for a
higher rated current (prevented by blocking devices on
rails and on withdrawable unit wheel undercarriage)
As an option the cubicle may be equipped with motorised
racking mechanism.
10
1.2.7.
Temperature
indicators
An option with which Safesix cubicles can be provided is

temperature indicators consisting of two small self-adhesive
markers positioned to detect the temperature at critical
points on the conducting path. They replace thermography
and are used for preventing malfunctions due to overheating.
1. The 104C marker is white when unaffected and turns
darker when subjected to excessive temperature. Neither
time nor temperatures below 104C affect it. It is placed
close to critical points in cases where they are visible from
the front of the cubicle.
2. The 70C marker is reversible. Up to 70C it is red but
beyond that it turns darker and displays the numerals 70.
It reverts to red upon cooling. It is placed in a clearly
visible position adjacent to the point that may become
hottest in cases where the critical point cannot be seen
from the front of the cubicle.
Fig. 6. Temperature indicators for 12 kV.
11
1.3.
Circuit breaker
cubicle
Data
Rated current
Rated voltage
Insulation level
Insulation level
Rated short-time
current peak value
Rated short-time current, 1 s
Rated short-timecurrent, 3 s
kV
kV
kV
630, 800, 1250, 1600,

2000, 2500, 3150
12
28/75
38/75 (option)
kA
kA
kA
62.5, 79, 100

25, 31.5, 40
25, 31.5 (option)
This cubicle contains an SF6-circuit breaker (described

separately) of the withdrawable type and can be provided with
current transformers, voltage transformers, earthing switch and
cable fastenings. In the light series (max. 1600 A) four parallel
cables can be connected. In the heavy series there is space for
up to six parallel cables. The cubicle incorporates interlocks to
prevent the connection of undersized units.
The withdrawable unit can be shifted inside the closed door,
thereby creating a disconnection distance that can be viewed
through the window in the LV compartment (see Fig. 7).
Window in
low voltage
compartment
Fig. 7. Circuit breaker cubicle.
12
1.4.
Switch disconnector
cubicle SFL
Contains an SF6-switch disconnector which is drawer-mounted

and placed in the withdrawable unit cell. The rated current is up
to 630 A without fuses and up to 100 A with high-power fuses.
The switch disconnector is operated manually inside the
closed door by means of a control lever. For fuse replacement
the unit has to be pulled out onto the door (see separate
instructions 1VEH 580901-901. The racking mechanism can be
used inside the closed door to shift the withdrawable unit to
disconnected position, thereby creating a disconnection distance that can be viewed through the window in the bottom of
the LV compartment. This cubicle can be used for up to 20 kA if
the withdrawable unit has no HV fuses or for 40 kA with fuses.
The upper door is extended by 40 mm, making a total cubicle
depth of 1375 mm.
Window in
low voltage
compartment
Fig. 8. Switch disconnector cubicle with SFL.
13
1.5.
Switch
disconnector
cubicle
NAL/NALF
Contains a drawer-mounted switch disconnector in the withdrawable unit cell.

The switch disconnector is operated manually inside the
closed door by means of a control lever. It can be provided
with high-power fuses up to 100 A. For fuse replacement the
withdrawable unit has to be pulled out onto the door. It has a
visible disconnection distance at the knives, so it has no
disconnected position in the cubicle. It is therefore connected in service position when just inside the door. This
cubicle can be used for 40 kA if the withdrawable unit has
fuses and for 25 kA without fuses. It can be provided with
current and voltage transformers and an earthing switch.
Window in
low voltage
compartment
Fig. 9. Switch disconnector cubicle NAL/NALF.
14
1.6.
Disconnector
cubicle
Same construction as the circuit breaker cubicle. The withdrawable disconnector has the same contact positions in the
conducting path as the corresponding circuit breaker. Disconnection is achieved by shifting the withdrawable unit from
service position to disconnected position. Disconnection can
be effected by means of racking mechanism inside the closed
door. The cubicle can be provided with current and voltage
transformers and an earthing switch.
The disconnector has no make and break facilities. Interlocks prevent incorrect operation. The disconnection distance can be viewed through the window in the LV compartment. Blocking devices prevent withdrawable units with too
small a rated current being run into the cubicle.
Window in
low voltage
compartment
Fig. 10. Disconnector cubicle.
15
1.7.
Metering
cubicle
This cubicle can measure current or voltage or both. It can be

provided with IHBF type current transformers or with transformers to DIN standard (small model).
Max. operating voltage
12 kV
Primary rated current:
IHBF type, 12C
Up to 1250 A, two cores
DIN type
Up to 3200 A, three cores
Secondary rated current 5 A
Frequency
50 - 60 Hz
The cubicle can be provided with KRES type voltage transformers, which are single-phase versions intended for connection between phase and earth. All three phases should be fitted.
Primary rated voltage
12 kV
Secondary rated voltage 110/3 V for metering and
110/3 V for earth-fault protection
Frequency
50 - 60 Hz
The cubicle can be equipped with an earthing switch type
NJS 12 with making capacity 40 kA, 1 s.
Fig. 11. Light-series metering cubicle measuring both current and voltage.
16
1.8.
Sectioning
cubicle
The function of this cubicle is to divide switchgear into two

sections. It is mainly constructed in the same way as the circuit
breaker cubicle with a circuit breaker or disconnector withdrawable unit. It can be equipped with current and voltage
transformers and an earthing switch. In the light series
everything is housed in one cubicle. In the heavy series two
cubicles are used, one of them containing the withdrawable
unit, measuring transformers and earthing switch, the other
containing only sectioning busbars. There are two different
sectioning combinations, one with current measurement before
the withdrawable unit, the other with it after.
Light series:
Rated current 630-2000 A, max. short-time current 31.5 kA.
Heavy series:
Rated current 630-3150 A, max. short-time current 40 kA.
Fig. 12. Light-series circuit breaker cubicle with sectioning. For the heavy series a two-cubicle combination is used.
17
1.9.
Contactor
cubicle
Data
Rated voltage . . . . . . . . . . . . . . . . . . .3.6 kV . . .7.2 kV
Insulation level . . . . . . . . . . . . . . . . . . .10/40 kV .20/60 kV
Rated current with fuse . . . . . . . . . . .315 A . . . .315 A
Fuse length . . . . . . . . . . . . . . . . . . . . .292 mm . .442 mm
Rated short-time current . . . . . . . . . .9 kA . . . . .9 kA
Rated short-time current with fuse . .40 kA . . . .40 kA
This cubicle contains a VRC type vacuum contactor which is
drawer-mounted and placed in the withdrawable unit
compartment. It is operated electrically and has both electrical
and mechanical latch. For fuse replacement the withdrawable
unit has to be pulled out onto the door. Racking mechanism
can be used to shift the contactor to disconnected position
inside the closed door, thereby creating a disconnection
distance that can be viewed through the window in the
bottom of the LV compartment. The upper door is extended
by 40 mm, making a total cubicle depth of 1375 mm.
Fig. 13. Contactor cubicle.
18
2
Erection instructions
CAUTION! Take good care to follow these instructions precisely so that cubicles are not dropped or tipped over during
unloading, moving in and setting up. When handling cubicles,
take particular care to avoid causing pinching or injuries.
2.1.
Erection
requirements
A pallet lifter with maximum width 540 mm may be used to

move cubicles into the switchgear room. This is catered for
by placing two lifting yokes on the cubicle as in Fig. 18.
Before moving the cubicle, check that apertures for cables
are in accordance with layout drawings and with Figs. 27 and
15. Examine the floor surface and note irregularities so that
the cubicle can subsequently be adjusted to the correct level.
2.1.1.
Trolley
CAUTION! When using a trolley, the unit concerned must

always be carried in the lowered position. Do not leave it in
the raised position on the trolley.
Removing a withdrawable unit from a cubicle or putting it in
involves using a trolley. The trolley will lift the circuit breaker,
drawer-type disconnector, switch disconnector or contactor
from the floor to the correct height for placing it on the opened
upper door.
Order no.
Description
1VES 841930-AAA Trolley

