Professional Documents
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ZX2
ZX2
Danger!
Pay special attention to the hazard notes in the instruction manual marked
with this warning symbol.
WARNUNG
Anerkannte Regeln der Technik und Betriebsanleitungen
beachten !
Gefhrliche Spannung
kann elektrischen Schock und Verbrennungen verursachen.
Vor Aufnahme von Arbeiten jeder Art dieses Gert unbedingt freischalten,
erden und kurzschlieen.
WARNING
Always observe the instruction manual and follow the rules
of good engineering practice !
Hazardous voltage
can cause electrical shock and burns.
Disconnect power, then earth and short-circuit before proceeding
with any work on this equipment.
If you have any further questions on this instruction manual, the members of
our field organization will be pleased to provide the required information.
Contents
Page
Contents
Page
Summary
28
1.1
General
4.1
Condition on delivery
28
1.2
4.2
Packaging
28
4.3
Transport
28
4.4
Delivery
28
1.3
Operating conditions
4.5
Intermediate storage
28
30
Technical data
5.1
30
2.1
5.2
Construction data
30
2.2
5.3
31
5.4
Foundation frame
31
2.3
10
5.5
31
2.4
11
5.6
33
5.7
38
12
38
3.1
17
38
3.2
17
5.8
44
3.3
17
3.4
Disconnector/earthing switch,
type UX2TE
44
18
44
3.5
18
5.9
3.6
Sensor systems
18
3.7
18
3.8
3.9
19
19
19
20
20
44
5.10
44
Commissioning/operation
45
6.1
Commissioning
45
45
45
6.2
45
Switching operations
6.2.1 Circuit-breaker
45
46
46
6.3
46
21
3.10
22
Test facilities
46
Contents
Page
6.4
46
Test procedures
46
47
47
48
48
6.5
49
Maintenance
53
7.1
General
53
7.2
Inspection/servicing
53
54
54
54
54
7.3
Repair
54
7.4
55
55
55
We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual - or
extracts to third parties is prohibited. The information supplied is without liability. Subject to alteration.
ABB Calor Emag Mittelspannung GmbH, 2000
Summary
1.1
General
technical data,
detailed list of equipment fitted,
rated voltage up to 36 kV
three-phase metal-enclosed
gas-insulated
gas-tight metal-clad busbar compartment
1.2
factory-assembled
type-tested.
Operating conditions
vacuum circuit-breaker
Ambient temperature:
1.3
Maximum
+40 C
+35 C
Minimum (corresponding to
minus 5 indoor class)
5 C
Site altitude:
1000 m above sea level
Ambient air:
The ambient air is not to be significantly
contaminated by dust, smoke, corrosive or
flammable gases, or salt.
Technical data
2.1
kV
12
17.5
24
36
50 1)
70 1)
28 1)
38 1)
75
95
125
170
1.0
1.0
1.0
1.0
Rated frequency
Rated current of busbars
Rated current of tee-offs
3)
Hz
50/60
1250/2500
...2000/25004)
kA
...100
...100
...100
...100
kA
...40
...40
...40
...40
kA
...40
...40
...40
...40
kA
...100
...100
...100
...100
5)
Break time:
manual tripping
protection tripping
ms
ms
4590
4055
4590
4055
4590
4055
4590
4055
Closing time:
manual tripping
protection tripping
ms
ms
6595
60
6595
60
6595
60
6595
60
Insulating gas
SF6 8)
SF6 8)
SF6 8)
bar
1.36
1.36
1.36
1.36
bar
1.3
1.3
1.3
1.3
bar
1.2
1.2
1.2
1.2
Charging motor
<200
<200
<200
<200
Closing coil
250
250
250
250
Opening coil
250
250
250
250
1)
2)
3)
4)
5)
6)
Gas-tight enclosure
IP 65
IP 65
IP 65
IP 65
Control cabinet
IP 4X 10)
IP 4X 10)
IP 4X 10)
IP 4X 10)
7)
8)
9)
10)
2.2
Test voltages
Rated voltage
Rated power frequency withstand
voltage across the isolating distance
Rated lightning impulse withstand
voltage across the isolating distance
kV
12
17.5
24
36
kV
32
45
60
80
kV
85
110
145
195
N2 3)
SF6 4)
SF6 4)
SF6 4)
3)
4)
bar
1.3
1.3
1.3
1.3
bar
1.2
1.2
1.2
1.2
Rated voltage
kV
12/17.5/24/36
Test currents
Rated current
630 5)
12501)
2500 2)
...100
kA
63
80
kA
25
31.5
...40
180
180
180
Centre position to BB
18
18
20
18
18
20
Motor data
Motor power, max 3).
