Me d i u m v o l t a g e p r o d u c t

UniGear ZS1
Installation, operation and maintenance instruction manual

1.
. Yo u r s a fe t y f i r s t – at a l l t im e s! 1
2. . Sum m a r y ...................................................................................2
2.1 1 In t r od u c t i on ......................................................................2
2.2 2 Ge ne r a l ................................................................................2
2.3 3 S t an d a r d s an d sp e c i f i c a t io n s .............................2
2.4 4 Op e r at i n g co nd i t i o n s .................................................2
3. . T e ch n i c a l d a ta ......................................................................3
3.1 1 E l e c t r i c a l da t a ...............................................................3
3.2 2 R e s i s ta n ce t o i n te r n a l a r c f a u l t s ......................3
3.3 3 D im e n s i on s a n d w e i g ht s ..........................................4
4. . Pa n e l d e s i gn an d e qu i pm en t ........................................6
4.1 1 B a s i c s t r u c tu r e a n d v a r i an t s ...............................6
4.2 2 E n c l o su r e an d p a r t i t i on i ng ....................................6
4.3 3 C om pa r tm e nt s i n th e p ane l s ..................................12
4.4 4 In t e r l o ck / p r o te c t i on ag a i ns t i n c o r r e c t o p e ra t i o n 17
4.5 5 P l u g co nn e c to r c o d in g .............................................22
4.6 6 It h L im i te r s .......................................................................23
5. . D i s p a t ch an d st o r ag e ......................................................24
5.1 1 C on d i t i on on de l i v e r y ...............................................24
5.2 2 P a ck i ng ...............................................................................24
5.3 3 T r an s p o r t .........................................................................24
5.4 4 D e l iv e r y .............................................................................24
5.5 5 In t e rm e d i a t e s t o r ag e ...............................................25
5.6 6 H an d l i ng ............................................................................25
6. . A s sem b l y o f t he sw i t c h ge ar a t s i t e ........................29
6.1 1 Ge ne r a l ...............................................................................29
6.2 2 Fo u nd a t io n s ....................................................................29
6.3 3 A s s em b l y o f th e sw i t c hg ea r p an e l s .................47
6.4 4 P r o c e du r e fo r s e tt i n g - up th e do o r s .................48
6.5 5 In s t a l l at i o n o f t h e b u sh i n g ...................................52
6.6 6 F i xi n g o f t he pa n e l s ...................................................53
6.7 7 In s t a l l at i o n o f t h e b u sb a r s ..................................54
6.8 8 In s t a l l at i o n o f t h e t op -m ou n t ed bo xe s ...........63
6.9 9 P r e s s u r e r e l i ef du c t s ...............................................70
6.10 1 0 C a b l e c o nn e c t io n ..................................................72
6.11 1 1 E a r th i n g t he sw i t c h ge a r ....................................78
6.12 1 2 I n s ta l l a t i on of i n te r c o n nec t i n g bu nd l e s . 78
6.13 1 3 F i n a l e r e c t i o n w o rk .............................................78
7. . O pe r a t i on of t he sw i t c hg e ar ........................................79
7.1 1 S w i t ch i n g o pe r a t i on s ...............................................79
7.2 2 T e s t p r o ce du r e .............................................................90
7.3 3 S e rv i c e t r u ck s ...............................................................93
8. . C om m i s s i on i n g.................................................................9 5
8.1 1 P r e p a ra t o r y w o rk.......................................................95
8.2 2 M ea s u r em en t s a n d t e s t s......................................96
9. . M a i n te na n c e.......................................................................97
9.1 1 M a in t en a n ce s t r at e g ie s.........................................97
9.2 2 P r ev e nt i v e m a i nt e na n ce.......................................97
9.3 3 In s pe c t i o n......................................................................98
9.4 4 S e rv i c i n g......................................................................10 0
9.5 5 R ep a i r s..........................................................................10 3
9.6 6 R i sk - B a se d m a in t en a n ce...................................10 5
9.7 7 S p a r e p a r t s, au xi l l a r y m ate r i a l s a n d l u b r i c an
t s............................................................................................10 5
9.8 8 Op e r at i n g a c c e s so r i e s.......................................10 6
10. . P r o d u ct qu a l i t y a n d e nv i ro nm e nt a l p r ot e c t i on
...................................................................................................10 7
1. Your safety first – at all times!
That is w hy our instructi on manual begins w ith If you hav e any f urther questions about this instructio
the follow ing recommendati ons: n manual, ABB’s f ield serv ice team will be pleased t o
Only install s witchgear in closed rooms suitable f or prov ide the required inf ormation.
electrical equipment.
Ensure that installation, o peration and maintenance is W e reserv e all rights to this publication. Misuse ,
only carried out b y qualif ied competent electricians. including in particular, duplication and making th is
Fully co mpl y with the le gally recognized standar ds manual - or e xtr acts there of av ailable to third parties
(IEC or local), the connec tion conditions of the loc al is prohibited. W e do not accept an y responsibili t y f or
electrical utility an d the relev ant saf ety at wor k the inf ormation prov ided, which is sub ject to change.
regulations.
Observ e the relev ant information in th e instructi
on
manual f or all actions inv olv ing switchgear.