1VES 841930-AAB Adaptor for voltage
measuring sets
Section to
front wheel
Section to
front wheel
Square tube
Square tube
Fastening bolt
Fastening bolt
Position for 12 kV
Position for 24 kV
Fig. 14a. Trolley.
19
The same trolley is used for both 12 and 24 kV switchgear and

is normally supplied in the 12 kV position. If it is in the 24 kV
position, it can still be used if there is space beside the outer
cubicle. The trolley can be made about 100 mm narrower (12
kV position) by slackening the bolts (two on each side) that
fasten the sections on which the front wheels are mounted to
the fixed square tube in the truck frame. Adjust the position of
the sections in the square tubes and retighten the bolts (see
Fig. 14 a).
Lifting voltage measuring sets requires the use of a special
lifting adaptor which is suspended on the trolley forks by
placing the front ends of the forks in the two slots in the square
sections that act as guides in the lifting adaptor. Inset the pin in
the hole in the movable spacer tube, then insert one end of the
spacing tube in the lowest square tube in the lifting adaptor.
Push out the two guided stays and push the screws at their
bottom ends in through the holes in the side panels of the
voltage measuring set and lift as in Fig. 14b.
Pin
Spacer tube
Fig. 14b. Adaptor for lifting voltage measuring sets.
2.2.
Floor
20
Cubicles can be erected on various types of floor. The

maximum permitted variation in level is 10 mm over the
whole length of the switchgear.
Concrete floor: Should incorporate the smallest possible

holes for the power cables. Note that single-phase cables
should not be run through their respective holes if there are
steel reinforcements between holes. The reason for this is
to prevent reinforcements forming magnetic loops that
might cause heating and losses. After cable erection, the
holes should be sealed against fire and small animals.
Alternatively the cubicle bottom may be provided with a
cable seal plate. Cable holes should be aligned with cable
fastening points as in Fig. 27. For cubicle fastening to floor,
see section 2.5, Setting up.
Switchgear floor on framework: Should be constructed so
that cubicle feet stand on the longitudinal square tubes.
No height adjustments are required on floors of this type.
Fastening by bolts through the square tube as in Fig. 20b.
Floor with longitudinal cable channel: A 500 mm cable
channel maybe used. Place the cubicle so that its bottom
hole is over the centre of the cable channel, the front
adjusting feet are in front of the channel and the rear feet
behind it. With this kind of arrangement the cubicle should
be provided with a cable seal plate to keep out small
animals by being clamped tight to the cubicle bottom.
2.2.1.
Space requirements
Cubicles may be positioned with their rear as close to a wall

of the building as the construction tolerances allow (about 20
mm). Figs. 15 and 16 show the space requirements around a
cubicle.
Fig. 15. Dimensional drawing for cubicle bottom.
21
700
65
min 150
65
min 150
Right-hand end cover without earthing switch
N.B. According to SS 4362101 and the Electrical Safety Authority's heavy

current regulations (ELSAK-FS 1994:7), if there is another row of switchgear
opposite, the space between the cubicle fronts must be at least 1920 mm.
min 2650
Switchgear with end covers
Circuit breaker door folded out
Right-hand end cover with earthing switch on busbar
min 450
65
400
min 1500
700
65
min 150
Fig. 16. Space requirements for Safesix switchgear.
22
710
2.3.
Unloading
Cubicles are supplied wrapped in plastic, banded to pallets

or packed in boxes. Withdrawable units are locked in
disconnected position inside their cubicle. The easiest way
to unload cubicles is by fork truck. If they are unloaded by
crane, the four lifting eyes should be used (see Fig. 17).
Check that there is no transport damage.
Fig. 17. The lifting weight of cubicles is normally 400-600 kg.
2.4.
Moving in
CAUTION! If the transport protection was broken during

loading, the cubicle enclosure will have sharp edges on the
sides and top. Be particularly careful when handling or touching these areas.
Keep cubicle packaging as long as possible. Use a pallet
lifter to remove the cubicle from the shipping pallet by inserting it in the cubicle and placing two lifting yokes as in Fig.
18. The cubicle can only be transported in this way with the
Lifting tackle
Fig. 18. Pallet lifter positioning.
23
circuit breaker removed.

Before inserting the pallet lifter in the cubicle, lift off the
lower door and keep it well protected during the erection
period, e.g. on a pallet. The measuring transformer unit is
sized for possible use as a rear yoke.
NB! If the cubicle cannot be transported upright, e.g.
because of doorways being too low, it may be placed on its
back on a pallet and carried by pallet lifter to the erection site.
Remove the withdrawable unit before placing the cubicle on
its back.
CAUTION! Keep in mind the risk of pinching or injury
between doorways and equipment and between trucks and
equipment. To remove the withdrawable unit, place the selector in position 2 (removal onto door). The unit is thus released
and can be rolled out onto the door. This may be done with
the cubicle standing on a pallet.
CAUTION! Only in the lowered position should a unit be
carried by lift truck. Do not leave it in the raised position on the
truck. The safest way to run a lift truck carrying a withdrawable unit is in the lowered position.
Roof panels and busbars are supplied packed separately in the
respective cubicle. Check the materials sent with them against
the accompanying specification. Complaints about missing or
damaged items must be raised as soon as possible.
2.5.
Setting up
CAUTION! Cubicle enclosures have sharp edges on the

sides and roof. Take particular care when handling these areas.
Figu.19. Positions of bolted connections.
24
Setting up commences with the cubicle standing on the

highest part of the floor. Use the four adjusting screws as
necessary to adjust the cubicle to the correct level (this does
not apply to switchgear floors with framework). Check the
distance between the set-up cubicle and sidewalls (distance =
number of cubicle widths + side arrangements) as in Fig. 16. If
the cubicle is to stand with its rear against a wall, check that all
the screws in the rear panel are tightened before positioning
the cubicle against the wall. Place the next cubicle and adjust
to the correct position. See that its front is in line with the first
cubicle. Bolt the cubicles together with four M8x16 as per Fig.
19.
Fasten cubicles to the floor as per Figs. 20a and 20b. In a row
of up to four cubicles, fasten only the outer ones. Where there
are more than four, fasten every third.
Drill holes in the floor, using the square holes of the adjusting
screws as jigs. For Hilti HKDM10 type expanders drill to
diameter 12, depth 50. Washers should be used (see Fig. 20a).
The bellows for control lines between cubicles is permanently
mounted on the lefthand side of each cubicle and should be
inserted in the respective hole in the cubicle to the left (multipole contacts with bellows are optional).
For erection of busbars, see section 2.6.
Erect the other cubicles in the row by the same procedure.
CAUTION! Beware the risk of pinching when closing
doors. When all the cubicles in the row have been set up,
check that their fronts are in line and that their doors and
locking devices function properly. It is important that the
doors be closed and the handles folded into them in
order that they should withstand the pressure caused by
any arcing fault. The handles should be easy to operate.
Check the movement of the withdrawable units by shifting
them from door to operating position and back.
Adjust the threshold in each cubicle downwards towards the
floor.
When handling an upper door, the handle should be grasped
with both hands. To open an upper door, raise the handle and
the door will fold out downwards. To close it, raise the handle
and close the door, then press the handle down against the
25
Use a small-diameter
hose to blow drill
cuttings away
Hilti type expander
Fig. 20a. Cubicle fastening to concrete floor.
Fig. 20b. Cubicle fastening to