3)
60,110,220
2.3
2300
1232
895
2100
1)
26001)
ZX2
ZX2
n panels 2)
Figure 2/1:
800
600
220
30
1710
2)
View X
A
n panels
Figure 2/2:
2)
800
600
220
30
775
1105
2300
2100
1)
26001)
ZX2
ZX2
1710
2)
10
Panels with rated currents greater than 2000 A are also fitted with a cooling fan. The panel height is then increased by 200 mm
to 2500 mm or 2800 mm.
n1
ABB Power Distribution
Weights:
Weight of a standard panel, double busbar,
panel width 400 mm, rated current 630 A:
approx. 650 kg
approx. 1200 kg
approx. 1700 kg
2.4
600 mm
800 mm
Core modul/BB-compartment
25 kA, 1s
31.5 kA, 1s
40 kA, 1s
Cable compartment
kV
IK, 3s
kA
25
31.5
31.5
40
40
20
25
31.5
40
IP
kA
63
80
80
100
100
50
63
80
100
Itee-off
630
1250
2000/
2500
1250
2000/
2500
630
1250
2000/
2500
1250/
2000/
2500
Panel width
mm
400
600
800
600
800
400
600
800
800
Rated voltage
kV
IK, 3s
kA
IP
kA
Itee-off
630
1250
2000/
2500
1250/
2000/
2500
1250/
2000/
2500
1250
1250/
2000/
2500
1250/
2000/
2500
Panel width
mm
400
600
800
800
800
600
800
800
12
17.5
24
20
36
25
25
31.5
40
25
31.5
40
63
63
80
100
63
80
100
11
20
1.1
Figure 3/1:
Figure 3/2:
5.1
5.2
Figure 3/3:
12
B
23.5
G
2
19
20
Figure 3/4:
E
H
B
E
G
H
I
19
20
23.5
Figure 3/5:
Figure 3/6:
13
-Q5
-Q1
-Q5
-Q1
-Q16 -Q11
-Q0
-Q15 -Q12
-Q0
Feeder
Cable connection
Coupler
Riser
Busbar metering
-Q5
-Q1
-Q2
-Q0
Feeder
Bus coupler
Bus sectionaliser
(without C.B.)
-Q0
Bus sectionaliser
Trunking bar
connection
Busbar metering
14
Figure 3/8:
Figure 3/9:
15
26
25
G
24
1
2
23
22
SS2
SS1
(21)
3
(4)
20
19
18
17
K
16
-Q5
-Q1
-Q2
15
-Q0
-T1
10
14
I
13
11
-R1
-C1
12
Busbar system 1
Busbar system 2
Pressure relief duct, top
Pressure relief duct, rear
Control cabinet
Circuit-breaker compartment
Cable termination compartment
-Q0
-Q1
-Q2
-Q5
-T1
-R1
-C1
Circuit-breaker
Tee-off disconnector
Tee-off disconnector
Tee-off earthing switch
Current sensor
Voltage sensor
Capacitive voltage divider
1
2
Panel enclosure
Disconnector/earthing switch -Q1/-Q5
(three-position switch)
3
Three-position switch operating mechanism
(4) Pressure sensor for busbar compartment 1
5
Bay control and protection unit REF542
6
Measuring sockets for capacitive voltage indicator
system
7
Pressure sensor for circuit-breaker compartment
8
Circuit-breaker operating mechanism
9
Cable or test plug socket
10 Cable socket
11 Cable plug
12 Surge arrester
13 Floor plate, split
14 Connecting link panel/panel for item 15
15 Main earthing bar
16 Combined current and voltage sensor
17 Pressure relief disk
18 Circuit-breaker
19 Disconnector -Q2
20 Disconnector operating mechanism
(21) Pressure sensor for busbar compartment 2
22 Tee-off conductor
23 Busbar connection, plug-in type
24 Busbar
25 Drying agent bag
26 Pressure relief disk
Inert gas
16
3.1
The operating pressure (pe) (equals filling pressure) in the individual compartments is monitored by temperature compensated pressure
sensors:
The modular structure provides the conditions necessary for all panel variants normally required in a
relatively simple manner.
Pressure relief disk 26 on the busbar compartment into pressure relief duct (B).
Control cabinet with the bay control and protection unit REF542
17
3.4
connecting,
disconnecting, and
earthing.
The three switch positions are unequivocally specified by the operating mechanism. The switch has
its disconnecting position at the centre. In the limit
positions, disconnector ON and earthing switch
ON, the moving contact (sliding part) driven by an
insulating spindle, reaches the isolating contacts,
which are fitted with one or two spiral contacts respectively.
