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ZX1.

2
Gas-insulated medium voltage switchgear
Instruction manual BA 468/01 E

IT
Power
PowerIT

Ihre Sicherheit
hatfirst
Vorrang
immer!
Your safety
always!
That's why our instruction manual begins with these recommendations:
Only install switchgear and/or switchboards in enclosed rooms suitable for
electrical equipment.
Ensure that installation, operation and maintenance are carried out by
specialist electricians only.
Comply in full with the legally recognized standards (DIN VDE / IEC), the
connection conditions of the local electrical utility and the applicable safety
at work regulations.
Observe the relevant information in the instruction manual for all actions
involving switchgear and switchboards.

Danger!
Pay special attention to the hazard notes in the instruction manual marked with
this warning symbol.

Make sure that under operation condition of the switchgear or switchboard


the specified data are not exceeded.
Keep the instruction manual accessible to all persons concerned with
installation, operation and maintenance.
The users personnel are to act responsibly in all matters affecting safety at
work and the correct handling of the switchgear.

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
17

Summary

3.10

1.1

General

1.2

Standards and specifications

3.10.1 Electrical earthing of a busbar section


using the sectionalizer/riser

17

3.10.2 Manual earthing of a busbar section


using the sectionalizer/riser

17

Earthing the busbar

1.2.1 Switchgear production

1.2.2 Installation and operation

1.3

Operating conditions

3.10.3 Maintenance earthing of a busbar


using the test sockets in a tee-off

17

1.3.1 Normal operating conditions

3.11

Test facilities

18

1.3.2 Special operating conditions

Despatch and storage

24

Technical data

4.1

Condition on delivery

24

2.1

Panel type ZX1.2

4.2

Packaging

24

2.2

Busbar compartment with disconnector/


earthing switch type UX2TE

4.3

Transport

24

4.4

Delivery

24

2.3

Dimensions and weights

4.5

Intermediate storage

24

2.4

Resistance to internal arc faults

Design and function of the switchgear system and its equipment

Erection of the switchgear


at site

26

12

5.1

General site requirements

26

3.1

Design and equipment of the panels

12

5.2

Construction data

26

3.2

Gas system in the panels/switchgear

13

5.3

Fundamental notes on
erection work

27

5.4

Foundation frame

27

3.2.1 Monitoring of operating pressure

11

13

3.2.2 Limitation of the effects of


an internal arc fault

13

5.5

Raised false floor

27

3.3

Vacuum circuit-breaker, type VD4 X

13

5.6

3.4

Disconnector/earthing switch,
type UX2TE

Erection and connection


of the panels

27

13

5.6.1 Preparatory work

27

3.5

High voltage connections

13

5.6.2 Erection of the switchgear

27

3.6

Control and monitoring

14

5.7

38

3.6.1 Bay control and protection


unit REF542 plus

14

5.7.1 High voltage XLPE cables


with plug-in connectors

38

3.6.2 Bay control unit CC (optional)

14

5.7.2 Control cables and wiring

38

3.7

Conventional secondary systems in


combination with a protection device

3.7.1 Conventional control


3.8

Protection against maloperation/


interlock dependencies

3.8.1 Interlocks in general

5.8

Preparing the insulating


gas system for operation

38

5.9

Final erection work

38

Commissioning/operation

39

15

6.1

Commissioning

39

15

6.1.1 Preparatory work

39

6.1.2 Initial start-up

39

6.2

39

14
15

3.8.2 Function of the interlock between


the circuit-breaker and the threeposition switch

15

3.9

16

Earthing a tee-off

3.9.1 Electrical operation using the bay control


and protection unit REF542 plus or
push buttons on the panel front
16
3.9.2 Manual earthing

Connection of cables and wiring

16

Switching operations

6.2.1 Circuit-breaker

39

6.2.2 Three-position switch

40

6.2.3 Undervoltage release

40

6.3

Observation of the display and


monitoring facilities

40

Contents

Page

Contents

Page

6.3.1 Gas monitoring

40

7.2.1 Vacuum circuit-breaker

46

6.3.2 Electrical/mechanical
display/monitoring

7.2.2 Three-position switch

46

40

7.2.3 Gas system and gas servicing

46

6.4

40

7.3

46

6.4.1 Testing for the off-circuit condition

40

6.4.2 Testing for the in-phase condition

41

7.3.1 Replacement of circuit-breaker parts


and accessories

46

6.4.3 High voltage tests

41

7.3.2 Checking the dimensional accuracy


of the settings

46

6.4.4 Maintenance earthing

42

7.3.3 Touch up of surfaces

46

6.5

Application of the X-ray regulations

42

7.4

48

Maintenance/disposal

45

7.4.1 Working materials

48

7.1

General

45

7.4.2 Auxiliary materials

48

7.2

Inspection/servicing

45

7.5

48

Test procedures

Repair

Working and auxiliary materials

Disposal

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, 2002
5

1
1.1

Summary

VDE 0105, Operation of electrical installations

General

DIN VDE 0141, Earthing systems for special


power installations with rated voltages above
1 kV,

Fundamental features of the panels:


rated voltage up to 36 kV (40.5 kV)

the accident prevention regulations issued by


the appropriate professional bodies,

three-phase metal-clad

the safety guidelines for production materials,

gas-insulated

the order-related details provided by the


switchgear manufacturer.

sealed pressure system for busbar compartment


sealed pressure system for circuit-breaker compartment

1.3

Sensor technology and conventional instrument


transformers for adaptive measuring

1.3.1 Normal operating conditions

indoor installation
factory-assembled
type-tested

Operating conditions

Designed in accordance with VDE 0670 Part


1000,Common specifications for high-voltage and
controlgear standards and IEC Publication 60694,
with the following limit values:
Ambient temperature:

routine tested.

Maximum

+40 C

Basic panel variants:


incoming and outgoing feeders

Maximum 24 hour average

+35 C

Minimum (corresponding to
minus 5 indoor class)

5 C

bus sectionalisers/bus riser panels

Site altitude:

metering panel.

1000 m above sea level

Panel equipment, variants:

Ambient air:

vacuum circuit-breaker
disconnector/earthing switch
switch) with functions of:

(three-position

The ambient air is not to be significantly


contaminated by dust, smoke, corrosive or
flammable gases, or salt.

busbar connection,
disconnection,

Details on the technical design and equipment of a


switchgear, such as

Special operating conditions are to be agreed by


the manufacturer and operator. The manufacturer
is to be consulted in advance about each special
operating condition:

technical data,

Site altitude above 1000 m:

earthing.

detailed list of equipment fitted,


detailed circuit diagrams, etc.
are stated in the order documents.
1.2

Standards and specifications

1.2.1 Switchgear production


The panels comply with the following VDE standards and the corresponding IEC publications:
VDE 0670 resp. IEC 62271, 60129, 60298 and
60694
VDE 0373 resp. IEC 60376 and 60480.
1.2.2 Installation and operation
The relevant standards are to be observed during
installation and operation, in particular:
DIN VDE 0101, Power installations exceeding
AC 1 kV,
6

1.3.2 Special operating conditions

The manufacturers specifications are to be


observed.
Increased ambient temperature:
The current carrying capacity is reduced,
Additional cooling facilities for heat dissipation
are to be provided.
Climate:
The risk of corrosion or other impairment, e.g.
in the control cabinets, is to be avoided in
areas:
with high humidity and/or
with major, rapid temperature fluctuations.
Take countermeasures to prevent condensation phenomena (e.g. provide electric
heaters).

Technical data

2.1

Panel type ZX1.2


Electrical data

IEC Standard ratings

Rated voltage
kV
Max. operating voltage
kV
Rated power frequency withstand voltage kV
Rated lightning impulse withstand voltage kV
All voltages quotes apply to an insulating
gas pressurte, absolute, at 20C, of
kPa 2)
5)
Rated frequency
Hz
A
Rated current of busbars5)
Rated current of tee-offs5)
A
Rated peak withstand current
kA
Rated short time current 3s
kA
Rated short-circuit breaking current of
the circuit-breaker
kA
Rated short-circuit making current of
the circuit-breaker
kA
Rated operating sequence
Total opening time
ms
Closing time
ms
Insulating gas system
Insulating gas
Design pressure, absolute
Operating pressure, absolute, 20C
(equals filling pressure)
Rated pressure, absolute, 20C
(minimum operating pressure)
Motor- and release data
Charging motor
Closing coil
Opening coil
Rated supply voltage
DC
Degree of protection
(IEC 60529, DIN VDE 0470-1)
High voltage live parts
Control cabinet
Ambient temperature:
Maximum value
Maximum value of 24-h-mean
Minimum value
Altitude for erection above sea level 9)

12
12
28
75

24
24
50
125

100
50
2000
2000
80
31.5

100
50
2000
2000
80
31.5

31.5

31.5

1)
1)

3)

80
O - 0.3s - CO - 3 min - CO 4)
ca. 40...55
ca. 40...55
ca. 60
ca. 60
SF6
147

36
36
70
170

1)
1)

100
50
2000
2000
80
31.5

80

6)

Special ratings

6)

31.5

40.5
85
185 1)
120
50
2000
2000
80
31.5

3)

31.5 3)

80

80

ca. 40...55
ca. 60

ca. 40...55
ca. 60

SF6
147

6)

SF6 6)
147

kPa

SF6
147

kPa

130

130

130

130

kPa

120

120

120

120

W
W
W

150
250
250

150
250
250

150
250
250

150
250
250

60, 110, 220 7)

IP 65
IP 4X
C
C
C
m

+40
+35
-5
1000

mm
mm
mm
mm
mm

2100
1300 1800
600
800
1250

8)

IP 65
IP 4X

8)

+40
+35
-5
1000

IP 65
IP 4X

8)

+40
+35
-5
1000

IP 65
IP 4X 8)
+40
+35
-5
1000

Dimensions
Hight (for transport)
Depth 11) 13)
Width 1250 A, 31.5 kA
> 1250 A
Height of cable fixing
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)

10)

2100
1300 1800
800
800
1250

10)

3)

2100
1300 1800
800
800
1250

10)

3) 12)

2100 10)
1300 1800
800 3) 12)
800
1250

Higher values in accordance with international standards on request


100 kPa = 1 bar
600 mm panel width up to 25 kA rated short-circuit breaking current
Other operating sequence on request
Rated current 60 Hz on request
Insulating gas: Sulphur hexafluorid SF6
Other voltages on request
Other degrees on request
Higher altitude for erection on request
See figures 2/1 to 2/4 for total height including plasma diverter or pressure relief ducts
Dependent on the number of cables per phase
With plug-in voltage transformer, panel width 800 mm
As an option, with conventional control systems, the panel depth can be extended by 100 mm
(see notes to figures 5/10 and 5/12)

2.2

Busbar compartment with


disconnector/earthing switch (three-position switch) type UX2TE
Test voltages

IEC Standard ratings

Special ratings

Rated voltage

kV

12

24

36

Max. operating voltage

kV

12

24

36

40.5

Rated power frequency withstand


voltage across the isolating distance

kV

32

60

80

1)