"switchgear floor".
door panel. To open a lower door, pull the handles out towards
you, then turn them upwards. The door will move upwards and
outwards. To close the lower door, fold the handles out from
the door and turn them upwards. Use the guide pins on the
door to raise it into position, then press the door downwards,
turn the handles downwards and fold them in.
The gap between cubicle front side-panels is a nominal 3 mm
and should not be reduced, as cubicles are tight together in
middle part.
26
2.6.
Fitting busbars
2.6.1.
Light series
CAUTION! Cubicle enclosures have sharp edges on their

sides and roof. Be particularly careful when handling these
areas.
Supplied with busbars mounted on their insulators and tilted

so as not to protrude from the sides of cubicles. Torquing as
per section 2.11.
Right-hand
outer cubicle
Intermediate
cubicle
Right-hand
outer cubicle
Intermediate
cubicle
Left-hand
outer cubicle
View from rear
Front
Busbars for
sectioning cubicle,
as seen from above
Rear
Fitting busbars and droppers

A-A
Busbars for:
Droppers for:
1250, 1600 A
1250, 1600 A
A-A
1250, 1600 A
800 A
A-A
1250, 1600 A
630 A
A-A
800 A
630, 800 A
A-A
630 A
630 A
Fitting busbars
B-B
Busbars for:
1250, 1600 A
B-B
800 A
B-B
630 A
Fig. 21. Fitting light-series busbars and droppers.
27
2.6.2.
Heavy series
Delivered with busbars mounted against the panel in the

busbar compartment. Torquing as per section 2.11.
CAUTION! Shipping screws must be removed from switchgear before energisation.
The black plastic shipping interlay is intended to facilitate
busbar fitting and should be removed.
Fit these busbars in each cubicle as it is set up. Bolting
together and torquing in the case of outer cubicles and
during retightening should be carried out from above.
Intermediate cubicle
Outer cubicle
Busbars
Droppers
2500 - 3150 A
2500 - 3150 A
Outer cubicle
Busbars
Droppers
2500 - 3150 A
1600 - 2000 A
Outer cubicle
Busbars
Droppers
2500 - 3150 A
800 - 1250 A
Fig. 22a. Fitting heavy-series busbars and droppers.
28
Outer cubicle
Busbars
Droppers
1600 - 2000 A
1600 - 2000 A
Outer cubicle
Busbars
Droppers
1600 - 2000 A
800 - 1250 A
Fig. 22b. Fitting heavy-series busbars and droppers.
Outer cubicle
Busbars
Droppers
800 - 1250 A
800 - 1250 A
Fig. 22c. Fitting heavy-series busbars and droppers.
29
2.7.
Cubicle
and system
earthing
Fig. 23. Single earth bar
Fig. 24. Through earth bar.
30

areas.
In the case of cubicles with single earth bars, connect an
external earth cable to each cubicle as in Fig. 23. Make the
connection either with a spare loop or with a cable lug and an
M10 bolt in the hole in the copper bar.
In the case of cubicles with earth bars running right through,
link the bars up as in Fig. 24. Make sure that the bushings
between cubicles seat properly. Only connect the external
earth cable to the outer cubicles in the row, following the procedure described above.
Copper bars connected directly to Aluzink panels should
be lubricated in with grease "G" (see section 6.2, Lubricants)
as protection against galvanic corrosion.
2.8.
Fitting roof
panels
2.9.
Connecting
power
cables

areas.
Roof panels are supplied in cartons placed in the
respective cubicles.
CAUTION! To prevent pressure relief via front doors on the
occasion of any arcing faults, roof panels must be fitted as
follows:
Panels made of 0.7 mm Aluzink sheet should be fitted from
above and fastened at the front edge with bolts and clamping
sections. The rear edge should only be fastened with plastic
rivets so as to allow the pressure due to any arcing fault to be
reliefed by the rivets at the rear edge sliding and the rear edge
of the panel bending upwards. The position of the front edge of
the panel will remain unchanged.

areas.
Connect incoming/outgoing cables in the cable compartment. There are facilities for connecting up to six parallel singlephase cables, depending on the rated current. Before connecting power cables, remove withdrawable units, racking mechanism and doors. The PC partition may remain in place, it is transparent. When working on cable connections, the fitter may sit in
the cable cell or on the threshold.
If space allows, the rear panel may be removed, using a
long-handled socket wrench.
Connection facilities depend on rated current and cubicle
type (Fig. 27 shows a standard selection).
Cable connection procedure:
1. Remove withdrawable units.
See section 5.1.3.
2. Remove doors.
Release the hinge pins by turning the screws through 90
as per instructions on the door. Release the swivel arms
on the upper door. Fold the door upwards about 15 and
lift it out obliquely upwards.
31
Fig. 25. Racking mechanism bolts.
3. Remove racking mechanism.

This is done by slackening the bolts arrowed in Fig. 25.
Pull the racking mechanism straight out.
4. Remove voltage transformers (option).
If the cubicle has a set of voltage transformers, two screws at
the front edge have to be slackened. Pull the set out as far as
it will go. Release the safety screws on the guides. The
adaptor can then be removed, using a trolley (see section
2.1.1).
5. Remove lower PC partition.
For good access, remove also the lower PC partition after
slackening the screws all round.
6. Run the cable upwards into the cubicle.
7. Terminate the cable as per manufacturer's instructions.
CAUTION! Make sure that the cable screen reaches the
earth bar. Where necessary, insert earth line with at least
the same cross-section as the cable screen. Make sure that
the clearance between the XLPE insulation and the field
guide of cables in the same phase is at least 10 mm. The
field guides on all three phases must be at the same height
if they are close to one another.
8. Run cable up through cable current transformer (option).
If necessary, this transformer may be loosened from its
32
mounting. Note how the transformer has to be positioned

in relation to the cable (see Fig. 26). The earth conductor
has to be run back insulated through the transformer. The
transformer mounting is adjustable relative to the cable.
9. Contact-press the cable lugs and connect.
If cupped spring washers are used on bolted connections,
apply torque as per section 2.11, otherwise M12 connections should be tightened at 80 Nm.
10. Use suitable clips to straighten and destress the cable.
For example, use cable clips type UKR 90, order no.
E0702971. Fasten with available bolts and nuts (see Fig.
26). Cable positions are illustrated in floor plan in Fig. 15
and connection points in Fig. 27.
11. Apply transparent protective flexible tubing to screen connections.
Connect the screen to the earth bar of the cubicle.
Insulated earth conductor
Cable clip type UKR 90