3.5
Sensor systems
(Figures 3/3, 3/11, 3/12 to 3/15, 6/3 and 6/7)
In comparison with conventional inductive instrument transformers, sensors require much less
space. They facilitate measured value acquisition
suitable for the control and automation system
REF542.
The following sensors are used in ZX2 panels:
Sensors for current measurement 16
Sensors for voltage measurement 16
18
3.8
Busbar protection
Tee-off protection
Control
Measurement
Position indication
Hazard and fault signalling
19
Operating sequence:
Operating sequence:
Circuit-breaker ON.
Disconnector ON.
20
b) Busbar 2:
21
Test facilities
The panels are properly filled with insulating gas at
the works and tested to the VDE or IEC standards.
Testing on completion of switchgear installation is
therefore unnecessary. Should there be any need
to perform tests, the tests are to be performed as
follows:
For voltage and current tests, direct access to
the conductors in the connection area is possible without removing the cable connection or
extracting the insulating gas. Access is effected
via free cable connecting sockets or via the cable sockets for the surge arresters.
The surge arresters must be removed during
voltage tests.
Voltage tests:
cable tests with DC voltage,
cable fault location measurements with impulse voltage and
system tests (without cables) with a AC voltage
can be performed with a test plug as shown in
Figure 6/8.
A test plug for current tests as shown in figure
6/9 can be used to test the protection devices
by primary current injection (see also the note
in section 6.4.4). This configuration is short-circuit proof and can also be used as an
additional maintenance earth.
The possible testing processes are described in the
following sections:
22
Section 6.4.1
Section 6.4.2
Section 6.4.3
current tests:
Section 6.4.4.
23
-XI.. ,-XU..
P1
Terminal
designation
-XI..
1
S1
-1
Primary conductor
2
S2
640A/150mV
In = 1250 A
Ip = 100 kA
Ith 3sec = 40 kA
Front view
80A /240A /640A /150mV
S3
240A/150mV
-XU..
Capacitance C1 35pF
max 55pF
S4
80A/ 150mV
Pick-off: 10 000 :1
20kV/ V3
Class 1
2V/ V3
1
2
a
n
Working area
Leakage
capacitance 25pF
P2
S1 - S2: 320...1280A
S1 - S3: 120... 480A
S1 - S4: 40... 160A
Figure 3/12:
CK
Combined current and voltage sensor with capacitive pick-off KEVCI 24 AE1, for rated
voltages up to 24 kV and panel width 600 mm
Sensor:
KEVCI 36 AE1
Pick-off:
20 000:1 bzw.
Capacitance:
C1 18 pF, max. 22 pF
30 kV / 3
1,5 V / 3
-XI.. ,-XU..
P1
Terminal
designation
-XI..
1
Primary conductor
S1
-1
In = 2500 A
Ip = 100 kA
1600A/150mV
S2
Ith 3sec = 40 kA
Front view
1600A/150mV
Class 1 without correction factor 3
-XU..
20kV/ V3
Klasse 1
2V/ V3
Capacitance C1 35pF
max 55pF
Pick-off: 10 000 :1
a
1
2
Working area
Leakage
capacitance
25pF
P2
S1 - S2: 800...3200A
Figure 3/13:
CK
Combined current and voltage sensor with capacitive pick-off KEVCA 24 BE1, for rated
voltages up to 24 kV and panel width 800 mm
24
Sensor:
KEVCI 36 BE1
Pick-off:
20 000:1 bzw.
Capacitance:
C1 18 pF, max. 22 pF
30 kV / 3
1,5 V / 3
L1 L2 L3
P1
d28
II
IL1
IL2
-Q2
IL3
-XI.. ,-XU..
Terminal
designation
-Q0
-T1L1..L3
z24
2
2
1
3
150mV
-R1L1..L3
Tee-off
protection;
measurement,
metering
Front view
P2
2
2
UL1
d16
z16
1
2
UL2
d12
z12
UL3
d8
z8
T1L2
S1
-XIL2
S.
1
2
Current and
voltage
sensors
T1L3
-XItL2
S1
-XIL3
-XItL3
-XUL1
-XUtL1
-XUL2
2
2
-C1L1..L3
S.
-XItL1
20kV/ V 3
2V/ V 3
z20
-XIL1
P1
d24
d20
P1
S1
2
1
-A200
-Q1/Q5
z28
P1
T1L1
-X3
-XUtL2
S.