Rated lightning impulse withstand


voltage across the isolating distance

kV

85

145

195

1)

SF6 3)

SF6

Insulating gas system 2)


Insulating gas

1)
2)

3)
4)

SF6

3)

3)

SF6

Operating pressure, absolute, 20C


(equals filling pressure) 4)

kPa

130

130

130

130

Operating pressure, absolute, 20


(minimum operating pressure) 4)

kPa

120

120

120

120

Data on request
For further details see BA 427/E
insulating gas system for ZX switchgear
Insulating gas: sulphur hexafluoride, SF6
100 kPa = 1 bar

12

24/361)

12/24/361)

mm

600

600 (800)

800

... 1250

1250

2000

Rated peak withstand current

kA

80

63 (80)

80

Rated short time current, 3s

kA

31.5

...25 (31.5)

31.5

180

180

180

Centre position to busbar

18

18

20

Centre position to earth

18

18

20

Rated voltage
Panel width
Test current
Rated current

Motor data
Motor power, max.2)
2)

Motor running times, max. :

Rated supply voltage


DC 3)
1)
2)
3)

Higher values on request


At rated supply voltage
Other voltages on request

60, 110, 220

3)

2.3

Dimensions and weights


View X

View Y
G

G
E

ZX1.2

ZX1.2

E
I

A
D
B

1250

1250

B
C

50
50

600

n panels

600

2100

2100

2640

2370

50

250

1300

1500

a) Feeder panel: 1 cable per phase

b) Feeder panel: up to 2 cables per phase

Figure 2/1: Dimensions


Figure shows panels with rated current 1250A
Circuit-breaker compartment
Busbar compartment
Cable termination compartment
Control cabinet
Pressure relief duct, above (optional)

F
G
H
I

Pressure relief duct for busbar compartment


Pressure relief duct with absorber (optional)
End cover
Pressure relief chimney, lateral (optional)

View Y

View X
G
E
ZX1.2

ZX1.2

2640

D
B

1250

1250

2370

A
2100

F
800

800

50
1250/1450

1800

b)

a) Busbar riser or busbar


sectionalizer

Sectionalizer
Riser
Sectionalizer
Riser

2640

2370

2100

A
B
C
D
E

Busbar
A

Depth
mm

Width
mm

1250
1250
> 1250
> 1250

1250/1450
1250/1450
1450
1450

600/800
600/800
800
800

Incoming feeder panel up to


4 cables per phase

Figure 2/2: Dimensions


Figure shows panels with rated currents 1250 A
A
B
C
D

Circuit-breaker compartment
Busbar compartment
Cable termination compartment
Control cabinet

E
F
G

Pressure relief duct , above (optional)


Pressure relief duct for busbar compartment
Pressure relief duct with absorber (optional)
9

View X

View Y
L

ZX1.2

ZX1.2

L
Y

A
D

D
B

1250

1250

B
C

50
600

n panels

600

50

50

1300

1500

a) Feeder panel: 1 cable per phase

Dimensions
Figure shows panels with rated current 1250 A, equipped with plasma diverter.
Cable connection department C is not covered to the rear side.
A
B
C
D

Circuit-breaker compartment
Busbar compartment
Cable termination compartment
Control cabinet

F
H
L

Pressure relief duct for busbar compartment


End cover
Plasma diverter (standard)

View Y

View X
L
ZX1.2

ZX1.2

D
B

1250

1250

2275

A
2100

F
800

800

50
1250/1450

1800

a) Busbar riser or busbar


sectionalizer

Sectionalizer
Riser
Sectionalizer
Riser

2275

Figure 2/3:

b) Feeder panel: up to 2 cables per phase

2100

50

2100

H
2100

2275

Busbar
A

Depth
mm

Width
mm

1250
1250
> 1250
> 1250

1250/1450
1250/1450
1450
1450

600/800
600/800
800
800

b)

Incoming feeder panel up to 4 cables


per phase

Figure 2/4: Dimensions


Figure shows panels with rated currents 1250 A, equipped with plasma diverter L.
Cable connection department C is not covered to the rear side.
A
B
C
10

Circuit-breaker compartment
Busbar compartment
Cable termination compartment

D
F
L

Control cabinet
Pressure relief duct for busbar compartment
Plasma diverter (standard)

Weights:
Weight of a standard panel:

2.4

Panel width 600mm, Panel depth 1300 mm:

ca. 600 kg

Panel width 600mm, Panel depth 1500 mm:

ca. 650 kg

Panel width 800mm, Panel depth 1300 mm:

according to equipment installed

Panel width 600mm, Panel depth 1500 mm:

according to equipment installed

Panel width 600mm, Panel depth 1800 mm:

according to equipment installed

Resistance to internal arc faults

Resistance to internal arc faults

Panel width
600 mm

800 mm

Circuit-breaker compartment/
Busbar compartment

31.5 kA, 1s

31.5 kA, 1s

Cable connection compartment

not relevant

not relevant

Criteria 1 - 6 of PEHLA directive no. 4 (in


conjunction with VDE 0670, Part 6, Appendix
AA and IEC 60298, Appendix AA) are fulfilled.
The panels can have optionally integrated
pressure relief ducts with the opportunity for:
conducting out of the switchroom in a
manner suitable for the building dimensions,
or
conducting through an absorber on the last
two panels (when the ceiling height is
sufficient).

When plasma diverters are used (standard), the


arc gases are conducted to the rear
panel by panel for the circuit-breaker compartment, and
centrally via a pressure relief duct (F), (see
page 9 and 10), from the busbar compartments to a metering panel or sectionalizer
panel. If the installation does not contain a
metering panel or sectionalizer panel, an
outgoing feeder panel can be used for
pressure relief.
In the case of an arc fault, an increase of
pressure in the switchroom is to be expected.
This is to be taken into account in the planning.
Calculations can be supplied on request.

11

Design and function of the switchgear system and its equipment

3.1

Design and equipment of the panels


(Figures 3/1 to 3/11)
The circuit-breaker and busbar compartments of
the metal-clad panels of type ZX1.2 are manufactured in a laser cutting and welding process.
The stainless steel encapsulation and the insulating
gas protect all live parts in the high voltage area
permanently from soiling, humidity, foreign bodies
and other injurious influences.
With the segregation of the switching devices into
maintenance-free components in the insulating gas
compartment and accessible, low maintenance
operating mechanism components in the low voltage bay, the ZX1.2 switchgear fulfils requirements
of IEC 60694 for sealed pressure system.
The modular structure provides the conditions
necessary for all panel variants normally required in
a relatively simple manner.

Cable termination compartment (3.0)


In systems without covers and cell partitioning, the plasma gases escape into the
space behind the switchgear (standard).
In systems with rear covers and cell partitioning at the sides, internal arcing in the
cable termination compartment causes a
flap (3.5) leading to the lower pressure relief
duct (3.6) to open. From there, the gases
are channelled through the side pressure
relief chimney into the upper duct (1.9).
Each panel is a self-contained unit whose
busbars (2.4) are connected to the busbars in
the adjacent panels by plug-in busbar
connectors (2.5).
Equipment in the panels

For example:

Circuit-breaker VD4X

Feeder panel,

Three position switch UX2TE

Busbar sectionalizer panel/busbar riser panel,

Circuit-breaker compartment (1.0)

Metering panel,

with or without current transformers

different connection methods, such as multiple


cables,

with or without combination sensors


Busbar compartment (2.0)

solid insulated bar.

Cable termination compartment (3.0)

Pressure relief:

without current transformers

There are facilities for pressure relief either panel


by panel or via pressure relief ducts.

with conventional ring core current transformers (customized)

In the unlikely event of an internal arc fault, the


relevant pressure relief disks open.

with current sensors (At present only possible


with one cable per phase. The sensors must
be installed before the plugs are fitted.)

Circuit-breaker compartment (1.0)


Pressure relief is effected via a pressure relief
disk 1.3 fitted at the top:
Standard: relief to the rear by means of a
plasma deverter (1.15) (panel by panel
pressure relief).
Optional: discharge into a pressure relief
duct (1.9) and from there via an absorber
(1.10) into the switchroom or without an
absorber for direct relief to the outside.
Busbar compartment (2.0)
Pressure relief is effected via a pressure relief
disk (2.11) fitted at the bottom into the
pressure relief duct (3.6).
In systems with pressure relief to the rear
(standard), discharge is effected centrally
via the pressure relief duct (3.6) into a
sectionalizer panel / busbar riser panel or
metering panel. There, flap 3.15 opens.
12

Optionally, in systems with pressure relief


ducts at the top, the plasma gases are
discharged through the lower pressure
relief duct (3.6) to the side pressure relief
chimney (I) (refer to page 9) and into the
upper pressure relief duct (1.9).

Control cabinet, optionally equipped with:


bay control and protection unit REF542 plus
bay control unit CC in conjunction with protection relays
mechanical auxiliary switches in conjunction
with protection relays
Cable and test plug sockets
Switchable sockets for plug-in voltage transformers (optional)
Insulation test criteria
The insulation test criteria of VDE and IEC list 2 are
fulfilled by the ZX1.2 standard series up to and
including 36 kV even when the gas filling is
at atmospheric pressure. The special series for
40.5 kV fulfils the insulation test criteria at a gas
pressure of 120 kPa absolute at 20C.

3.2

Gas system in the panels/switchgear


(Figures 3/7 to 3/11)

short-circuit breaking operations,


earthing function in conjunction with three-position switch (2.1).
The earthing function of the three-position switch
prepares de-energized for the connection to
earth. Earthing proper is performed by the circuitbreaker. This integration of functions is advantageous, as a circuit-breaker is of higher quality in the
earthing function than any other earthing switch. The
circuit-breaker poles are installed horizontally in the
circuit-breaker compartment (1.0). The circuitbreaker operating mechanism (1.2) is located
outside the gas compartment and is therefore
easily accessible. It is connected to the breaker
poles by a gas-tight bushing.

A permanently protected climate for the entire live primary area is ensured by the gas-tight encapsulation
of the panels and their filling with dry insulating gas.
The circuit-breaker compartment (1.0) and the
busbar compartment (2.0) in each panel are
separate gas compartments with their own filling
connectors. The gas compartments in the
individual panels set up side by side are not
connected together.
Details on the gas system and gas servicing of
the ZX1.2 switchgear can be found in instruction
manual BA 427/E Insulating gas system for ZX
switchgear.
The gas compartments contain drying agent
bags.

3.4

Further details on the drying agent material can


be found in instruction manual BA 427/E.

The ZX1.2 panels are fitted with specially designed


three-position disconnectors and earthing switches
(2.1) (-Q1/-Q5). These switches are motor-operated
rod-type switches whose live switching components
are located in busbar compartment (2.0) (insulating
gas compartment), while the operating mechanism
block is easily accessible from the control cabinet
(4.0).