Fig. 26. Fitting a cable current transformer.
33
Cables
Primary
reconnectable
Position 1
800 A
IHBF 12 A
Circuit
breaker
cubicle
Primary
reconnectable
Position 1
2 x 3 phase
150-300 mm2
1250 A
IHBF 12 A
4 x 3 phase
300 mm 2
Circuit
breaker
cubicle
Primary
reconnectable
Position 2
4 x 1 core
500-630 mm2
630
65
Fig. 27. Safesix 12 kV cable fastening points.
34
769
645
75
75
480
75
75
90
6 x 1 core
500-1000 mm2
480
Primary not
reconnectable
6 x 1 core
500-1000 mm2
75
Cable
cubicle
700
75
6 x 1 core
500-1000 mm2
90
DIN-TRAFO
700
480
65
90
3150 A
645
90
4 x 3 phase
300 mm 2
562
Primary not
reconnectable
Position 3
90
90
32
65
Circuit
breaker
cubicle
663
805 from floor

720
772
4 x 1 core
500-630 mm2
90
DIN-TRAFO
65
D=13
90
2500 A
720
90
Primary not
reconnectable
Position 3
65
90
Circuit
breaker
cubicle
D=13 18
90
DIN-TRAFO
663 from front
90
2000 A
D=13 18
622
Primary not
reconnectable
Position 2
1 x 3 phase
150-300 mm2
713
Circuit
breaker
cubicle
Circuit
breaker
cubicle
Holes
805 from floor
IHBF 12 A
DIN-TRAFO
Pattern
663 from front
800 A
1600 A
Cable lugs
692
Current
transformer
2.10.
Connecting
control
cables

areas.
Control cable connections are made in the LV compartment.
If control cables come up through the floor, they can be run
inside the side panels in a space measuring about 65 x 340
mm (see Fig. 28).
These ducts have openings at their bottom and top ends and
via a cover on the inside halfway up the lefthand side of the
cubicle.
Run control cables to each cubicle via the cable duct above
the LV compartment, then into the connection box via a 30
mm wide gap at the rear of the duct.
Fig. 28. Cable run from floor to LV compartment.
35
Control cables may also be run from the basement beneath

the switchgear up into each cubicle division in which there is a
duct (external lines) (see Fig. 15).
In the LV compartment, run the cables to the group of terminal
blocks to which most of the strands are to be connected. Use
stripe to fasten the cables to the fixed bars situated at the
rear, and fasten any protection conductors to overhead earth
bars (see Fig. 29).
An option for making linking connections between cubicles is
to use a connector which includes a fixed element situated on
the lefthand side of the LV compartment and mounted in a
bellows, while its movable element is situated in the cubicle to
the left and has to be inserted in the bellows and screwed to
the fixed element with a centre screw.
Terminal blocks for
current measurement
Terminal blocks for

control voltage
Terminal blocks for

relay protection
Terminal blocks for
auxiliary contacts
and earthing switch
Cubicle lighting
Cable duct
Terminal blocks for
cubicle lighting
Sliding terminal
blocks
Fig. 29. Connecting control cables.
36
Terminal blocks for

voltage measurement
2.11.
Posttightening
of busbar

areas.
The final step in cubicle erection is to check the primary current
paths. The post-tightening of bolts on busbar connections requires the following torques to an accuracy of + 10%. They
apply in cases where the spring washers that form part of the
supply are used.
M8
Nm dry
15
Nm lubricated 10
M10
30
20
M12
60
40
M16
120
80
If washers of some other kind are used, e.g. in the erection of

power cables, larger torques have to be applied. In such
cases the torque for M12 connections is 80 Nm in the dry
state.
N.B. Connections at voltage transformer terminals and at
other terminals that have brass threads potted in epoxy should
only be subjected to the following torques:
Nm
M8
10
M10
20
M12
35
M16
75
IMPORTANT! When all erection work has been completed,

clean the cubicles thoroughly. Wipe clean all insulators,
measuring transformers and screens.
37
3
Functional testing
Only servicing personnel are allowed to open cubicle doors.
The following points are to be checked before commissioning
switchgear:
CAUTION! DANGER TO PERSONNEL
1. While switchgear is being worked on, it must be earthed to
eliminate any risk of its being energised by mistake.
CAUTION! When operating the earthing switch, no-one
must be in the cubicle, to avoid the risk of being pinched by
the switch. Effect earthing by closing the earthing switch
and connecting the temporary earthing to a through earth
bar or to each cubicle separately.
Only during phase identification and insulation testing
may the temporary earthing be temporarily removed.
For safety measures before and after energisation, see ABB
publications 1WAT 910034-031 and 1WAT 910034-051.
In some cases the earthing switch is electrically interlocked
so that if there is no control voltage the contact cannot be
released.
2. Unfasten and disconnect connected power cables.
3. Check the phase identify of the busbars.
Connect a battery box as follows:
Earth: - 0 V
L1 - 4.5 V
L2 - 9 V
L3 - 13.5 V
Check in every cubicle that the voltages measured on the
various busbars are correct.
Busbar positioning in ABB indoor switchgear is as follows:
a) From top to bottom: L1, L2, L3
b) From left to right: L1, L2, L3
Note: A diagram is provided in cases where any other
phase sequence is used.
4. Check the following on all withdrawable units:
38
a) that the busbar main contacts engage the connection

bars properly, minimum overlap 17 mm (see Fig. 34)
b) that the units are in the correct cubicles
c) that the interlocks work
d) that there are control voltages to the units and that
control can be exercised
e) that local control works when the selector is on
[DISCONNECTED] and the unit is in disconnected
position
f) that the emergency trip works in operating position
g) that a closed circuit breaker cannot be run into or
taken out of service position
h) that the sliding contacts are undamaged
5. Insulation test. Use a megger to measure the switchgear
insulation resistance.
N.B. Before doing so, check:
that all voltage transformer primaries are disconnected
that any surge arrestors are disconnected
that all current transformer secondary circuits are

closed
In cases where switchgear is not subjected to a HV test,

the insulation resistance should be measured with a 5 kV
megger. In other cases a 1 kV or 0.5 kV megger will suffice.
Measure insulation resistance as follows:
a) L1 , L2 , L3 b) L1 - L2, L2 - L3, L3 - L1
Measured insulation values should amount to at least 1
Mohm per kV of rated voltage of the switchgear.
6. Reconnect the power cables and the components disconnected in item 5 above. Apply correct torque to all
connections that have been slackened.
7. In the case of units with fuses, check on the equipment
list that all the high-power fuses tally.
8. Check the settings of all relays against the installation
documentation.
39
9. Check control circuits in all cubicles against the installation

documentation.
10. Check the control circuit transitions between cubicles.
11. Check that all screws on terminal blocks are tight and
that no insulation is pinched.
12. Check that units cannot be connected in bays intended
for ones with a higher rated current. The mechanical
blocking devices must prevent any such mistakes.
13. Check that units cannot be shifted while they are closed.
Where there is disconnector, check the interlock system.
14. Check that selector and racking mechanism works.
15. Check that the black bushings on through earth bars seat
properly and provide a seal between cubicles.
16. Open the earthing switch so that the indicator displays
either "0" or "OPEN".
17. Check that the doors are properly closed and the handles
folded down/in towards the door.
CAUTION! Beware door pinch risk. It is important that
the handle should be easy to fold down when the door to
the withdrawable unit cell is closed, so that the door lock
will work as intended, i.e., so as to withstand pressure due
to any arcing fault.
40
CAUTION! Before taking action, follow the safety instructions on page 41.
4
Commissioning
The operator access zone is the aisle in front of the switchgear.
door. The cable side must be de-energised and be earthed by
closing the earthing switch before opening the lower door.
When operating the earthing switch, no-one must be in the
cubicle, to avoid the risk of being pinched by the switch.
Unauthorised access inside the doors may be prevented by
padlocking the handles of both the lower and upper doors.
CAUTION! Beware risk of being pinched when closing
doors.
areas.
4.1.
Commissioning
new switchgear
4.2.
Commissioning
after stoppage
for repaire or
other action
4.3.
Commissioning
after stoppage
Carry out functional tests as per chapter 3 and maintenance

points as per chapter 6.1.
Carry out appropriate parts of functional tests as per chapter