R1L1
P2
a
n
R1L2
P2
a
n
R1L3
P2
-XUL3
a
n
-XUtL3
d4
-XIL0
z4
GND
IL0
2
1
-XItL0
Circuit-breaker
Busbar tee-off disconnector
Busbar tee-off disconnector
Tee-off earthing switch
Current sensors
Voltage sensors
Capacitive voltage divider
25
110 kPa
26
-B0G
-B1G
4
3
-B5E2
2
12
-F106:24
-A200
-B2A -B2E
M
M
-M1
-M0
A7
A14
-Y3
-F102
2
4
23
1
3
24
A2
-V3
C1 C2
X6: z2
X6: d2
24
X6: z4
MMK
23
X6: d4
X6: z6
X6: z8
X6: d6
24
X6: z10
X6: d10
X6: d8
A3
23
X6: z12
A5
X6: d12
X7: z18
X6: z18
- F101
X7: z22
E16
X7: z20
X7: d18
-B5E1
X6: z20
X6: z22
X6: d18
X7: d22
E17
X6: d22
SPA - BUS
X7: d20
+
X6: d20
- F116
X5: z2
-B5E3
X5: d2
E6
BK
BN
BU
X4: d16
X4: d12
X4: z2
X4: d2
X4: z4
X4: d4
X4: z12
BK
BN
BU
BK
BN
BU
BK
BN
BU
X4: z14
X4: d14
X1: 3
X1: 1
X5: z4
X5: d4
BK
BN
BU
E9
140 kPa
X5: z6
12
E1
110 kPa
11
E2
X5: d6
E5
E7
140 kPa
E10
BK
BN
BU
X4: z8
E4
110 kPa
12
X4: d28
12
X4: z18
11
140 kPa
11
140 kPa
6
BK
BN
BU
E12
X4: z28
-A200
110 kPa
5
X4: d8
X4: z24
X4: d24
E3
X4: d20
X4: z20
X4: z6
X4: d18
X4: z10
BK
BN
BU
X4: d6
110 kPa
140 kPa
X4: d10
110 kPa
140 kPa
BK
BN
BU
+
(1)
-F100
-F106
2
4
23
(2)
1
3
24
-F102: 24
A6
A1
E8
A4
-V2
C1 C2
-Y2
Figure 3/15a:
1
(1)+
11
(2)
E14
A13
A12 A15
E15
-M2
-B2G
Figure 3/15: Circuit diagram of the panel controller for a double busbar system
The circuit diagram is identical for the single busbar system, but without M2, B2G,
B2E, B2A and F102. Inputs E15, E16 and E17 and outputs A12 to A15 on the
REF542 are not then used.
-B0A
-B0E
-B0S
-B5E
-B5A
-B5E13
-B1E
-B1A
-B2E
-B2A
-B0G
-B1G
-B2G
-M0
-M1
-M2
-MMK
-Y2 and -V2
-Y3 and -V3
-A200
-F100
-F101
-F102
-F106
-F116
27
4.1
Condition on delivery
The factory-assembled panels are checked for
proper assembly and function.
Condition on delivery:
Compliance of the equipment with the order
checked.
Routine testing to VDE 0670 Part 6 or ICE 60298
performed.
Installation material and accessories packaged
separately.
Bushings for the busbars closed off with
transport covers.
Condition of the gas compartments:
Filled with insulating gas at rated operating
pressure,
Fitted with drying agent bags.
Note:
Air freight is to be discussed and agreed in
individual cases.
4.2
Packaging
Panels with basic packaging or without packaging.
Panels with seaworthy or similar packaging (also
containerised for overseas transport):
sealed in polythene sheeting,
transport drying agent bags inserted,
moisture indicators inserted,
sight window fitted for checking of the indicator
when AL composite sheeting is used.
Observe the directions for the drying agent bags
to DIN 55 473. The following applies:
Coloured indicator blue: contents dry.
Coloured indicator pink: contents moist (e.g.
relative humidity over 40%).
4.3
Transport
(Figures 4/1 to 4/3)
Note:
Do not walk on the tops of the panels (rupture point
for the pressure relief system!).
The transport units are normally individual panels.
Take account of the weights of the transport
units.
Take account of the high centre of gravity.
Handle the panels in the upright position.
Only perform loading operations taking account
of all safety precautions to protect personnel
and the material transported with:
a crane, and/or
fork-lift truck.
Handling by crane:
Attach suspension ropes of a sufficient loadbearing capacity with shackles (opening angle 30 mm).
28
Delivery
The responsibilities of the consignee include but
are not limited to:
Checking the delivery for completeness and
freedom from damage (e.g. also for moisture
and its injurious effects).