3.2.1 Monitoring of operating pressure


The operating pressure (equals filling pressure) in
the individual compartments is monitored by
temperature compensated pressure sensors:
Pressure sensor (1.8) for the circuit-breaker
compartment,

The operating mechanism block contains the drive


motor, the position indicators (sensors and
mechanical indicators) and the emergency manual
operating system.

Pressure sensor (2.3) for the busbar compartment.


When the pressure in a gas compartment
decreases below rated pressure (minimum
operating pressure), this is detected and
displayed on LEDs by the REF542 plus.

The three-position switch performs the functions of:

As an alternative, in versions without the bay


control and protection unit REF542 plus, a
shortfall below the minimum operating pressure
is displayed by signal lamps.

earthing.

connecting,
disconnecting and

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 contact rings respectively.

A pressure drop below the minimum operating


pressure in a gas compartment is signalled
selectively by LED terminals in the control
cabinet.
3.2.2 Limitation of the effects of an internal arc fault
In the unlikely event of an internal arc fault, a
contact in the gas density sensor opens a loop
circuit which runs through all the panels in a busbar
section. On detection of overcurrent at the same
time, the REF542 plus opens the corresponding
circuit-breaker.

3.3

Disconnector/earthing switch, type UX2TE


(Three-position switch)
(Figures 3/7, 6/3 and 6/5)

3.5

High voltage connections


(Figures 3/2, 3/7, 5/8 and 6/6)
Cable plug connector systems:
High voltage plastic insulated cable with internal
cone cable plug connector system and sockets
to DIN 47637.

Observe the details in the order documents.

Plug systems: size 2 or 3.

Vacuum circuit-breakers, type VD4 X


(Figures 3/3, 3/7, 6/4 and separate manual
BA 463/E)

Plug-in cable sockets (1.7) mounted in a gastight manner in the floor plate of the circuitbreaker compartment maintain the partitioning
between the insulating gas compartment and
the cable termination compartment. The
connection height for the cables is 1250 mm.

Functions of the vacuum circuit-breaker (1.1):


opening and closing on rated currents,

13

Test socket (1.4): plug system size 2.

Hazard and fault signalling

Solid-insulated busbar system: Connection of a


solid-insulated bar by sockets acc. to DIN 47637
size 3 or plug-in busbar sockets.

Connection to automation systems


Panel interlocks and the sequence of switching
operations are controlled by the bay control and
protection unit.

Observe the details in the order documents.


3.6

The single line diagram providing information on


switching device positions is made visible on the LC
display on the control unit of the REF542 plus (4.2).

Control and monitoring


by digital secondary systems with bay control and
protection unit REF542 plus or bay control unit CC.
(Figures 3/4, 3/7, 6/1, 6/5 and 6/6)

Measured values such as conductor currents,


conductor voltages, energy metering and active
and reactive power, number of operating cycles
and number of operating hours appear numerically
and/or as a bar diagram on the display. Further
information, such as alarm and fault signals, is
displayed with text by LEDs (4.6).

Sensors detect actual operating conditions. Their


information is then processed by the combination
unit REF542 plus or the bay control unit CC. Further
details on the REF542 plus and the CC can be
found in the relevant separate instruction manuals
(see section 7.1).

The bay control and protection unit REF542 plus


can be connected to an automation system via
fibre-optic cables. Electromagnetic interference is
avoided by the use of optical waveguides.

The following sensors are used in ZX1.2 panels:


Sensors for insulating gas pressure monitoring

Please refer to the REF542 plus instruction manual


for details on handling of the bay control and
protection unit and a detailed technical description
(see section 7.1).

Sensors to detect the switch positions of the


circuit-breaker
and
disconnector/earthing
switch (three position switch)
Sensor to detect the charging condition of the
circuit-breaker stored energy spring.

3.6.2 Bay control unit CC (optional)

Arrangement of the sensors:

The following functions are integrated in the bay


control unit CC:

Sensors for pressure monitoring:


(B0G) for the circuit-breaker compartment:
on the circuit-breaker base plate in the control
cabinet.

Control

(B1G) for the busbar compartment:


beside the operating mechanism for the
disconnector/earthing switch (three position
switch) -Q1/-Q5 in the control cabinet.

Fault signalling

Switch position indication via mechanical


contacts

Connection to remote control or automation


systems
Protection against maloperation and the
sequence of switching operations are controlled
by the bay control unit CC.

Sensors for detection of the switch positions:


(B0E) and (B0A) for the circuit-breaker:
on its operating shaft.

Information on switching device positions can be


made visible on display units.

(B1E, B1A, B5E and B5A) for the


disconnector/earthing switch (three position
switch):
on its operating mechanism in the control
cabinet.
Sensor B0S of the charging condition of the
stored energy spring: located above the drum
with the spiral spring for the circuit-breaker
operating mechanism.
3.6.1 Bay control and protection unit REF542 plus
(Figures 3/1, 3/3, 3/4, 3/7 and 6/1)
The following functions are integrated in the bay
control and protection unit REF542 plus:
Protection
Control
Measurement
Switch position indication
14

Floating contacts are available for further signals.


Please refer to the CC instruction manual BA
456/E for details on handling and a detailed
technical description of the bay control unit CC.
3.7

Conventional secondary systems in


combination with a protection device
The conventional version of the ZX1.2 has
microswitches on the operating mechanism base
plate for detection of the position of the three
position switch (2.1). These are used to start and
stop the relevant drive motor (disconnector or
earthing switch). These microswitches are
positioned in such a way as to detect the limit
positions of the three position switch.

5 pole sets of positively driven auxiliary switches are


available for each of the positions
earthing switch ON
earthing switch OFF and disconnector OFF
disconnector ON.
Three (four) of the five contacts of the auxiliary
switch are pre-assigned for internal purposes
within the panel, such as circuit-breaker
interlocking or local position indication.

3.8

Protection against maloperation / interlock


dependencies
(Figures 6/3, 6/5 and 7/1)

3.8.1 Interlocks in general


In order to prevent hazardous situations and
maloperation, a series of interlocks are provided to
protect the operators and the switchgear itself.
Protection against maloperation can be implemented by the following two devices:
- Bay control and protection unit REF542 plus

As an option, the following mechanical interlock is


available between the circuit-breaker (-Q0) and the
three position switch (-Q1/-Q5). With the circuitbreaker closed, the access flap (2.22) to the
actuating shaft of the three position switch is
blocked. If the circuit-breaker is open, this flap can
be opened and a hand crank (6.1) inserted for
operation of the disconnector or earthing switch.
When flap (2.22) is open, electrical and mechanical
switching of the circuit-breaker are prevented.

The circuit-breaker and three position switch can


be controlled directly at the panel and/or remotely,
for instance from the control room. Operation at the
panel is by selection on the REF542 plus or
conventionally with push buttons and bar-type
annunciators in the mimic diagram.

The flap (2.22) for the three position switch can only
be closed when the switch is in one of the limit
positions

Three position switch UX2TE and the


corresponding circuit-breaker type VD4X are
electrically interlocked.

earthing switch ON
earthing switch OFF and disconnector OFF
disconnector ON.
The circuit-breaker is only enabled again when flap
(2.22) is closed.
3.7.1 Conventional control
The ZX1.2 variant with a conventional control
system has the following features:

or
- Bay control unit CC.

In the case of manual operation of the three


position switch, a mechanical interlock can
become effective (optional).
Details of further interlocks/dependencies, e.g.
with neighbouring systems, can be found in the
relevant order documents for the system
concerned.
The interlock polling (electrical only) between
panels, where implemented, is effected by loop
lines from panel to panel.

Mimic diagram with bar-type annunciators for


position signalling on the door of the control
cabinet.

Operation on failure of auxiliary power:

Push buttons for operation of the circuit-breaker


(1.1) and the three position switch (2.1).

The details for the specific system are also to be


observed.

Drop indicator relays for signalling of switch and


mcb tripping.

Emergency manual operation:

Starting and stopping of the operating


mechanisms by microswitches in combination
with motor control relays.

Where no mechanical interlock or optional interlock


is fitted, intervention in the interlock concept is
possible by opening the control cabinet door.
Emergency manual operation is possible by means
of a hand crank and mechanical push button.

Electrical interlocks between the circuit-breaker


(1.1) and the three position switch (2.1).
Floating contacts for position signalling for
customized applications (e.g. remote signalling
or interlocking of the opposing side).

On failure of the auxiliary power, the devices can be


operated manually.

Note:
Perform all switching operations fully until the
defined limit position is reached!
3.8.2 Function of the interlock between the circuitbreaker and the three-position switch
a) Electrical interlock
The electrical interlock is achieved by polling and
logical operations on the positions of the three
position switch and the circuit-breaker.
This interlock is always effective when auxiliary
voltage is applied.
15

b) Mechanical interlock (optional)


The mechanical interlock only permits access to
the manual operating shaft of the three position
switch under certain conditions.
A flap (2.22) in front of the shaft can only be
opened when the circuit-breaker is off.
Do not use force!
The three position switch can be moved by approx.
24 turns of the corresponding hand crank (6.1)
either from the
disconnector ON position into the
disconnector OFF / earthing switch OFF position,
or from the
earthing switch ON position into the
earthing switch OFF / disconnector OFF position.
A cam on the hand crank acting together with a pin on
the operating mechanism prevent the mechanism
from overrunning the centre position.

3.9

Earthing a tee-off

3.9.1 Electrical operation using the bay control and


protection unit REF542 plus or push buttons on
the panel front
Operating sequence for tee-off earthing:
Circuit-breaker (-Q0) OFF.
Disconnector (-Q1) OFF.
Earthing switch (-Q5) ON.
Test for off-circuit condition.
Circuit-breaker (-Q0) ON.
Secure panel to prevent reconnection.
M.c.b.s (F101) and (F106) OFF.
Lock the control cabinet door or secure the
mechanical OFF button for the circuit-breaker
if necessary.
Label the panel to indicate that earthing has
been effected.

If the hand crank is withdrawn in an intermediate


position, the flap (2.22) in front of the manual
operating shaft cannot be closed. In this position,
the circuit-breaker remains blocked and cannot be
closed.

Cancelling the earthing:

This intermediate position can be detected on the


one hand by the lack of a mechanical limit position
indication for the three position switch, and on the
other hand electrically at the indicators on the front
door.

Circuit-breaker (-Q0) OFF.

The limit positions are only correctly displayed


when they have actually been reached, i.e. when
the contacts have their full current carrying
capacity. Flap (2.22) can then be closed and the
circuit-breaker switched on.
In reverse, the flap can always be opened when the
circuit-breaker is off, even in an intermediate
position, allowing the hand crank to be fitted.

Open the control cabinet door and switch on the


m.c.b.s. Release the OFF button for the circuitbreaker if necessary.

Earthing switch (-Q5) OFF.


3.9.2 Manual earthing
Follow the same sequence as for electrical
operation, but using the manual push buttons for
the circuit-breaker and the crank to operate the
three position switch.
When an additional mechanical interlock between
the circuit-breaker and the earthing switch is fitted,
the following actions are necessary:
Open the control cabinet door.

The details of the individual system ordered are


also to be observed.