3 and maintenance points as per chapter 6.1.
Carry out checks as per section 3.17 and instructions as per

6.1. Also maintenance as necessary.
41
5
Operating instructions
padlocking the handles of both the lower and upper doors.
doors.
areas.
5.1.
Circuit breaker
HPA and HA
Interlock chain in Safesix cubicles with HPA or HA circuit

breaker. Conditions to be fulfilled to make connection possible:
1. The selector has to be in service position (position 4) or test
position (position 1). The circuit breaker interlock rod must
be in its topmost position, use the microswitch in the
"make" circuit to check that it is.
2. The control voltage must be 85-110% of nominal.
3. The circuit breaker "make" springs must be tensioned, use
the microswitch in the "make" circuit to check that they are.
Closing results in:
1. Mechanical blocking of the racking mechanism selector.
2. Links coming out on the righthand side of the circuit breaker
so that the closed circuit breaker cannot shift while in service
position (applies to HPA).
Conditions to be fulfilled to make opening possible:
1. The circuit breaker must be closed, use auxiliary contacts
to check that it is.
2. The control voltage must be 70-110% of nominal DC or
85-110% of nominal AC.
42
Mechanical opening is always possible by emergency trip on
the front of the cubicle (HPA) or by mechanical push-button
on the front of the circuit breaker (HA), neither of which are
affected by mechanical or electrical blocking.
If the circuit breaker has an anti-pumping relay (HPA option),
closing is blocked so long as the "make" pulse persists after a
make/break sequence. If the circuit breaker has an undervoltage trip (option) it opens the circuit breaker if the control
voltage falls below 70% of nominal.
The switchgear may have both manual and remote control.
Remote control makes it possible to use an actuator on the
cubicle front to select "local" in order to bar remote signals.
The unit can then be controlled manually.
5.1.1
Circuit breaker
shift
The mechanical control devices are situated below the door

to the withdrawable unit.
The control on the left is a selector that has to be placed in the
correct position for the control operation intended.
The racking mechanism is to the right of the selector. Use the
crank to wind the withdrawable unit between the disconnected
(OPEN) and service (CLOSED) positions.
On the far right is the control mechanism for the earthing
switch. Use the same crank to operate the earthing switch.
The first step is to place the selector in the earthing position
(1). If the earthing switch has electrical interlocking, the blocking device to the right of the earthing switch operating hole
has to be moved to the left and pressed downwards so as to
open the hole for inserting the crank. If the blocking device
cannot be pressed downwards, this is because the interlock
magnet is preventing it (is not "pulled"). This means that the
switchgear is energised and cannot be earthed before the
supply [residual supply] is disconnected. Unauthorised operation of the withdrawable unit or earthing switch can be
prevented by inserting a locking device in the hole and padlocking it. The flanged half of the locking device is first inserted far enough to become firmly fastened behind the
bushing, followed by inserting the other half in the hole and
padlocking one of the three holes (see Fig. 30).
43
Fig. 30. Locking the controls.
5.1.2
Circuit breaker
shift to operating
position
The procedure for placing the circuit breaker in the cubicle

and shifting it to service position or disconnected position
(test position) is as follows:
1. Before the circuit breaker can be placed in it, the cubicle
must be earthed, which involves turning the selector to the
earthing position (Fig. 31a), thereby opening the earthing
switch operating hole. Insert the crank in the hole and wind
it clockwise to close the earthing switch. If there is electrical
interlocking (option), the blocking device to the right of the
operating hole has to be moved to the left and pressed
downwards to free the hole.
2. Use a trolley to raise the circuit breaker. CAUTION! When
using a trolley, the unit concerned must always be carried
in the lowered position. Do not leave it in the raised position
on the truck.
3. Turn the selector to removable position (Fig. 31b), open the
door to the circuit breaker compartment (see section 2.5 on
door handling). Place the circuit breaker on the door so that
the wheels are on the door rail sections. CAUTION!
Beware the risk of being pinched by the closing door or
between the circuit breaker and the rails. Push the circuit
breaker all the way into the cubicle and close the circuit
breaker door. The circuit breaker can be test-operated by
turning the selector to the earthing position (Fig. 31a). In
this position the circuit breaker is isolated from the busbar
system. Remember that the LV circuits are connected.
44
4. Turn the selector to the movement position (Fig. 31c). Insert
the crank in the operating hole and wind the circuit breaker
to service position so that the indication below the operating hole becomes "CLOSED". Remove the crank and turn
the selector to service position (Fig. 31d), thereby locking
the unit in service position and releasing the circuit breaker
control circuit.
Position a
Position b
Position c
Position d
Fig. 31. Circuit breaker shift to operating position.
5.1.3
Circuit breaker
shift to disconnected position
The procedure for removing the circuit breaker from the cubicle
or shifting it from service position to disconnected position
(test position) is as follows:
1. Use the cubicle front push-buttons to open the circuit
breaker (see Fig. 32a). If the circuit breaker is closed, the
selector cannot be operated.
2. Turn the selector from service position (Fig. 31d) to
45
movement position, as in Fig. 32b.
Insert the crank as in Fig. 32c. Wind it anticlockwise. Shifting the circuit breaker from service position (CLOSED) to
disconnected position (OPEN) takes place inside the closed
door. The circuit breaker position indicator displays
CLOSED in service position, OPEN in disconnected position
and a series of dots during shifting. Remove the crank.
3. Turn the selector to removable position, as in Fig. 32d.
Open the door to the withdrawable unit compartment and
pull the circuit breaker out onto the folded-down door. If the
circuit breaker is to be removed from the cubicle, go on to
item 5.
4. If the circuit breaker is not be removed from the cubicle,
turn the selector to earthing position (Fig. 31a), which is
used when the circuit breaker is to be test-operated. In this
position the circuit breaker is isolated from the busbar
system. It is also used when the cubicle is to be temporary
Position a.
Position c.
Fig. 32. Circuit breaker shift to disconnected position.
46
Position b.
Position d.
earthed. If there is risk of residual voltage in the cubicle, the
earthing switch should be provided with an interlock
magnet. When the selector is in position test/earthing, the
earthing switch can be closed, thereby earthing the cable
side, but remember that the LV circuits are not affected.
When the earthing switch is closed, the selector is
blocked. The indicator may display
or CLOSED.
5. Take the circuit breaker trolley away. CAUTION! When
using a trolley, the unit concerned must always be carried in
the lowered position. Do not leave it in a raised position on
the trolley. Pump the lifting cradle on the trolley up so that
the lifting lugs on both sides of the circuit breaker fit into the
recesses on the cradle. Then pump the cradle still higher so
that the circuit breaker can be removed from the door.
5.2.
Switch disconnector SFL
When it is outside the cubicle, it is only possible to switch