Any deficiencies/transport damage noted
are to be documented on the waybill,
reported to the shipper/carrier in accordance
with the ADSP or KVO liability conditions for
German insurance.
Note:
Always document major damage with photographs.
4.5
Intermediate storage
Conditions for optimum intermediate storage:
1. Panels with basic packaging or without packaging.
Dry and well ventilated storage room. Climate
in accordance with VDE 0670 Part 1000/
IEC 60694.
Room temperature not falling below -5C.
No other injurious environmental influences.
Store the panels upright.
Do not stack panels.
Panels with basic packaging:
open the packaging at least partially.
Panels without packaging:
loosely cover with protective sheeting.
sufficient air circulation must be preserved.
Check regularly for any condensation.
2. Panels with seaworthy or similar packaging with
internal protective sheeting:
Store the transport units:
protected from the weather,
in a dry place,
protected from damage.
Check the packaging for damage.
Check the drying agent (see section 4.2):
on delivery,
later at appropriate intervals.
When the service life from the date of
packaging has been exceeded:
the protective effect of the packaging is no
longer ensured,
take action for further intermediate storage.
4
n.
ZX2
725
530
1232
895
Figure 4/1:
ZX2
(170)
(64)
1)
565
530
1105
1464
775
Figure 4/2:
Figure 4/3:
29
5.1
In the interests of the best possible erection sequence, and in order to ensure a high quality standard of the panels, local installation of the switchgear
should only be carried out, or at least responsibly
managed and supervised, by specially trained
skilled personnel.
Construction data
(Figures 5/4 to 5/7)
Panel width
mm
Rated current
Ceiling height1)2):
without additional absorber
with additional absorber
with additional cooling fan and
without absorber
with additional cooling fan and
with absorber
400
600
800
800
630
1250
2000
> 2000
mm
mm
2500
2800
2500
2800
2500
2800
mm
2800
mm
3100
mm
mm
mm
mm
500
1810
900
2300
700
1810
1100
2300
900
1810
1300
2300
900
1810
1300
2300
mm
mm
800
1100
800
1300
800
1500
800
1500
kg
ca. 650
ca. 1200
ca. 1700
ca. 1800
kg/m2
ca. 1200
ca. 1400
ca. 1500
ca. 1600
Assembly opening1):
in ceilings:
in doors:
width
length
width
height
Aisle width3):
Inspection aisle
Operator aisle
Panel weight
(outgoing feeder, double busbar)
Floor load
1)
2)
3)
Minimum dimensions
Panel including top pressure relief duct
Governed by DIN VDE 0101 and the data on maximum panel width.
Note:
30
5.3
Evenness tolerance:
Recommended
tightening torque1)
Nm
Lubricant2)
Thread
M
M
M
M
M
M
1)
2)
3)
6
8
83)
10
12
16
Without
Oil or
grease
10 ,5
26
12
50
86
200
4 ,5
10
4 ,5
20
40
80
Foundation frame
(Figures 5/1 to 5/3)
Switchgear on a foundation frame:
The relevant data for the order in hand can be
found in the ABB documentation.
The single or multiple panel foundation frame can
be supplied with the switchgear. It is as a rule laid
by site personnel and should be aligned and inspected under the supervision of a responsible
specialist.
The specifications of DIN 43 661 are also to be
maintained when laying the foundation frame, in
particular the evenness and straightness tolerances as a condition for perfect switchgear assembly.