Switch off the circuit-breaker (-Q0) by operating


the mechanical push button.

Note:

Open flap (2.22) on the three position switch


operating mechanism (see Interlocks, section
3.8.2b).

If the disconnector operating mechanism should


fail during a switching operation with the
disconnector in an intermediate position, the
electrical interlock between the circuit-breaker type
VD4X and the three position switch type UX2TE
established by the REF542 plus or CC is effective.
The VD4X circuit-breaker could however be closed
mechanically if the control cabinet door is open.
Even the optional mechanical interlock does not
prevent this possibility.

Note:
Flap (2.22) can only be opened when the circuitbreaker is OFF.
Do not use force!
Switch off the disconnector (-Q1) with the hand
crank.
Switch on the earthing switch (-Q5) manually
using the hand crank (6.1). (Note: Observe
Emergency manual operation in section 6.2.2).
24 turns clockwise.
Close flap (2.22) again.

16

Note:
When flap (2.22) is open, the circuit-breaker is
blocked in the OFF position.
Test for the off-circuit condition (capacitive
voltage indicator system, see section 6.4.1).
Switch the circuit-breaker (-Q0) on using the
mechanical ON push button.
Secure the panel to prevent switching operations:
m.c.b.s (F101 and F106) OFF.
Lock the control cabinet door or secure the
mechanical OFF button for the circuit-breaker if
necessary.
Label the panel to indicate that earthing has
been effected.
Cancelling the earthing manually:
Open the control cabinet door and switch on the
m.c.b.s. Release the OFF button for the circuitbreaker if necessary.
Switch circuit-breaker (-Q0) OFF with the mechanical push button.
Open flap (2.22).

Cancelling the busbar earthing:


Open the control cabinet door in the sectionalizer
and switch on the m.c.b.s. Release the OFF
button for the circuit-breaker if necessary.
Circuit-breaker (-Q0) OFF.
Earthing switch (-Q51 or -Q52) OFF.
3.10.2 Manual earthing of a busbar section using the
sectionalizer/riser
Perform the switching operations as described in
sections 3.9.2 and 3.10.1 accordingly.
3.10.3 Maintenance earthing of a busbar using the test
sockets in a tee-off
Condition:
The tee-off is earthed (see section 3.9).
All disconnectors in the busbar to be earthed
are OFF.
Operating sequence:

Switch earthing switch (-Q5) OFF manually.

3.10

The busbar section is then earthed. All the panels in


the section concerned are to be secured to prevent
switching operations, e.g. by tripping the mcbs.

Close flap (2.22).

Fit a short-circuiting bridge to the test sockets


for the earthed tee-off and connect to main
earthing bar (3.1).

Earthing the busbar

Circuit-breaker OFF.

The procedure for earthing the busbar or a busbar


section is dependent on the configuration of the
system. Systems with sectionalizers/risers permit
earthing of a busbar section without additional
equipment.

Earthing switch OFF.

3.10.1 Electrical earthing of a busbar section using the


sectionalizer/riser
Operating sequence:
Circuit-breaker in the sectionalizer panel OFF.
All disconnectors in the busbar section to be
earthed OFF, apart from the disconnector (-Q11
or -Q12) between the busbar section to be
earthed and the sectionalizer breaker.
Switch earthing switch (-Q52 or -Q51) on the
opposite side of the sectionalizer breaker ON
(condition for release for the following step).

Disconnector ON.
Circuit-breaker ON.
Secure the
operations.

panel

to

prevent

switching

M.c.b.s (F101) and (F106) OFF.


Lock the control cabinet door or secure the
OFF button for the circuit-breaker if
necessary.
Label the busbar to indicate that earthing has
been effected.
The busbar is then earthed. All the panels affected
are to be secured to prevent switching operations,
e.g. by tripping the m.c.b.s.
Cancelling the busbar earthing:

Sectionalizer breaker (-Q0) ON (testing for the


off-circuit condition is replaced by closing the
circuit-breaker).

Open the control cabinet door for the outgoing


feeder and switch the m.c.b.s on, if necessary
releasing the OFF switch for the circuit-breaker.

Secure the
operations.

Circuit-breaker (-Q0) OFF.

panel

to

prevent

switching

M.c.b.s (F101) and (F106) OFF.


Lock the control cabinet door or secure the
mechanical OFF button for the circuit-breaker
if necessary.

Disconnector OFF.
Cancelling the tee-off earthing:
Earthing switch ON.
Circuit-breaker ON.

Label the panel to indicate that earthing has


been effected.
17

Remove the short-circuiting bridge from the test


sockets and close the sockets off with blanking
plugs.
Circuit-breaker OFF.
Earthing switch OFF.
3.11

Test facilities
The panels are properly filled with insulating gas at
the works and tested to the VDE or IEC standards.
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 the test sockets (1.4).
Surge arresters must be removed during voltage
testing. The exposed sockets must be closed off
by blanking plugs during the tests!
Voltage transformers must be isolated from the test
circuit prior to testing.
Voltage tests:
Close off and insulate free cable sockets with
blanking plugs!
See section 6.4 for further details and the
applicable test voltages.
Perform cable tests with DC voltage or with
very low frequency (VLF) cosine or square
wave voltage.
Cable fault location measurements with
impulse voltage and
switchgear tests (without cables) with AC
voltage can be performed with a test plug as
shown in figure 6/7. (Test cables are to be
used for tests on the 36 kV variant.)
A test plug for current tests as shown in figure (6/8)
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:

18

Testing for the off-circuit


condition:

Section 6.4.1

Testing for the in-phase


condition:

Section 6.4.2

High voltage tests:

Section 6.4.3

Maintenance earthing:

Section 6.4.4.

1.9

4.0

1.16

1.17
1.5
1.0

1.6

2.0

2.5

Figure 3/1: Panel type ZX1.2, front view with bay control and
protection unit REF542 plus, measuring sockets for
capacitive voltage indicator system at front (optional),
with pressure relief duct at top (optional), (assembly
opening on circuit-breaker compartment irrelevant).

3.7

Figure 3/2: Panel type ZX1.2, rear view.


Connection of two cables per phase

Figure 3/3: Panel type ZX1.2, front view.


Shown without low voltage compartment door, with a
view into the low voltage compartment
19

4.7

4.6

4.2

Figure 3/4: Bay control and protection unit REF542 plus

1.15

1.3

Figure 3/5: Panel top, pressure relief disk on the circuit-breaker


compartment
Before installation of a pressure relief duct or plasma
diverter
20

Figure 3/6: Panel top, pressure relief disk on the circuit-breaker


compartment.
Shown with plasma diverter

1.10
1.9

ZX1.2

1.3
1.1
1.0
1.5
1.4
1.6
1.7
3.4
2.1
3.1
3.2
3.3
5.1
3.0
2.12
3.5
3.7

1.11
4.0
4.3
1.8
4.2
1.2
1.12
4.5
2.3
2.2
4.4
2.0
4.1
2.10

ZX1.2

1.5
1.4
1.6
1.7
3.4
2.1
3.1
3.2
3.14
3.0

-C1

-C2
-T1

2.4
2.11
3.6

1.11
4.0
4.3
1.8
4.2
1.2
1.12
4.5
2.3
2.2
4.4
2.0
4.1
2.10
2.5

2.12

2.4

3.5

2.11
3.6

3.7

-Q0

2.5

Figure 3/7: Feeder panel type ZX1.2,


Shown with pressure relief duct and plasma diverter
(optional)

1.15
1.3
1.0
5.3
5.4
1.1

-Q1/Q5

-Q0
-Q1
-Q5
-T1
-C1

Insulating gas
Circuit-breaker
Tee-off disconnector
Tee-off earthing switch
Current transformer
Capacitive voltage divider

-C2

Capacitive voltage divider, optional

-Q1/Q5
-Q0
-T1
-C1

-C2

Figure 3/8: Outgoing feeder panel type ZX1.2, with 2 parallel cables,
basic structure shown with plasma diverter for
discharge of the plasma gases to the rear of the system
(See item 3/7 for symbols)
21

1.9
1.3
ZX1.2

2.5
2.4
1.31
1.1

2.1
3.1
3.2

1.11
4.0
4.3
1.8
4.2
1.2
1.12
4.5
2.3
2.2
4.4
2.0
4.1
2.10

-Q11/Q52
-Q0

2.5
3.13

2.4

3.15

2.11
3.6

Figure 3/9: Busbar coupler with circuit-breaker and three position


switch

-Q0
-Q11
-Q52

Circuit-breaker
Tee-off disconnector
Tee-off earthing switch

1.9

2.4

4.0
4.3
1.8

1.32

1.14

ZX1.2

2.5

1.12

2.1
3.1
3.2

2.3
2.2
4.4
2.24
2.0

-Q12/Q51

2.10
2.5

3.13
3.15

Figure 3/10:

22

Busbar riser with three position switch

2.4
2.11
3.6

-Q12
-Q51

Tee-off disconnector
Tee-off earthing switch

4.0
ZX1.2

4.3
5.2
2.8
2.34
3.1
3.2
2.7

2.9
2.3
4.4
2.24
2.6
2.5
2.4

3.15

2.11
3.6

Figure 3/11: Busbar metering panel with plug-in voltage


transformers.
Voltage transformers earthed after isolation.
Disconnecting device (2.9) only to be used when the
busbar is off-circuit.
Always perform the switching operation fully to the limit
position.

23

Despatch and storage

4.1

Condition on delivery

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.
Safety note:
Handling by crane:
Attach suspension ropes of a sufficient load
bearing capacity with shackles (opening angle
30 mm).
Use edge guard (1.19) on the top edge of the
panel.
Bolt on handling brackets (1.8) (if not already
fitted).

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 nonsurge-proof transport covers.

Handling by fork-lift truck:


The panel must be fully supported on the forks of
the lift truck. The high centre of gravity means
that there is a great risk of tipping. On no account
should handling be jerky or violent.

Condition of the gas compartments:


Filled with insulating gas at the operating
pressure,
Fitted with drying agent bags.

Handling in the switchgear room can be effected


by a trolley with steerable wheels. As with
handling by fork-lift truck, take account of the
high centre of gravity of the panels. Danger of
tipping!

Note:
Air freight is to be discussed and agreed in
individual cases.
4.2

4.4

Packaging
Panels with
packaging.

basic

packaging

or

without

Checking the delivery for completeness and


freedom from damage (e.g. also for moisture and
its injurious effects).

Panels with seaworthy or similar packaging (also


containerised for overseas transport):
sealed in polythene sheeting,

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.

transport drying agent bags inserted,


moisture indicators inserted,
sight window fitted for checking of the
indicator when AL composite sheeting is used
(optional).

Note:
Always document major damage with photographs.

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
(Figure 4/1)
Note:
Do not walk on the tops of the panels (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.
Danger of tipping!
Handle the panels in the upright position.

24

Delivery
The responsibilities of the consignee include but are
not limited to:

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 (depending on
the project):
the protective effect of the packaging is no
longer ensured,
take action for further intermediate storage.