the switch disconnector on and off if it is on the upper door
or there is at least 20 mm clearance between its bottom
panel and the support.
Conditions to be fulfilled before the unit can be switched
on:
SFL inside the cubicle:
Selector to be in service position (Fig. 31d) or test
position (Fig. 31a).
Operating device to be tensioned manually by control
lever.
SFL outside the cubicle:
The slide on the bottom panel must be in its extreme left or
right position to permit movement of the interlock rod inside the righthand side panel of the SFL frame. The slide is
normally actuated by the selector when the unit is in the
cubicle but has to be actuated manually when the unit is
out.
5.2.1
Safesix interlock
chain for SFL
1. The interlock rod prevents a unit that is closed being

pushed into the cubicle from the door.
2. A unit that is closed cannot be shifted from test position to
service position.
3. The unit cannot be closed while being shifted.
47
4. Mechanical interlocking prevents rotation of the selector
if the unit is closed.
5. Mechanical blocking of the racking mechanism selector prevents a closed unit being withdrawn from service position.
6. It is not possible to close the earthing switch if SFL is in
service position or being shifted.
5.2.2.
Shifting switch
disconnector SFL
5.2.3.
Shifting switch
disconnector SFL to
service position
SFL is shifted in the same way as shifting a circuit breaker,

as described in Chapter 5, which also describes the operation and functions of the racking mechanism.
The procedure for placing SFL in the cubicle and shifting it to

service position or disconnected position (test position) is as
follows:
1. Check that the cubicle is earthed before SFL is placed in it.
Earthing involves using the built-in earthing switch, the position of which is shown by an indicator on the cubicle front
or can be viewed through the window in the lower door.
The first step is to turn the selector to the earthing position
(Fig. 31a), thereby opening the earthing switch operating
hole. Insert the crank in the hole and wind clockwise until
the earthing switch closes. If there is electrical interlocking
(option) the blocking device to the right of the hole has to
be moved to the left and pressed downwards to free the
hole.
2. Use a trolley to raise SFL. CAUTION! When using a
trolley, the unit concerned must always be carried in the
lowered position. Do not leave it on the trolley in the raised
position.
3. Check that the slide on the SFL frame bottom panel is in
the central position (torsion spring untensioned). Turn the
selector to removable position (Fig 31b) and open the door
to the withdrawable unit compartment.
Open the door by grasping the black horizontal handle
with both hands and turning it upwards, thereby releasing
the locking devices so that the door can fold outwards to a
horizontal position in which its dimensioning enables it to
take the weight of the withdrawable unit. Place SFL on the
door so that its wheels are on the door rail sections.
48
CAUTION! Beware the risk of pinching as the door
closes or between SFL and the door rails. Push SFL all the
way into the cubicle, fold its handle upwards, close the
door to the withdrawable unit compartment and fold the
door handle downwards. CAUTION! Beware the risk of
injury caused by arcing fault. It is important that the door
should be closed properly so as to prevent injury due to
any arcing fault. When the door closes, the handle should
be easy to slide down against the door panel.
4. Turn the selector to test/earthing position (Fig. 31a). SFL
can be tested in this position, in which it is disconnected
from the main circuit. N.B. The auxiliary circuit remains
connected.
In this position it is also possible to use the earthing
switch to earth the cable side temporary.
5. To put SFL into service position, disconnect the earthing
switch by inserting the crank in the operating hole and
winding it anticlockwise until the earthing switch opens.
The indicator below the operating hole will display "0" or
"OPEN". Turn the selector to movement position (Fig.31c),
insert the crank in the racking mechanism operating hole
and wind SFL to service position. The indicator below the
operating hole will then display "CLOSED". Remove the
crank and turn the selector to service position (Fig.31d),
thereby locking a cam on the selector shaft the unit in
service position.
5.2.4.
Switching switch
disconnector on
5.2.5.
Shifting switch
disconnector SFL to
disconnected position
The door to the withdrawable unit compartment should be

closed when SFL is being operated. Take the control lever and
open the operating hole cover on the door. Insert the control
lever and make sure that it goes into the socket grip on the
SFL control shaft. Tension the springs of the operating device
by turning the control lever clockwise until you hear a click or
reach the stop. To switch the switch disconnector on, turn the
control lever anticlockwise until the unit is closed (the torque
required is 80-100 Nm). Interlocks prevent rotation of the
selector so long as SFL is closed.
The procedure for removing switch disconnector SFL from the
cubicle or shifting it from service position to disconnected
position (test position) is as follows:
49
5.2.6.
Switching switch
disconnector off
There may be both manual and remote control of the

switchgear. Remote control makes it possible to change over
to manual control by turning the actuator on the cubicle front to
the "local" position.
1. For manual switching off, take the control lever and open
the operating hole cover in the upper door. Insert the
control lever and make sure that it goes into the socket grip
on the SFL control shaft. Turn it clockwise until the unit is
switched off. Only slight rotation is required. Remove the
control lever.
The switch disconnector may be provided with a disconnecting magnet for remote tripping. The auxiliary voltage
must be 70-110% DC or 85-110% AC of nominal. The
interlock of the selector drops out when SFL is switched
off.
2. Turn the selector to movement position (Fig 32b), insert the
crank in the racking mechanism operating hole and shift
SFL to disconnected position by winding the crank anticlockwise. The indicator below the operating hole will display "OPEN". Remove the crank.
3. Turn the selector to test/earthing position (Fig 31a). In this
position it is possible to test-operate SFL, which is now
disconnected from the main circuit. N.B. Remember that
the auxiliary circuit is still connected. It is also possible in
this position to use the earthing switch to earth the cable
side temporary.
4. To remove SFL from the cubicle, close the earthing switch.
The indicator will display
or "CLOSED". Turn the selector to removable position (Fig.31b), open the door to the
withdrawable unit compartment, fold out the handle of SFL
and pull the unit out all the way onto the open door.
5. Use a trolley to raise SFL and lift it down from the door
CAUTION! When using a trolley, the unit concerned must
always be carried in the lowered position. Do not leave it in
the raised position on the trolley. N.B. To avoid damage
to SFL, it must be switched off (indicator displaying 0)
before being placed on a level support, otherwise there has
to be at least 20 mm clearance between the bottom panel
and the support.
50
5.3.
Switch disconnectors Interlock chain for Safesix cubicles with NAL 12/630, NALF
12/630.
NAL 12/630,
Conditions to be fulfilled for switching on to be possible:
NALF 12/630
1. Selector to be in service position.
2. Control lever to be inserted manually and operating
device tensioned before the unit can be switched on.
Switching on results in:
1. Mechanical blocking of the racking mechanism selector,
prevents a closed unit being withdrawn from service
position.
2. The interlock fork situated on the left under the front
cover of the switch disconnector preventing the unit
being pushed into the cubicle (see Fig. 33d).
Conditions to be fulfilled for switching off to be possible:
1. Switch disconnector to be closed, use auxiliary contacts to
check that it is.
33 a.
33 c.
33 b.
33 d.
Switching on
Switching off
Fig. 33. Shifting and operating NAL/NALF.
51
2. For manual switching off the control lever has to be inserted in the operating hole. With a switched off magnet
(option) the switch disconnector can be switched off electrically, in which case the control voltage has to be 70110% DC nominal or 85-110% AC nominal.
The switchgear may have both manual and remote control.
Remote control makes it possible to use an actuator on the
cubicle front to select "local" in order to bar remote signals.
The unit can then be controlled manually.
5.3.1.
Operating
NAL/NALF
CAUTION! The cubicle must be de-energised when the