5.5
31
27.1
27.4
Figure 5/1:
n x FT = a
Panel width FT
27.3
1333
(1423)
27
27.1
27.9
Panel
width
Figure 5/2:
FT
400
400
600
800
800
1200
1600
600
1200
1800
2400
800
1600
2400
27.2
27.6
Foundation frame
27
27.1
27.2
27.3
27.6
27.9
32
Section A-A
(without item 1)
(1423)
1
1333
13 mm
1.5
1.4
27.3
27.5
27.9
27.4
A
27
Figure 5/3:
27.2,27.6
27.3
27.4
27.5
27.6
27.8
27.9
h
5.6
27.8
Panel
Panel fastening bolt
Foundation frame element
Bolt and dished washer for fastening of the
foundation
frame to the concrete floor
Jacking screw for foundation frame
Compensation bolt
Bolt for the connecting link
Plug
Steel shim
Auxiliary bolt for frame installation
Screed height 40 to 50 mm
33
250
600
600
110
1)
85
1710
660 1)
3x160
430
800
800
800
180
85
500
660
600
600
250
800
4
1)
c 1)
1)
1)
1)
580 1)
a 1)
400
190
265
815
150
665
(1423)
150
150
210 210
230
150
160 160 230
190
150
870 1)
8x150
800 1)
2000
50
Figure 5/4:
34
Minimum
Inspection aisle
Operator aisle
Basement entrance
Platform, approx. 25 kN
Earthing bar
Door
10
11
12
13
14
15
( 27 )
(155)
60
Panel width
in switchgear
mm
mm
mm
mm
600 mm
1327
1455
1300
1100
800 mm or
600 mixed with
800 mm
1527
1655
1500
1300
Room height
22
Rated
current
A
Absorber
Room height
2000
with
2800
16
To earthing bar
2000
without
2500
17
18
> 2000
with
3100
19
> 2000
without
2800
20
21
mm
Section A - A
11
16
(27)
10
16
1)
815
(155)
12
265 180
18
20
17
14
12
a 1)
(1423)
1)
a 1)
Section D - D
c
1)
800
1)
1710
11
11
ZX2
19
(1423)
14
a 1)
b 1)
19
85 180
(1423)
17
22
13
15
21
870
12
1)
2300 1)
2600
2100
22
2600
17
13
9
d
(155)
(27)
Figure 5/5:
16
21
b 1)
870
85 180
10
(27)
20
12
d 1)
15
16
2300 1)
10
2100
1)
1)
ZX2
200
200
1)
200
200
1710
14
Section C - C
800
13
17
(1423)
1)
b 1)
265 180
18
21
660
15
13
b 1)
660
(27)
21
2800
2800
230 150
1)
1)
1)
2100
2600
2300
10
11
ZX2
1)
ZX2
2300
200
200
c 1)
1710
15
800 1)
c 1)
1710
2100
2600
800 1)
Section B - B
14
a 1)
Minimum
35
250
600
3x160
1710
190
600
800
500
800
800
600
600
250
800 1)
b 1)
1)
1)
210 210
a 1)
400
190
660
665
815
1333
150
150
8x150
150
230
150
160 160 230
150
800
1)
2000
M 10
M 10
M 10
B
100
400
100
mm
mm
mm
600
100 100
Figure 5/6:
36
Panel width
in switchgear
Minimum
Inspection aisle
600 mm
1327
1300
1100
Operator aisle
Basement entrance
Platform, approx. 25 kN
800 mm or
600 mixed
with 800 mm
1572
1500
1300
Earthing bar
Door
10
11
12
13
Room height
21 :
Rated
current
A
Absorber
Room height
14
15
16
To earthing bar
2000
with
2800
17
2000
without
2500
18
> 2000
with
3100
19
20
> 2000
without
2800
mm
Section A - A
800 1)
Section B - B
b 1)
800
1)
b 1)
1710
665
c 1)
10
(72)
11
1)
21
ZX2
14
2300
150 150
16
10
1)
ZX2
14
16
9
c1)
2300 1)
13
200
11
2100
2600
2800 1)
200
13
2100
2600
200
1710
20
X
1333
a 1)
12
17
19
X
1333
(72)
a
1)
15
18
15
17
12
Detail X
(72)
Figure 5/7:
Minimum
37
5.7
38
View X
40
37.2
40
37.2
35
23.1
23.2
23
40
37.1
37.2
A
23.3
B
B
40
37.2
40
37.1
37.2
X
C
40
37.2
40
37.2
40
37.2
a) Double busbar
40
37.2
40
37.2
40
37.1
37.2
B
40
37.2
40
37.1
37.2
40
37.2
40
37.2
40
37.2
b) Single busbar
Figure 5/8:
Switchgear erection
(See figure 5/9 for sections and details)
23
23.1
23.2
23.3
35
37.1
37.2
40
Section A-A
23.4
23.1
23.2
23
1)
ca. 50
10
1)
Panel division
Busbar connection
Insulating part
Section C-C
Section B-B
Panel division
10
Panel division
15
39
38
37.2
37
Panel/panel connection
Figure 5/9:
Switchgear erection
(section for figure 5/8)
14
15
23
23.1
23.2
23.4
35.1
35.2
37
37.2
38
39
40
35.2
14
35.2
35.1
Section A-A
35
36
35.2
35
A
35.1
Section B-B
35.2
35.2
35.1
36
36
35
Guide pin
M10 hexagon nut
Dished washer 10
Socket head bolt M10 x 50
41
Detail X
35.2
35.2
43
35.1
42
Detail Y
37.2
41
40
Evenly greased,
assembly paste AP
42
Y
Figure 5/11: Busbar end in an end panel
35.1
35.2
37.2
40
41
42
43
1330
250
220
665
44
45
A
B
2600
42
44
45
23.1
23.2
23.3
L3
L2
L1
12
27
10
11
13
Figure 5/15: Plug connector for single-core plastic-insulated cable
10
11
K
Socket
Cable plug
Cable earthing conductor to be connected to
switchgear earth, do not establish cable earthing via
the plug
13.1
13.3
13.4
13.2
Surge arrester
Floor plate, split
Reducer ring
Cable mounting
Supporting section, at earth potential
Insulated earthing point for cable jacket (nonstandard)
High voltage cable
43
5.8
5.10
Properly refit any cladding and covers of operating mechanisms, cable ducts, etc. removed during the erection work.