1.19
> 60

> 60

1.19

1.23

1.18

1.18

1.23

a)

Feeder panel with low circuit-breaker compartment

b) Feeder panel with high circuit-breaker compartment

Figure 4/1: Preparation for handling by crane.


Handling bracket (1.18) to be removed after handling

25

Erection of the switchgear at site

5.1

General site requirements


At the start of erection, the switchgear room at site
must be complete, fitted with lighting and power for
the erection work, lockable, dry, and with good
ventilation facilities. All necessary provisions for
laying of the power and control cables such as
openings, ducts, etc. must already be in place.

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.

Compliance with the conditions for indoor switchgear to DIN VDE 0670 Part 1000 etc., including
those for the minus 5 indoor temperature class,
must be ensured.
5.2

Construction data

Panel width
Panel depth 1)
Panel height 2)

mm
mm
mm

600
1300
2100

600
1500
2100

800
1300-1800
2100

mm

2800

2800

2800

mm
mm

2600
2950

2600
2950

2600
2950

mm

27005)

27005)

27005)

mm
mm
mm
mm

700
16006)
1100
2300

700
18006)
1100
2300

900
1600-21006)
1300
2300

mm
mm

700
1100

700
1100

700
1300

kg

8)

8)

8)

kg/m2

8)

8)

8)

Ceiling height3) 4):


with plasma diverter
with pressure relief duct
without absorber
with absorber
with plug-in voltage transformers
at the top
Assembly openings3):
in ceilings:
in doors:
Aisle width7):
Inspection aisle
Operator aisle
Panel weight
Floor load
1)
2)
3)
4)
5)

6)
7)
8)

width
length
width
height

Depending on the number of cables per phase


For total height including plasma diverter or pressure relief duct see figures 2/1 to 2/4
Minimum dimensions
Panel including voltage transformers, plugged-in from above (36 kV panel width = 800 mm)
Details for system versions with pressure relief duct - leading to the outside.
Otherwise equal the ceiling height, required for panels with pressure relief duct with absorber
Complies with the panel depth, plus 300 mm
Governed by DIN VDE 0101 and the data on maximum panel width
Depending on the equipment installed (data on request)

The ZX1.2 switchgear installations are mounted on


a foundation frame set into the screed, or on a
raised false floor. Floor openings can be
produced either as large openings or as drill
holes, depending on the number of high voltage
cables.

26

Openings (drill holes) for power cables in the


station floor are to be constructed so as to be
eddy-current free.

5.3

Tolerance conditions for laying of the frame to


DIN 43 661, version A:

Fundamental notes on erection work


DIN-bolts of tensile class 8.8 are to be used.

Evenness tolerance:

Straightness tolerance: max. 1 mm per metre,


but max. 2 mm for the
entire length of the frame

Recommended

tightening torque1)
Nm
Lubricant2)

5.5

Thread

Without

Oil or
grease

M
M
M
M
M
M

10 .5
26
12
50
86
200

4 .5
10
4 .5
20
40
80

6
8
8 3)
10
12
16

+/- 1 mm per metre.

Raised false floor


(Figures 5/12, 5/13)
When a raised false floor is used, the manufacturers installation instructions are to be observed. The false floor must satisfy all requirements
specific to the switchgear installation.

5.6

Erection and connection of the panels


(Figures 5/1 to 5/6)
Note:

1)

2)
3)

The rated tightening torques for fasteners without


lubrication are based on a coefficient of friction for the
thread of 0.14 (the actual values are subject to an
unavoidable, partly not inconsiderable, spread).
Rated tightening torques for fasteners with lubrication in
accordance with DIN 43 673.
Thread and head contact surface lubricated.
These values apply to welded on studbolts only.
Any tightening torques which deviate from those in the
general table (e.g. for contact systems or device terminals) are
to be taken into account as stated in the detailed technical
documentation.
It is recommended that the threads and head contact
surfaces of bolts should be lightly oiled or greased, so as to
achieve a precise rated tightening torque.

Remove any dirt from the surfaces in general and


from insulating material surfaces. Observe the
cleaning instructions in Section 7.2.
When handling SF6, avoid any escape of gas into
the switchroom:
ventilate well if leakage occurs.
5.4

Foundation frame
(Figures 5/9, 5/10, 5/11)
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.

Do not walk on the top of the panels (rupture point


for pressure relief system!).
5.6.1 Preparatory work
Grease the upper surfaces of the foundation
frame (this facilitates erection and alignment of
the individual panels).
5.6.2 Erection of the switchgear
Erect the end panel of the switchgear at the
precise position specified on the foundation
frame.
Remove the handling bracket (1.18).
Align the panel.
Perform a final check on the aligned position of
the panel and fasten it to the foundation frame.
Remove the protective caps from the busbar
sockets (2.13).
Carefully check insulating parts (2.14) and
contact tubes (2.21) for any dirt, and clean if
necessary (see also section 7.2).
Note:
Only prepare insulating parts and contact tubes for
the panel currently being erected. Protect them
from further contamination!
Evenly apply a thin coating of assembly paste AP
to the conical surfaces A of insulating parts (2.14).
Note:
Leave no ungreased areas on conical surface A.
Carefully insert bus connectors (2.21) and insulating
parts (2.14) into the busbar sockets (2.13).
Slide the adjacent panel carefully and evenly
(without tipping) against the erected panel in
such a way that the bus connectors, insulating
parts and guide pins slide into the
corresponding bores without the use of force.
If necessary, align the panel.
27

As soon as the distance between the two panels


is so small that bolts (2.16) can be entered in the
bores in the erected panel, insert these, each
with nuts and dished washers respectively.
Then join the two panels together by tightening
bolts (2.16) crosswise step by step.
Completely bolt the panels together with bolts
(1.20), each with dished washers (1.22).
When the panels have been completely joined,
check the second panel again for correct
alignment and fasten it to the foundation frame.
Dismantle connecting link (3.2) for the main
earthing bar (3.1) in the cable compartment and
lead it through to the adjacent panel. Bolt the
connecting link to the main earthing bar with
bolts (2.20) and one dished washer at each of
the bolt head and nut ends.
Check the bolted connection between main
earthing bar (3.1) and the connecting link (3.2) in
the previously erected panel and tighten
bolt 2.20 if necessary.
Erect the further panels by following the same
procedure.
Assembly of the top pressure relief duct and the
absorber can be effected during installation of
the individual panels or when all panels have
been joined together.

28

1.20
1.21
1.22

1.20
1.21
1.22

2.16
2.18
2.19
2.17
2.18
2.19

2.5

2.16
2.18
2.19

3.8

Figure 5/1: Switchgear assembly, see figures 5/2 to 5/4 for details.
(Bay control and protection unit REF542 plus not shown
completely)

2.14

ca. 50 mm

Figure 5/2: Switchgear assembly,


insulating part
On assembly of the busbar, the conical surface A is to be
evenly lubricated with assembly paste AP.
No areas must be left unlubricated.

29

2.18
2.19
3.2
3.1
2.20

3.1

Panel 1

Panel 2

Figure 5/3: Switchgear assembly


Earthing bar connection

2.19

2.17

2.18

Panel 1

Panel 2

2.19

2.19

2.18

2.16

Panel 1

Panel 2

Figure 5/4: Switchgear assembly


Panel/panel connection

30

L1

L2

L3

Figure 5/6: Assembly of the busbar connection, shown for 1250 A

2.13 2.33

2.14

2.21

Figure 5/5: Busbar connection


Before assembly the proper position of the contact
rings must be checked
1250 A, 1 contact ring
> 1250 A, 2 contact rings

L1, L3: Protective caps removed


L2:
Insulating part (2.14) and
bus connector (2.21) fitted

1.7
3.4
3.7
3.10
3.11
3.12
3.9

Figure 5/7: Plug connector for single-core XLPE cable


K

Cable earthing conductor to be connected to


switchgear earth. Refer to the mounting instruction of
the supplier.

Figure 5/8: Cable termination compartment, single-core cable


(panel side wall cut out)

31

a = n x FT

A
A

7.5

455
300
450

7.1
3

45

7.10
7.20

7.6

(with panel depth 1300 mm)

7.6
7.10
7.20

(60)

30

145
110
75

(60)

FT

7.2
7.7

7.4

1216

7.3

(60)

480
600

(60)

7.6

7.1

7.6

7.8

7.6

Figure 5/9a: Foundation frame unit for two panels


X Frame arrangement, rear, for equal panel depths
Y Frame arrangement, rear, for unequal panel depths
Z Frame arrangement, front

Panel width

Foundation frame width a = n x FT


Number of panels n

FT

32

mm

mm

mm

mm

600 mm

600

1200

1800

2400

800 mm

800

1600

2400

Feeder panel
Feeder panel
Feeder panel
Metering panel

Panel
depth

Foundation frame
depth b

mm

mm

1300
1500
1800
910

1216
1416
1716
901

50

50

for metering panel

20

25

25

(Profile: 50x50)

30

30

50

23

30

22

5 20

30

38
40...50

21

38

21

25

38

24

30

30
18

17

17

17

A-A
7.12
7.20
7.13

30

3
7.10
7.20

min. 40

7.10
7.20

7.11
7.21
7.30

A-A

max. 50

7.14

Figure 5/9b:

Foundation frame unit on concrete floor for two panels


When laying the foundation frame in floor topping first tighten screw 7.12.
17

Opening for control cable

18

Opening for power cable

22

Control cabinet

23

Switchgear panel

24

Foundation frame
33

8x150

190
85

150

210 210

190

700

1)

630

150

600

630

600

800

800

800

800

800

600

600

Figure 5/10: Guideline construction for a foundation frame on a


concrete floor
See figure 5/11 for sections

800 1)

50

B
Panel width
in switchgear

mm

mm

mm

mm

1)

Minimum

600 mm

1120

1255

1100

1100

2)

Dimension for panel width 800 mm. These dimensions


are reduced by 200 mm for a uniform panel width of
600 mm.