switch disconnector is pushed into it, since connection to the
primary circuit takes place when the door is open.
1. Move the interlock fork to its righthand position (see Fig.
33d) and push the switch disconnector into the cubicle.
2. Close the door.
3. Turn the selector from test/earthing position to service as in
Fig. 33a.
4. Use the control lever to switch on the switch disconnector
(see Fig. 33b). At the same time, the selector will be locked
so that it cannot be turned from the service position. The
first step in making it possible to switch on is to tension the
operating device by turning the lever clockwise all the way.
The unit is then switched on by turning the handle anticlockwise until the unit is switched on. Remove the handle
and place the masking disc over the operating hole, which
can then be padlocked.
5. Switching off involves inserting the control lever in the
operating hole and turning it clockwise (see Fig. 33b).
Earthing
1. Switch off the switch disconnector (see Fig. 33b). Its position can be viewed through the window in the door.
2. Move the selector from service position to test/earthing
position as in Fig. 33c. The switch disconnector can now
be pulled out onto the door, e.g. for fuse replacement.
3. Crank the earthing switch to closed position (indicator
displaying
), and at the same time lock the selector to
prevent its being moved to service position.
Test operation of switch disconnector on door.
52
CAUTION! Beware the risk of being injured during operation
of the switch disconnector, which has accessible open knives.
1. Move the interlock fork on the left under the front cover of
the switch disconnector to the lefthand position (see Fig.
33d). In this position the fork prevents the switch
disconnector being pushed into the cubicle while at the
same time allowing the unit to be operated.
2. Switch the switch disconnector on (see Fig. 33b) as per
item 4 under "Operating NAL/NALF".
CAUTION! Beware risk of accident due to switch
disconnector knives.
3. Switch the switch disconnector off (see Fig. 33b) as per
item 5 under "Operating NAL/NALF ".
4. Move the interlock fork to its upper position. The switch
disconnector can then be pushed into the cubicle.
53
6
Maintenance
rules
padlocking the handles of both the lower and the upper door.
doors.
areas.
Switchgear maintenance comprises inspection and cleaning
as per Table 6.1.
The maintenance intervals shown apply to normal environments and have to be shortened as necessary to cater for
severer conditions. Suitable times for undertaking maintenance
include when switchgear is taken out of operation to allow
extension work or is de-energised for other reasons.
The tool requirement is a normal set of tools for electrical
maintenance work and the special tools indicated in Chapter 7.
For circuit breaker maintenance, see separate manual.
CAUTION! Certain operations that require switchgear to be
completely de-energised and earthed for work are marked
in Table 6.1. Other operations that can be carried out with
switchgear energised are marked . Work under voltage is
governed by safety rules according to ESA. Operations marked
can be carried out both under voltage and/or when the
cubicle is temporary earthed.
54
6.1.
Switchgear cubicle
maintenance
Maintenance intervals
Before commissioning and
after 1 year
Every
5 years
Inspection/action
Dust and vacuum clean the following surfaces:

Underlined
instructions
to be carried
out as
necessary
regardless of
ordinary
maintenance
intervals
Underlined
instructions
to be carried
out as necessary regardless of
ordinary
maintenance
intervals
1. Shielding and PC partitions (partitions may be removed in

severely fouled cubicles to gain access to spaces behind them).
Treat PC partitions with Plexiklar or Antistatischer
Kunststoffreiniger und Pfleger to prevent static electricity.
CAUTION! Do not use other solvents such as acetone,
ammonia, ether, methanol, trichloroethylene or the like, as they
would damage the polycarbonate (spontaneous cracking).
2. Insulators
3. Measuring transformers
4. Cables and connections
CAUTION! Beware the risk of being pinched when operating

an earthing switch. Check its function and make sure that there is full
contact engagement in closed position . During maintenance of an
earthing switch, if the grease on the silvered contacts is dry or contaminated, remove it and apply a fresh coating of grease type G (see
section 6.2). If the grease on the worm gear is very contaminated,
remove the old grease and apply a fresh coating of grease type E.
Check the state of the spring and operate it. Lubricate the bearings
of control shafts and indicator spindles with oil A.
Damaged painted surfaces of cubicles are to be cleaned and painted with patching paint or protected from corrosion with a thin film
of grease type E.
Check that the lighting in each cubicle works.
CAUTION! In most cubicles, opening the lower door provides access to parts carrying high voltage. Check that the cooling
air valves are in the open position. This applies to 1600, 2000, 2500
and 3150 A cubicles.
Check that the silvered female contacts are not oxidised. If they
are, clean and lubricate with grease type G.
Inspect each cubicle visually to see that there are no damaged
components or conductors.
Lubricate the moving parts of running gear with oil A or grease E.
CAUTION! Check that shielding and PC partitions are in
position.
55
Maintenance intervals
Before commissioning and
after 1 year
Every
5 years
Inspection/action
Check that connecting bars for withdrawable units are not oxidised. If they are, clean and lubricate with a fresh coating of grease
type G.
Check that earth connections for withdrawable units are not oxidised. If they are, clean and lubricate with a fresh coating of grease
type G.
Check that connecting bars of withdrawable units engage
properly1. Lubricate the contacts with a thin film of grease type G.
Operate any units that have not been used for a long time, and
their racking mechanism.
Check that the sliding contacts in the roof of the compartment for
withdrawable units are intact and run easily into one another.
CAUTION! Cubicle contacts are energised with auxiliary voltage..
1
The engagement distance should normally be 25 mm (tolerance range 17-33 mm) as per Fig. 34. Maximum lateral displacement 3 mm.
Maintenance to be done only when switchgear deenergised and temporary earthed.
Maintenance can be done with switchgear energised.
Maintenance can be done both under voltage and/or
when cubicle temporary earthed.
Data on contacts appear in Information sheet 5216 701-V.
Fig. 34. Contact engagement.
56
6.2.
Lubricants
By way of guidance in choosing lubricants, the following table

shows a number of alternatives under different brands.
Brand
Oil A
Grease E
Grease G
O-ring grease
ABB no.
1171 2013-301
1171 4012-201
1171 4014-407
1171 4014-409
BP
Enegrol HLP 32
Energrease LS 2
Neblan
Klber
Microlube GL 261
Mobil
D.T.E. 24
OK
Hydraulic Oil 23
Q8
Hayden 32
Shell
Tellus Oil 32
Statoil
Hydraway HMA 32
6.3.
Cleaning
agents
Barrierta L55/2
Mobile Grease 28
718 EP Shynt. grease