44
Commissioning/operation
Commissioning
Switching operations
6.2.1 Circuit-breaker
(Figures 3/2, 6/1, 6/2 and 6/4)
The circuit-breaker is fitted with a charging motor.
Charging of the spring energy storage mechanism
takes place automatically.
Opening and closing the circuit-breaker:
Opening and closing are effected by selection on
the bay control and protection unit REF542.
ON-OFF switching operations may only be
performed with the control cabinet door closed.
Opening the control cabinet door constitutes
intervention in the interlock system.
Observe the position indicator.
Emergency manual operation:
1. On failure of the charging motor, the charging
process can be performed or completed by
hand:
Open control cabinet door 1.1.
Insert charging lever 8.9 into recess 8.8 and
pump for approx. 25 strokes until the charged
condition is displayed.
control wiring
power cables
remote controls
external earth with connection to main
earthing bar 15
switchroom equipment
switchroom condition.
6.1.2 Initial start-up
Discharged
Charged
Note:
45
Note:
Always perform every switching operation right
up to the stop in the relevant limit position.
Opening the control cabinet door constitutes intervention in the interlock system.
Observe the position indicator on LCD display
5.1 or on the control unit.
Sensors 29 to 32 on the three-position switch
operating mechanism 3 detect the following
switch positions:
Disconnector -Q1 ON and OFF, and earthing
switch -Q5 ON and OFF.
6.3
If the gas pressure falls below the minimum operating gauge pressure, an LED on the bay control and
protection unit signals that the gas should be
topped up.
Note:
Caution!
The interlock is ineffective on emergency manual
operation.
46
During operation of the switchgear, observe all visible operating data and condition displays in the
secondary system and watch out for irregularities
of any kind, including the external conditions of the
switchgear.
6.4
Test procedures
Note:
Only display units which comply with the IEC or
VDE standards and the technical design of the
indicator system in the relevant switchgear may be
used!
Note:
Perform a functional test on the display unit immediately before and after use, e.g. with interface tester KSP. The display must be clearly visible.
The presence of operating voltage is indicated
by a signal.
24 kV switchgear: 50 kV
Interface testing:
Perform interface testing as a functional test on
all coupling components, e.g. with interface
tester KSP.
The interface test is a repeat test to IEC 61243
Part 5 or draft DIN VDE 0682 Part 415.
6.4.2 Testing for the in-phase condition
Testing for the in-phase condition, e.g. when there
is more than one incoming feeder, can be performed with a suitable phase comparator at measuring sockets 6 on the capacitive voltage indication
system.
Test procedure:
Only use phase comparators which comply with
the IEC or VDE specifications and the technical
design of the display system in the relevant
switchgear!
Perform a functional test on the equipment at the
start of testing.
Do not exceed the maximum permissible length
of measuring leads per phase.
Connect the measuring leads precisely assigned
to the corresponding main conductor sections.
Always follow the details in the operating
instructions for the phase comparator!
36 kV switchgear: 70 kV.
Performance of voltage tests:
Isolate the switchgear area in accordance with
the safety rules of VDE 0105 and secure it to
prevent reconnection.
Verify the off-circuit condition with a suitable
hand-held display unit at measuring sockets 6
on the capacitive voltage indicator system.
Unscrew surge arresters where fitted, or
unscrew the cable blanking plugs from the free
cable sockets.
Check the test plug to ensure that the surface is
clean and dry, and clean it if necessary.
Grease the silicone part of the test plugs in
accordance with the directions.
Insert the test plug into the prepared cable
socket and screw it tight.
Notes:
Only fit the test plugs for voltage tests for the
duration of those tests.
Short-circuit the measuring sockets 6 in the
panels concerned for the duration of the testing
process at test voltages up to rated power frequency withstand voltage.
1)
48 kV1)
47
Test instruction:
The following is to be observed when testing the
protection system of the REF542:
In order to prevent damage to the OFF-release coil
during testing, either the OFF-release coil has to be
disconnected or the protection test equipment
must be deactivated by the trip command.