800 mm or
600 mm mixed with
800 mm

1320

1455

1300

1300

Inspection aisle

Operator aisle

Basement entrance

Platform, approx. 25 kN

Pressure relief duct at side,


including end cover

Instead of individual openings, continuos openings


or drilled holes are possible

Earthing bar

Panel without cable connection, e.g. bus coupler


panel, metering panel

34

800

d 1)

250

85

c 1)

430

b 1)

85

a 1)

500

1)

210

1300

1210

635

160

80

330

1800

1350

835

1500
170

1080

155

625

430
155
155

85

Door

10

Waste air opening

11

Intake air opening

12

Intake air opening, if required

13

Waste air opening

14

Waste air opening, (other alternative possible


according to the requirements of the project)

15

Height of cable basement as required

16

To main earthing bar

17

Opening for control cable

18

Opening for power cable

19

Power cable

20
21

Aisle width:
In the case of transverse installation of a panel, the minimum aisle
width is c:
Maximum panel depth (including possible overhangs) plus 300 mm.
The dimensions for a (wall clearance foundation frame) and b (wall
clearance ceiling opening for control cables) are to be adjusted
accordingly.
As an option, the dimension for the low voltage compartment (panel
depth) for systems fitted with conventional relays and control facilities can
be 100 mm greater than in the standard version.
The dimensions for a (wall clearance foundation frame) and b (wall
clearance ceiling opening for control cables) then become 100 mm
larger, while the aisle width remains unchanged.
Room height
Plasma diverter Absorber

min. room height


mm

Panel ZX1.2

with

2800

Panel ZX1.2

without

2600

Panel ZX1.2

with

2950

Absorber

Panel ZX1.2

with

2800

Screed

with plug-in voltage

without

2700

transformers above

with

2950

Section A - A

Section B - B
1300 1) 2)

700

1)

1300 1) 2)

1500

11

11

1300 1) 2)

(25)

13

1455 1) 2)
1320 1) 2) 3)

12

17
330

14

635
1410

210

13

1455 1) 2)
1320 1) 2) 3)

14

A
> o > 3mm

> o > 3mm

a)

18

15

17
635 210
1210

160

1)

15

18

12

2950

19

1)

10

2
1080
(155)

170

2600

16

2300 1)

ZX1.2

2100

WITH ABSORBER
1)

21

(25)

20

2950

1)

2640

2100

19

21

10

2
1080
(155)

2600

16

2370

ZX1.2

2300 1)

WITHOUT ABSORBER

20

WITH ABSORBER

1300 1) 2)

2640

1300

WITHOUT ABSORBER

1)

2370

700

b) Panel width 600 mm or 800 mm


Connection of 2 cables per phase, panel depth 1500 mm.
Cable plugs size 2 or 3

Panel width 600 mm or 800 mm


Connection of 1 cable, panel depth 1300 mm
Cable plugs size 2 or 3

Section C - C
700

1)

1300 1)

1800

11

1)

1)

2600

(25)

2950

2100

21

10

2
1080
(155)

19

2640

16

2370

ZX1.2
155 155 155

2300 1)

WITHOUT ABSORBER

20

WITH ABSORBER

1300 1)

18

17
625

635
1710

210

13

1455 1)
1320 1) 2)

15

12

14

> o > 3mm

c) Dimension for panel width 800 mm


Connection of up to 4 cables per phase, panel depth
1800 mm.
Cable plugs size 3
Figure 5/11: Sections for figure 5/10
See figure 5/10 for legend and dimensional table
1)
2)

3)

Minimum
Dimension for panel width 800 mm. These
dimensions are reduced by 200 mm for an
uniform panel width of 600 mm.
Distance wall to foundation frame element
35

190

600

800

800

800

800

800

800

600

600

800 1)

23

50

b 1)

a 1)

600

1)

500 1) 250

1300

8
1500

22

170

155
155

1800

155
1080

150

1150

210 210

8x150
150

1350
835

190

700

1)

B
D

M8
75

M8

450

M8

650

75

75 75

Figure 5/12:

Guideline construction data for a raised floor


See figure 5/13 for sections
1)
2)

Minimum
Dimension for panel width 800 mm. These
dimensions are reduced by 200 mm for a uniform
panel width of 600 mm.
1

Inspection aisle

Operator aisle

Basement entrance

Platform, approx. 25kN

Pressure relief duct at side, including end cover

Earthing bar

Panel without cable connection, e.g. bus coupler


panel, metering panel

36

Door

10

Waste air opening

11

Intake air opening

12

Intake air opening, if required

13

Waste air opening

14

Waste air opening, (other alternative would be


possible according to the requirements of
the project)

15

Height of cable basement as required

16

To main earthing bar

18

Opening for power cable

19

Power cable

20

Absorber

22

Intermediate frame construction, only shown in


the area for the switchgear.

23

Intermediate frame construction, supplied by others

24

Cover plate, supplied by others

Panel width
in switchgear

mm

mm

mm

600 mm

1150

1100

1100

800 mm or
600 mm mixed with
800 mm

1350

1300

1300

Aisle width:
In the case of transverse installation of a panel, the minimum aisle
width is b:
Maximum panel depth (including possible overhangs) plus 300 mm.
As an option, the dimension for the low voltage compartment (panel
depth) for systems fitted with conventional relays and control facilities
can be 100 mm greater than in the standard version.
The dimensions for a (wall clearance centre of floor support) then
becomes 100 mm larger, while the aisle width remains unchanged.

Room height
Plasma diverter Absorber

min. room height


mm

Panel ZX1.2

with

2800

Panel ZX1.2

without

2600

Panel ZX1.2

with

2950

Panel ZX1.2

with

2800

with plug-in voltage

without

2700

transformers above

with

2950

Section B - B

12

18

17

1150

1350

1350

1) 2)

1350

1) 2)

> o > 3mm

> o > 3mm

a)

2640

18
15

24

15

12

1)

(25)
A

2370

2
1080
(50)

19

2300 1)

170

16

WITH ABSORBER

14

ZX1.2

1)

10

11

20

2600

1)

2640

(25)

13
2950 WITH ABSORBER

19

1)

1080
(50)

2600

10

2370

16

2100

14

2300 1) 2)

ZX1.2

WITHOUT ABSORBER

11

20
1

1300 1) 2)

1500

1300 1) 2)

1300 1) 2)

13

1)

2950

700

1300 1) 2)

1300

2100

1)

WITHOUT ABSORBER

Section A - A
700

b) Panel width 600 mm or 800 mm


Connection of 2 cables per phase, panel depth 1500 mm.
Cable plugs size 2 or 3

Panel width 600 mm or 800 mm


Connection of 1 cable, panel depth 1300 mm
Cable plugs size 2 or 3

Section C - C

9
155

16

1)

2600

10

2
1080
(50)

19

2640

ZX1.2
155

2370

155

2300 1)

1
14

(25)

1)

11

2100

13

2950

1300 1)

20

WITH ABSORBER

1300 1)

1800

WITHOUT ABSORBER

700

1)

23

18

15

12

1650

1350

1)

> o > 3mm

c) Dimension for panel width 800 mm


Connection of up to 4 cables per phase,
panel depth 1800 mm.
Cable plugs size 3
Figure 5/13:

Sections for figure 5/12


See figure 5/12 for legend and dimensional table
1)
2)

Minimum
Dimension for panel width 800 mm. These
dimensions are reduced by 200 mm for an
uniform panel width of 600 mm.
37

5.7

Connection of cables and wiring

5.8

The cable compartments (3.0) in the panels are


fitted with cable connection fittings in accordance
with the cable types and sizes specified in the
project planning for the switchgear as a whole.
5.7.1 High voltage XLPE cable with plug-in
connectors
(Figures 3/2, 3/7, 5/7, 5/8)
Lay the XLPE cables as specified in the project
planning to the individual panels.
Remove the transport covers fitted to protect the
sockets.
Expose the cable cores, check the correct
phase assignment, and secure.
Fit current sensors if appropriate.
Fit cable plug (3.4) in accordance with the
manufacturers instructions.
Fit toroidal core current transformers (5.1) if
appropriate.
Fit the plugs to the sockets (1.7) mounted in the
circuit-breaker compartment floor (without
opening the insulating gas compartment) and
secure them with bolts.
Align the cables and fasten them at mountings
(3.3).
Fasten current sensors or current transformers if
appropriate.
Close off any unused sockets (1.7), e.g. in spare
panels, with suitable cable blanking plugs to
ensure the necessary insulation.
5.7.2 Control cables and wiring
Establish the necessary connections for
incoming and outgoing cables and wiring, and
cross connections.
The control cables and wiring are to be laid in
cable ducts at the right of the cable compartment (for external wiring).
The connections from panel to panel are to be
made by plug connectors in the control
cabinets.

38

Preparing the insulating gas system for


operation
Observe the relevant data in instruction manual
BA 427/E Insulating gas system for ZX switchgear.

5.9

Final erection work


Clean the external surfaces of the enclosure and
control cabinets in the switchgear where
necessary and check for any damage to the
paintwork, touching up with a suitable paint if
necessary (see Section 7.3.3).
Properly refit any cladding and covers of
operating mechanisms, cable ducts, etc.
removed during the erection work.
Remove all tools and other foreign bodies from
the switchgear.
Check the general condition of the switchgear.
Check that the areas adjacent to the switchgear
are in the proper condition.

Check that corresponding conductor sections


are in phase where relevant with several
incoming feeders and switchgear sections.

Commissioning/operation
Note on safety at work

Energise the switchgear step by step, observing


the displays on the REF542 plus.

Operation by trained specialists familiar with the


particular switchgear only.
6.1

Check measurements and functions dependant


on high voltage.

Commissioning

Look out for irregularities of any kind.


6.1.1 Preparatory work
In preparation for commissioning, the following
work is to be performed prior to connection with
the high voltage power supply:
Connect the supply and control voltage and
check the correct polarity.
Check mechanical and electrical interlocks for
compliance with the specified conditions.
Perform a functional test on the protective
devices (observe DIN VDE 0141).
Check the general condition of the switchgear
and external conditions for detrimental factors of
any kind.
Display the instructions for handling SF6 in the
switchroom. The handling specifications for SF6
also apply accordingly to nitrogen (N2).
Display the ABB instruction manual on the
handling of insulating gas and behaviour during
faults in the switchroom.
Instruct the local operators on the fundamental
details of operating the switchgear in normal
service.
Check the readiness for operation and the
switching condition of the upstream and
downstream electrical equipment.
Perform further checks where necessary on the
following equipment from the areas adjacent to
the switchgear:
power cables
control wiring
supply voltage and its polarity
remote controls

6.2

Switching operations

6.2.1 Circuit-breaker
(Figures 3/7, 6/1, 6/2, 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:
Closing and opening are effected by operation of
the devices fitted.
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. Opening of
the control cabinet door can constitute
intervention in the interlock system (see sections
3.8 to 3.10).
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 (4.3).
Insert charging lever (6.3) into recess (1.40)
and pump for approx. 25 strokes until the
charged condition is displayed.
When the charged condition is reached, the
charging mechanism automatically disengages
and further strokes of the charging lever have no
effect.
Key to the charging condition displays:

external earth with connection to main


earthing bar (3.1)
switchroom equipment
switchroom condition.
6.1.2 Initial start-up
Comply with all relevant safety regulations
Ensure that the switchgear circuit-breakers are
in the OFF position.
Close the disconnector for the relevant busbar
system.

Discharged

Charged

2. If the control voltage fails with the circuit-breaker


closed, it is possible to open it using the
mechanical OFF push-button (1.35).
Note:
On failure of the control voltage, there is no
maloperation protection for the circuit-breaker
and three-position switch during emergency
manual operation.

Cancel any existing short-circuiting and earthing


connections in the critical switching area.
39

Note:
Always perform every switching operation right
up to the stop in the relevant limit position.
Observe the mechanical and electrical position
indicators.
Close flap (2.22) again.

6.2.2 Three-position switch


(Figures 3/7, 6/1, 6/3 and 6/5)
The three-position switch (2.1) is fitted with
motor-operated mechanism. Opening and
closing are effected by selection on the bay
control and protection unit.