Aero Shell Grease 14 Aero Shell Grease 22
Uniway LYX 43
CAUTION! Only the following cleaning agents should be

used on polycarbonate screens and on plexiglas, otherwise
the material will develop spontaneous cracking:
Plexiklar" or "Antistatischer Kunststoffreiniger und Pfleger".
57
7
Accessories, spares and ancillary equipment
Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order no.
Microswitch . . . . . . . . . . . . . . . . . . . . . . .1VEB 537301-002
Microswitch . . . . . . . . . . . . . . . . . . . . . . .1VEB 537301-003
Circuit breaker sliding contact . . . . . . . . .2657 992-H
Cubicle sliding contact . . . . . . . . . . . . . . .2657 992-G
Cubicle sliding contact . . . . . . . . . . . . . . .2657 992-F
Lower hatch handle, right . . . . . . . . . . . . .2184 4403-AD
Lower hatch handle, left . . . . . . . . . . . . . .2184 4403-AE
Hatch hinge . . . . . . . . . . . . . . . . . . . . . . . .2184 4402-9
Interlock box electromagnet . . . . . . . . . . .5254 778-XX
Racking mechanism 1250 A . . . . . . . . . .LV 841 028-MD
Racking mechanism > 1250 < 2500 A . . .LV 841 028-MC
Racking mechanism 2500 A . . . . . . . . . . .LV 841 028-ME
Racking mechanism 3150 A . . . . . . . . . . .LV 841 028-MF
Earthing switch operating arm, 31.5 kA . .2239 702-AN
Earthing switch operating arm, 40 kA . . . .2239 702-AP
Limit switch contact . . . . . . . . . . . . . . . . .LV 841 708-XX
Each cubicle lower earth bar is provided with two bulldog grips
for connecting earth conductors for system and cable sheath
earthing. If further clips are necessary, they can be ordered as
per table. The data are for clips mounted on bars 4-8 mm
thick.
For mm2 line
Fuse wires
Fine wires
RK
Order no.
16-50
35-185
95-300
16-50
35-120
95-185
16-50
35-150
95-240
LV 889 031-A
LV 889 031-B
LV 889 031-C
Patching paint
Light-beige paint.
Order no.
SA 263 022-VA
Crank
For cubicle front control operations. Normally included in
cubicle supply.
Order no.
2247 953-A
For HPA circuit breaker spring tensioning:
Order no.
LV 899 361-A
58
Trolley
To carry withdrawable units.
Order no.
1VES 841 930-AAA, hydraulic variant
Adaptor to carry voltage measuring sets:
Order no.
1VES 841 930-AAB
Tool set
Tool set for switchgear with Combiflex relays. Box contains 1
groove chisel, 5 RTXD extractors, 1 chisel set (Torx), 1 Polykomb 13 mm wrench and 1 wheel for locks.
Best. nr
LV 899 011-G.
Groove chisel with insulated blade 240 mm long.
For Ben Kri URTK/S terminal blocks
Order no.
SK 176 2130
Polykomb wrench type VNPK 13
For jaw width 13 mm, set of two
Order no.
SK 176 0918
Hexagon socket for cable erection
Order no.
LV 851 940-AA
Equipment available on request:

Flue gas hoods
To guide pressure and flue gases from arcing faults directly out
into the open air without pressurising the building. To be fitted
according to documentation specific to each order.
Arc monitors
Available in two versions.
Standard monitor opens supply circuit breaker if one
condition is fulfilled:
1. Light beam from arc
Special version requiring fulfilment of two conditions:
1. Light beam from arc
2. High current
Other information appears in Instruction 1SFC 16601-SV
59
8
Documentation references
ABB publication
Content
IVEB 580901-911
........
IVEB 580901-902
........
IVEE 301701-900
........
9VLB 9304-11
HPA manual
HA1 manual
SafeGuard manual
Tightening torque for electrical
connections made of coppe
............
1WAT 910034-031 . . . . . . .Indoor medium voltage switchgear

1WAT 910034-051 . . . . . . .Energizing of switchgear
5216 701-V
Information on contacts
................
As this manual is subject to continuous updating, we would

appreciate comments on its content being sent to the following
address:
ABB Switchgear Dept. MC
Box 1023
S-732 27 Arboga
Tel: +46 589-851 00
Fax: +46 589-852 90
Address for further information on servicing under guarantee:
ABB Switchgear Dept.MQG
Box 1023
S-732 27 Arboga
Tel: +46 589-851 00
Fax: +46 589-852 90
60
NOTES
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Safesix: ABB Switchgear

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Safesix

Instruction 1VES 580901-902

The range comprises the following cubicles:

Switch disconnector cubicle, with SF6-or air-insulated

Disconnector cubicle, with drawer-mounted disconnector

Metering cubicle, with measuring transformers

Sectioning cubicle, with withdrawable switching or connecting unit

Contactor cubicle with vacuum contactor (max. 7.2 kV)

Mechanical electrical switch operated manually. Can make, carry and

break normal operating current. Can

Operated manually and has visible

Fig. 1. Examples of cubicle types in ABB Safesix range.

Standards complied with:

Cubicle frames and rear panels made of spot-welded 2 mm

Withdrawable switching or connecting unit compartment

Lead-in duct for

Fig. 2a. Safesix cubicle space distribution.

The front of cubicles for 1600 A or over is provided at the

Small animals, most commonly rats or mice, that make

Overheating due to bad threaded connections, oxidised

High overvoltages, e.g. during thunderstorms

Objects such as tools inadvertently left behind

Faulty or severely fouled components or cable terminations

The Safesix design incorporates the following measures to

Holes in outer enclosure too small for even small animals

Erection instructions give torques for correct tightening of

Spring washers used in threaded connections of primary

Busbar monitoring by SafeGuard (option)

Overvoltage limitation by surge arrestor (option)

Arcing fault prevention by arc monitor (option) to trip the

Exhaust gas channels (option)

It can be operated when the doors are closed

It has making capacity up to 40 kA rms

The window in the lower door makes it possible to see

Illicit operation is prevented by interlocking by means of a

Fig. 3. Dimensions of 12 kV switchgear cubicle.

Busbars and droppers are normally supplied uninsulated but

Earthing switch shaft

Fig. 4. PC partitions with shutters (racking mechanism removed).

Fixed earth paths, system earthing

earth conductors to the earth bar in each cubicle. The only

Fig. 5. Interlock system.

The interlock system has active interlocks (preventing access

An option with which Safesix cubicles can be provided is

Fig. 6. Temperature indicators for 12 kV.

630, 800, 1250, 1600,

62.5, 79, 100

This cubicle contains an SF6-circuit breaker (described

Fig. 7. Circuit breaker cubicle.

Contains an SF6-switch disconnector which is drawer-mounted

Fig. 8. Switch disconnector cubicle with SFL.

Contains a drawer-mounted switch disconnector in the withdrawable unit cell.

Fig. 9. Switch disconnector cubicle NAL/NALF.

Fig. 10. Disconnector cubicle.

This cubicle can measure current or voltage or both. It can be

The function of this cubicle is to divide switchgear into two

Fig. 13. Contactor cubicle.

A pallet lifter with maximum width 540 mm may be used to

CAUTION! When using a trolley, the unit concerned must

1VES 841930-AAA Trolley

Fig. 14a. Trolley.

The same trolley is used for both 12 and 24 kV switchgear and

Fig. 14b. Adaptor for lifting voltage measuring sets.