This ensures that the opening release is not
energised in the meantime by the trip command,
which could lead to the coil burning out.
Establishment of maintenance earthing in conjunction with an earthing and short-circuiting set.
The short-circuit resistance of the current test
plugs for the switchgear must correspond to the
condition of the individual switchgear.
Handling of the plugs for current tests:
Isolate the switchgear area in accordance with
the safety rules of VDE 0105 and secure it to
prevent reconnection.
Verify the off-circuit condition with a suitable
(hand-held) display unit at measuring sockets 6
on the capacitive voltage indicator system.
Unscrew surge arresters where fitted, or
unscrew the cable blanking plugs on the free
cable sockets.
Check the test plug to verify that the surface is
clean and dry, and clean it if necessary.
48
6.5
49
1.1
1.1
28
5
28.4
28.1
(28.2)
5.1
5.2
28.3
Figure 6/1:
Figure 6/2:
31 30 29 32
3
3.1
3.2
3.3
3.4
20
20.1
20.2
34
50
Figure 6/3:
33
8
8.1
8.2
8.9
8.3
8.4
8.8
8.5
8.7
8.6
Figure 6/4:
Figure 6/6:
Figure 6/7:
Figure 6/5:
51
Figure 6/8:
Figure 6/9:
52
7.2
Maintenance
Maintenance serves to preserve trouble-free operation and achieve the longest possible working
life of the switchgear. In accordance with DIN 31 051
and IEC 61208, it comprises the following closely
related activities:
Inspection: Determination of the actual condition
Servicing: Measures to maintain the specified
condition
Repairs:
7.1
General
It is essential to observe the following during all
maintenance work:
The relevant regulations in section 1.2.2
The notes on safety at work in section 6
Standards and specifications in the country
where the switchgear is erected.
Inspection/servicing
Under normal operating conditions (see section
1.3), checking of the operating mechanisms is to
be carried out by a suitably qualified electrician
after 10 years at the latest or after 10,000 operating cycles of the circuit-breaker and 2,000 operating cycles of the three-position switch or
disconnector.
In exceptional operating conditions (including
adverse climatic conditions) and/or particularly
adverse environments (including heavy contamination and aggressive atmosphere) inspection
at shorter intervals may be required.
Inspection is first and foremost to be visual examination for contamination, corrosion and
moisture.
The inspection should however also include
checking of the mechanical and electrical functions of the following devices:
Switching devices
Bay control and protection unit REF542.
Cleaning
Keep these instructions and manual permanently on display and available in the switchroom.
The length of the intervals for inspection and servicing of the control cabinet and its equipment is influenced by ambient conditions (for instance pollution
and aggressive atmosphere).
BA 427/E
BA 453/E
Circuit-breaker VD4 X
BA 436/E
Further details can be found in the technical documentation for the switchgear installation (including,
for example, any agreed special operating conditions).
53
7.3
Repair
Remove all rust from damaged paintwork areas
on sheet steel and other steel parts mechanically, e.g. with a wire brush. Lightly grind the surrounding paint coat and carefully degrease the
entire area. Then immediately apply an anti-rust
primer and, after an appropriate hardening period, apply the top coat. Only use suitable and
compatible paint products.
Use top coat paint in the standard colour
RAL 7032, or the relevant special colour.
Carefully remove any white rust from galvanised
and chromium plated functional parts and rust
on phosphated parts with a wire brush or a
cleaning pad, e.g. Scotch-Brite, and clean with a
dry cloth. Then grease evenly with Isoflex Topas
NB 52.
Notes:
Replacement procedure:
54
GCE0995403P0100
GCE0995404P0100
7.4
GCE0990267P0100
GCEA901007P0102
GCE0990253P0103
GCEA901004P0102
Note:
If extreme temperatures 50C cannot be ruled
out where gas cylinders are stored, transported or
temporarily stored in the open air in direct sunlight,
a reduced filling factor of 0.75 kg/l cylinder contents is to be required when ordering for safety
reasons!
GCE0990443P0100
GCE0007249P0100
GCE0009098P0100
GCE0007707P0100
GCEA901002P0102
Cleaning agent for conductive parts, parts in insulating material, and all parts with heavy contamination:
Cold cleaner 716,
GCE0007706P0100
GCEA901006P0102
GCE0009100P0100
Paintwork:
Paint in standard colour RAL 7035
1 kg-box
GCE9014060R0103
Spray tin
GCE0007895P0100
55
Oberhausener Strasse 33
D-40472 Ratingen
Via Friuli, 4
I-24044 Dalmine
Petzower Strasse 8
D-14542 Glindow