Note:

Routine opening/closing operations may only be


performed with the control cabinet door closed.
Opening of the control cabinet door can constitute intervention in the interlock system (see
sections 3.8 to 3.10).
Observe the switch position indication on the
LC display (4.7) or on the electrical position
indicators.

When flap (2.22) is open, the circuit-breaker is


locked in the OFF position.
Close the control cabinet door.
6.2.3 Undervoltage release
Undervoltage releases may be fitted as an option.
In order to prevent the circuit-breaker being
opened by the undervoltage release on power
failure with tee-off earthing, a tie wire is provided.

On the three position switch operating


mechanism (2.2), sensors (2.28) to (2.31) detect
the following switch positions:
- Disconnector (-Q1) ON and OFF

6.3

- Earthing switch (-Q5) ON and OFF


Emergency manual operation:
In place of motorised operation, the switching
process can also be initiated and completed
manually.

6.3.1 Gas monitoring


(Figures 6/1, 6/6)
All high voltage compartments in the switchgear
must have a sufficient insulating gas pressure during
operation. The minimum operating pressure is listed
in section 2.1. This is monitored by sensors (1.8) and
(2.3).

Caution!
Intervention in the interlock concept is possible by
opening the control cabinet door.

If the gas pressure falls below the minimum


operating pressure, a LED on the bay control and
protection unit signals that the gas should be
topped up. With conventional panel control, the
issue of the signal is optional and dependent on the
individual project.

Switch the three-position switch on or off


manually.
This requires the following actions:
Open the control cabinet door.
Switch the circuit-breaker off.
With the mechanical interlock between circuitbreaker and three position switch option,
opening flap (2.22) on the three position switch
operating mechanism activates a mechanical
interlock between the two devices.

Note:
If a panel is isolated for a relatively long period
(several weeks), m.c.b. (F116) for the auxiliary
voltage supply to the REF542 plus must remain on.
Only in this way is monitoring of the insulating gas
ensured. With conventional panel control, the details
in the order documents are to be observed.

Note:
The flap (2.22) can only be opened when the
circuit-breaker is OFF.
Prior to emergency manual operation, switch the
relevant m.c.b. (F101) off.

Details on the gas system of the ZX1.2 switchgear


can be found in instruction manual BA 427/E.
6.3.2 Electrical/mechanical display/monitoring

Insert the crank (6.1) in the hollow shaft (2.26).


Three-position switch operation:
If the three-position switch is in the central
position (i.e. disconnector and earthing switch
OFF), the disconnector can be closed with
approx. 24 clockwise turns, and the earthing
switch with approx. 24 anti-clockwise turns. If
the earthing switch ON position is to be
reached from the disconnector ON position, or
vice versa, the crank is to be removed in the selfinhibiting central position (disconnector and
earthing switch OFF) and refitted. When the
crank is refitted, the further switching operation
is automatically enabled.
40

Observation of the display and monitoring


facilities

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

6.4.1 Testing for the off-circuit condition


(Figure 6/1)
The panels are fitted with the low impedance,
capacitive voltage indicator system LRM (and
KVDS respectively) for testing of the off-circuit
condition.

For details, see draft DIN VDE 0682 Part 415, or


IEC 61243 Part 5.
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:
The measuring sockets must on no account be
short-circuited, except during voltage testing of the
system (e.g. with power frequency withstand
voltage or impulse withstand voltage)!
Testing for the off-circuit condition is performed with a
plug in display unit at corresponding pairs of measuring
sockets (1.6) and optional at (4.5) (Front side).
Use of the display unit:
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.
Observe the individual operating instructions for
the display unit for the relevant switchgear!
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 (1.6 and 4.5 respectively) 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!
6.4.3 High voltage tests
(Figures 3/7, 6/1, 6/6, 6/7)
The test plugs available for high voltage tests,
shown in figure 6/7, are suitable for the following
applications up to and including 24 kV rated
voltage.

For high voltage tests on the 36 kV rated voltage


level, separate test facilities are required (test
cable). Information on these can be obtained from
the switchgear manufacturer.
On account of the sensor technology used and the
bay control and protection unit, the test voltage
must not exceed the following levels:
Cable tests with DC voltage:
12 kV switchgear: 481) kV
14/26 kV switchgear: 701) kV
up to one hour.
1)

On use of voltage sensors which are not isolated. Voltage


sensors are to be isolated and taken off-circuit by the isolating
device.

Insulation testing of the switchgear at the relevant power frequency withstand voltage:
12 kV switchgear: 28 kV
24 kV switchgear: 50 kV
36 kV switchgear: 70 kV.
Performance of voltage test plugs:
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
(1.6) or (4.5) on the capacitive voltage indicator
system.
Unscrew surge arresters where fitted and close
off the exposed sockets with insulating cable
dummy plugs.
Close off emty cable sockets with insulating
cable dummy plugs.
Check the test plug to ensure that the surface is
clean and dry, and clean it if necessary.
Grease the insulating part of the test plugs in
accordance with the instructions.
Unscrew cable dummy plug (1.5) in the relevant
test socket (1.4) and remove it.
Connect an earthing lead to the test plug,
following the instructions on safety at work in
figur 6/6.
Insert the test plug into the prepared test 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 (1.6) or (4.5)
in the panels concerned for the duration of the
testing process at test voltages up to rated
power frequency withstand voltage.
For performance of cable tests, in the switching

41

condition tee-off disconnected and earthed,


earthing of the cable has to be cancelled by
opening the circuit-breaker. This is accomplished
by using the mechanical OFF button to open the
circuit-breaker (see also Section 3.10).
6.4.4 Maintenance earthing
Earthing of the busbar with the bus tie / riser, as
described in section 3.10.

Application of the X-ray regulations


One of the physical properties of vacuum insulation
is the possibility of X-ray emissions when the
contact gap is open. The specified type test
performed by the Physikalisch-Technische Bundesanstalt (PTB) in Brunswick demonstrates that
the local dosage output of 1 Sv/h at a distance of
10 cm from the touchable surface is not exceeded.
The results are as follows:

Earthing with an earthing and short-circuiting


set.

The use of the vacuum interrupters at rated


voltage is completely safe.

Handling during earthing with an earthing and


short-circuiting set:
(Figures 6/1 and 6/8)

Application of the rated power frequency


withstand voltage specified for the switching
device by DIN VDE 0670 and IEC 62271 or a DC
voltage of 48 kV or 70 kV during cable tests is
also safe.

The plugs shown in figure 6/8 in conjunction with


corresponding short-circuiting and earthing cable
sets are to be used for maintenance earthing. The
short-circuit withstand capability of the cable set
must correspond to the conditions of the switchgear installation.
Caution!
Observe the notes in Section 3.8 on the interlock
dependencies for all work with earthing and shortcircuiting sets!
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
(1.6) or (4.5) on the capacitive voltage indicator
system.
Unscrew surge arresters where fitted and close
off the exposed sockets with insulating cable
dummy plugs.
Close off empty cable sockets with insulating
cable dummy plugs.
Check the test plugs to ensure that the surface is
clean and dry, and clean them if necessary.
Carefully screw the short-circuiting and earthing
cable set to the test plug.
Connect the common earthing connector of the
cable set to the earthing terminal of the panel.
Unscrew cable dummy plups (1.5) in the relevant
test socket (1.4) and remove it.
Insert the test plugs into the prepared test
sockets and screw them tight.

42

6.5

Higher voltages than the rated power frequency


withstand voltage specified in DIN VDE or IEC
standards or the DC voltage must not be
applied!
Fulfilment of the above requirement with the
vacuum interrupter in the open position is
dependent on maintenance of the specified
distance between the contacts (which is
automatically ensured with correct mechanism
function and force transmission).

4.3
4.4
4.2
4.10
4.7

4.8
(4.9)

4.6

4.5
4.3

Figure 6/1: Display area of the panel

Figure 6/2: Handling of the door-lock

Figure 6/3: Operating mechanism three-position switch type UX2TE

Opening the control cabinet door:


Open the safety lock (if fitted)
Release the catch with the double bit key
Draw the closing lever out to an angle of 45 and
then switch it upwards to the left through approx.
135 until the stop is reached
Closing the control cabinet door:
reverse the procedure for opening

Figure 6/4: Emergency manual operation, circuit-breaker type VD4X

43

Figure 6/5: Emergency manual operation three-position switch type


UX2TE

Figure 6/7: Test plug for high voltage tests up to 24 kV rated voltage

Figure 6/6: Facilities for current and voltage testing


Notes for safety at work:
When using, e.g. when fitting and removing the voltage
and current test plugs, the following must be ensured:
The safety regulations of VDE 0105 are followed, e.g.
the section of the switchgear concerned:
- de-energised,
- is secured to prevent reconnection,
- the off-circuit conditions has been verified, and
- it is earthed

The occurrence of high voltage by secondary injection


from the voltage transformers must be avoided.

Before and during fitting and removal of the test


plugs, they are to be earthed at the terminal end with
an earthing lead. This is regarded as an additional
earth only, and shall not replace the earthing in the
panel. The earhting lead must be removed before the
test voltage is applied.
Caution !
During the test, the full test voltage is applied to the
terminal end of the test plugs. Guards are to be fitted.

Figure 6/8: Test plugs for current tests


Also usable as a maintenance earth in conjunction with an
earthing and short circuiting set

44

7.2

Maintenance/disposal
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

Under normal operating conditions (see section


1.3), inspection (visual examination) of the
operating mechanisms is to be carried out by a
suitably qualified electrician after 10 years at the
latest or after 5,000 operating cycles of the
circuit-breaker and 1,000 operating cycles of the
three position switch. Attention is also drawn to
instruction manual BA 463/E.

Measures to re-establish the specified condition

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.

It is essential to observe the following during all


maintenance work:

Inspection is first and foremost to be visual


examination for contamination, corrosion and
moisture.

Repair:

7.1

Inspection/servicing

General

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.

The inspection should however also include


checking of the mechanical and electrical
functions of the following devices:
Switching devices,

It is recommended that ABB after sales service


personnel be called in to perform servicing and
repair work.

Bay control and protection unit REF542 plus


or Bay control unit CC.

Follow/observe the instructions on SF6 systems


and the ABB instruction manual on the handling of
insulating gases and procedures for fault conditions. The handling regulations for SF6 also apply
accordingly to nitrogen N2.

If an incorrect condition is found, the


corresponding repair work is to be initiated
immediately.

Keep these instructions and manual


permanently on display and available in the
switchroom.

If the necessity of cleaning is established during


inspections, the following procedure is to be
adopted:

The inspection and servicing intervals for the


switching devices are determined by fixed criteria
such as switching frequency and number of shortcircuit breaking operations.

Prior to cleaning, isolate and secure the working


area if necessary in accordance with the safety
rules of DIN VDE and IEC.

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).

Remove weakly adhering dry dust deposits


with a soft dry cloth.

In addition to this instruction manual, the following


instruction manuals must be observed:

Conventional control units

Cleaning:

Cleaning of surfaces in general:

Remove more strongly adhering contamination


with slightly alkaline household cleanser, or with
Rivolta BWR 210.

Insulating gas system:

BA 427/E

Bay control and protection


unit REF542 plus, Handbook:

Cleaning of insulating material surfaces and


conductive parts (outside the gas compartments):

BA 464/E

Minor contamination with Rivolta BWR 210.

Bay control unit CC:

BA 456/E

Circuit-breaker VD4 X:
(according to the actual manual)

BA 463/E

Strongly adhering contamination with Cold


cleanser 716.

Further details can be found in the technical


documentation for the switchgear installation
(including, for example, any agreed special
operating conditions).

Cleaning of busbar insulating parts, cable


sockets and busbar sockets with cable cleanser
MAB.
Observe the manufacturers instructions and the
special ABB instruction manuals BA 1002/E and
BA 1006/E on safety at work.
Wipe down after cleaning, using clean water,
and dry properly.
45

7.2.1 Vacuum circuit-breaker


The vacuum circuit-breaker has a long service life.
It has a low maintenance operating mechanism
and the breaker poles are maintenance-free.
Consult the relevant sections of instruction
manual BA 463/E for further information.
7.2.2 Three-position switch
The three-position switch is maintenance-free
for 2000 operating cycles.
7.2.3 Gas system and gas servicing
Consult the relevant sections of instruction
manual BA 427/E for further information.
Caution when working in the gas compartment
concerned! The gas concentration may cause a
danger of asphyxiation!
7.3

Repair

7.3.1 Replacement of circuit-breaker parts and


accessories
Only remove and reassemble circuit-breaker parts
and accessories when the breaker has been
switched off and the working area is to be isolated
and secured against reclosing. The spring energy
store must be discharged.
All supply voltage sources must be disconnected
and secured against reclosing during the removal
and installation work.
7.3.2 Checking the dimensional accuracy of the
settings
(Figure 7/1)
After work which may be necessary on the circuitbreaker or three-position switch when the optional
mechanical interlock is fitted, the following checks
are necessary:
The distance between lever (1.28) operated by a
link rod and plastic cam (1.26) is to be 2+1 mm.
There must be space between lever (1.28) and
OFF release shaft (1.25).
If correction is necessary, tie wire (2.35) is to be
adjusted:
Release clamping screw (1.30) on clamping
piece (1.29).
Align flap (2.22) in such a way that the two
bores (2.23) are in alignment.
Fasten tie wire (2.35) with clamping screw (1.30)
in such a way that the above mentioned distance
of 2+1 mm is achieved. The tie wire must not be
tensioned.

46

7.3.3 Touch up of surfaces


Sheet steel parts, painted:
Remove rust, e.g. with a wire brush.
Grind off paint coat and grease.
Apply anti-rust primer and top coat.
Use top coat paint in the standard colour
RAL 7035, or the relevant special colour.
Sheet steel parts, with aluminium-zinc surface
and passivated functional parts:
Remove white rust with a wire brush or
cleaning pad (e.g. Scotch-Brite white).
Remove loosely adhering particles with a dry
cloth.
Apply zinc spray or zinc dust primer.
Functional parts, phosphated:
Remove rust with a wire brush or cleaning
pad (e.g. Scotch-Brite white).
Clean with a dry cloth.
Grease with Isoflex Topas NB 52.
Notes:
It is essential to observe the section on safety at
work in instruction manual BA 427/E for all work
on gas compartments.
Caution when working in gas compartments!
High gas concentrations may result in a danger
of asphyxiation!

+1

1.24

1.28

1.26

1.25

1.27
X
X
1.42
a)

1.29 1.30

Circuit-breaker, side view

2.23

2.22

2.35

b) Three- position switch, front view

Figure 7/1: Interlock between the circuit-breaker and the


three-position switch

47

7.4

Working and auxiliary materials

7.4.1 Working materials

Part no. (Order ref.)

Insulating gas system:


Nitrogen (N2)
Degree of purity 4.6
Delivery form: liquid gas in steel cylinders
Observe the relevant ABB instruction manual
BA 1007/E on safety at work!

GCE0990267P0100

GCEA901007P0102

Sulphur hexafluoride (SF6)


Delivery form: liquid gas in steel cylinders
Observe the quality requirements to IEC 60376/
VDE 0373!

GCE0990253P0103

Observe the relevant ABB instruction manual


BA 1004/E, pp. 1 to 3, on safety at work!

GCEA901004P0102

Note:
If extreme temperatures 50 C 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!
Drying agent material:
Drying agent bag to DIN 55 473,
capacity per bag 210 g

GCE0990443P0100

7.4.2 Auxiliary materials


Lubricants:
Isoflex Topas NB 52,

7.5

Assembly paste AP,


for insulating part/cast resin plug connections

GCE0009098P0100

Cleaning agents for general cleaning: Rivolta BWR 210,


Observe the relevant ABB instruction manual BA 1002/E

GCE0007707P0100
GCEA901002P0102

Cleaning agent for conductive parts, parts in insulating material,


and all parts with heavy contamination: Cold cleanser 716,
Observe the relevant ABB instruction manual BA 1006/E

GCE0007706P0100
GCEA901006P0102

Cleaning agent for busbar insulating parts


busbar sockets and cable sockets: Cable cleanser MAB

GCE0009100P0100

Paintwork:
Paint in standard colour RAL 7035
1 kg-box
Spray tin

GCE9014060R0103
GCE0007895P0100

Coupling piece with hose connection for gas connector (optional)

GCE0905093P0100

Disposal
Disposal of the clients systems and components
and the clients waste, residue materials and used
substances can be performed by ABB Calor Emag
Schaltanlagen AG. ABB Calor Emag Schaltanlagen
AG performs such disposal as a service enterprise
in connection with its servicing and installation

48

GCE0007249P0100

activities. The clients waste materials are passed


on to authorized disposal specialists close to the
point of origin.
Details can be found in instruction manual
BA 477/01 E.

49

We reserve the right to make changes in the course of technical development.


Instruction manual no. GCEA 68 0468 P0102 Printed in Germany (07.02-1000-PPI)

ABB Calor Emag Mittelspannung GmbH


Oberhausener Strasse 33
Petzower Strasse 8
40472 Ratingen
14542 Glindow
DEUTSCHLAND
DEUTSCHLAND
Phone: +49(0)21 02/12-12 30, Fax: +49(0)21 02/12-19 16
E-Mail: calor.info@de.abb.com
Internet: http://www.abb.de/calor

ZX1.2
Gas-insulated medium voltage switchgear
Instruction manual BA468/01E
Legend
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12

1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
1.29
1.30
1.31
1.32
1.33
1.34
1.35
1.36
1.37
1.38
1.39
1.40
1.41
1.42
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7

Circuit-breaker compartment
Circuit-breaker
Circuit-breaker operating
mechanism
Pressure relief disk, above
Test socket
Blind plug
Measuring sockets for capacitive
voltage indicator
Plug-in cable socket
Pressure sensor for circuit-breaker
compartment
Pressure relief duct (optional)
Absorber (optional)
Drying agent bag, circuit-breaker
compartment
Bushing circuit-breaker
compartment / busbar
compartment
Filling valve for circuit-breaker
compartment
Plasma diverter
Protection cover for current
transformer terminal board
Cover for metering cables
Handling bracket (to be removed
after handling)
Edge protection
Socket head screw M 8 x 25
Hexagon nut M 8
Dished washer 8
Centre of gravity
ON-release shaft
OFF-release shaft
Cam
Mechanical interlock circuit-breaker/
three-position switch
Lever
Clamping piece
Clamping screw
Tee-off conductor, bus-coupler
Tee-off conductor bus-riser
Front plate
On push-button
OFF push button
Operating cycle counter
Mechanical position indicator
Rating plate
Charging condition indicator
Recess for charging lever (6.3)
Terminal board for current
transformer
Auxiliary switch
Busbar compartment
Three-position switch
Three-position switch operating
mechanism
Pressure sensor for busbar
compartment
Busbar
Plug-in busbar connector
Tee-off conductor, metering panel
Support

2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
2.24
2.25
2.26
2.27
2.28
2.29
2.30
2.31
2.32
2.33
2.34
2.35
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
4.0
4.1
4.2
4.3
4.4

Plug-in socket for voltage


transformer
Switch-off devise for voltage
transformers
Tee-off conductor
Pressure relief disk for busbar
compartment
Drying agent bag, busbar
compartment
Busbar socket
Insulating part
O-Ring
Socket head bolt M 10 x 50
Guide pin
Hexagon nut M 10
Dished washer 10
Socket head bolt M 10
Bus connector
Flap
Bore for padlock
Central gas connector for busbarcompartment
Drive motor for three-position
switch
Hollow shaft (emergency manual
operation shaft)
Mechanical switch position
indicator
Sensor, disconnector ON
Sensor, disconnector OFF
Sensor, earthing switch ON
Sensor, earthing switch OFF
Bore for padlock
Contact ring
Manual drive for isolating device
Tie wire
Cable termination compartment
Main earthing bar
Panel / panel connecting link
Cable mounting (optional)
Cable plug
Pressure relief flap, optional
Lower pressure relief duct
High voltage cable
Parallel connector PB50,
GCE 0909125P0100
Floor plate splitted
Reducer ring
Cable mounting
Supporting section, at earth
potential
Rear panel compartment
Supporting section, at earth
potential
Pressure relief flap, optional
Control cabinet
Central unit of the Bay Control and
Protection Unit REF542 plus
HMI of the Bay Control and
Protection Unit REF542 plus
Control cabinet door
Door-lock

4.5
4.6
4.7

4.8
4.9
4.10

Measuring sockets for capacitive


voltage indicator, optional
Light-emitting diode (LED)
LC-Display of the Bay Control and
Protection Unit REF542 plus
(example)
Catch
Safety lock (if ordered)
Closing lever

5.0
5.1
5.2
5.3
5.4

Measuring facilities
Current transformer
Plug-in voltage transformer
Block-current transformer
Terminal board for current
transformer

6.0
6.1
6.2
6.3

Accessories
Hand crank
Double bit key
Charging lever for emergency
manual operation
Test plug for high voltage tests,
optional
Test plug for current tests, optional

6.4
6.5
7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7

7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.20
7.21
7.30

Foundation frame
Longitudinal bracket,
(this one for panel width 600 mm)
Longitudinal bracket, internal
(this one for panel width 600 mm)
Transverse bracket, left
(this one for panel depth 1300 mm)
Transverse bracket, right
(this one for panel depth 1300 mm)
Fixing angle bracket
Connecting link
Transverse bracket for two panel
frame, (this one for panel depth
1300 mm)
Connecting angle
Screwed connection for foundation
frame
Socket head bolt M 8 x 25
Socket head bolt M 10 x 25
Socket head bolt M 8 x 25
Socket head bolt M 8 x 25,
frame height 40 mm
Socket head bolt M 8 x 35,
frame height 50 mm
Dished washer 8
Dished washer 10
Fixing dowel