D ANGER !
Pa y special attention to the hazard notes in the
instruction manual ma rked w ith this w
arning s ymbol.
 M ake sure that the specified criteria are no
t exceeded under sw itchgear operating
conditions.
 Ensure the instruction manual is accessible to
all personnel invol ved in installation ,
operation
and maintenance.
 The user’s personnel must act responsibl y in
all matters relating to safet y at w ork
and
correct handling of the sw itchgear.

W ARNING
 Alw a ys follow the instruction manual and
respect the rules of good engineering practice !
 Hazardous voltage can cause electrical shocks
and burns.
 Disconnect pow er, then earth and shor
tcircuit before proceeding w ith an y w
ork on this
equipment.

W ARNING
Using of safet y clot hes like safet y glo
ves
according to EN 388 Blade cut resistance class 5,
long sleeved w ork jacket or safety slee ves, safet y
shoes is recommended during all acti vities done
w ith the sw itchgear.

1
2. Summary
2.1 Introduction
T he instructions in this p ublication ref er to UniGe ar
ZS1 mediu m v oltage switchgear with eit her
withdra wable apparatus o r LBS. For c orrect use of
the apparatus, please read the manual caref ully.
T hanks to th e adv anced design of ABB switchgear,
UniGear ZS1 is suitable not only f or man y dif f erent
applications, but also allo ws f or f urther technical and
construction modif ication s to suit an y installati on
requirements. Consequen tly, this manual ma y n ot
include some specif ic instructions concerning speci al
apparatus conf igurations. In these cases, it is
theref ore strongly reco mmended to consult both thi s
manual and the latest tech nical documentation (circui
t and wiring diagra ms, f oundation plans and any
protection s electiv ity studies).
2.2 General
UniGear ZS1 is three-p hase, metal -enclosed, ai r-
insulated, LSC-2B switchg ear and all the panels are
f actory-assembled, t ype -te sted and suitable f or
indoor applications up to 24 kV. T he panels are
designed as withdra wable modules an d are f itted with
a singl e busbar syste m. T he withd rawable parts are
equippe d with circuit -breakers and c ontactors.
Details of the technical d esign and conf iguration o f
indiv idual switchgear, su ch as the technical dat a,
detailed equipme nt lists f or the indiv idual panels and
comprehensiv e circuit documentation etc., can b
e f ound in the relev ant order documents.
2.3 Standards and specifications
UniGear switchgear panel s compl y with the standar
ds and specif ications f or f actory -assembled, metal -
enclosed and type tested high v oltag e switchgear to
IEC publications 62271 - 200 (2011) and 6227 1 -1
(2007). In addition, in accordance with IEC 60529, t
he switchgear panels hav e the f ollowing degrees of
protection:
IP 4X f or the enclosure a nd IP 2X f or the partition s.
All other correspondin g IEC publications, national or
local saf ety at work regulations and saf ety
regulations f or production materials must be f ollowed
duri ng erection and operation of these systems. Abov e
and beyond this, the order -rela ted data f rom ABB
must b e taken into account.
2.4 Operating conditions
2.3.1. Normal operating conditions
T he switchgear is basi cally suitable f or normal
operating conditions f or indoor switchgear i n
accordance with IEC 62271 -200. Among oth er
considerations , the f ollowing limiting v alues appl y:
2
Am b i e n t t e m p e r a t u r e :
Ma x i mu m + 40 °C
Ma x i mu m 2 4 h a v e r a g e + 35 °C
Mi n i mu m ( a c c o r d i n g t o " mi n u s 5 d o o r c l a s s " ) - 5 °C
Am b i e n t h u m i d i t y:
Ma x i mu m 2 4 h a v e r a g e o f r e l a t i v e h u mi d i t y 95 % RH
Ma x i mu m 24 h average of water vapour press 2.2 kPa
u r ex i mu m
Ma mo n h t l y a v e r a g e o f r e l a t i v e h u mi d i t 90 % RH
y x i mu m
Ma mo n h t l y a v e r a g e o f w a t e r v a p o u r p r 1.8 kPa
essure
T he normal operational altitude is up to 1000 m
above sea lev el. T he indoor ambient conditions are f
ree of signif icant pollution, such as dust, s moke,
corrosiv e and/or f lammable gases, v apors or salt, etc.
2.3.2. Special operating conditions
T he switchg ear is suitabl e f or operation in the W Da
type of climate according t o IEC 60721 -2-1.
Special operating conditions must be discussed with
ABB in adv ance. For example:
 At site altitudes abov e 1000 m, the eff ects of
the reduction in dielectric str ength of the air on
th e
insulation lev el must be taken into account ( F i g u
r e 1).
 Increased ambient te mperatures must be
compensated in the desi gn of the busbars and
branch conductors, other wise the current carr yin
g capacity will be li mited .
Note on special climatic operating conditions:
W hen switchgear is operated in areas with hig h
humidit y and/ or ma jor rap id temperature f
luctuations, there is a risk of de w depo sits which must
be e xclude d under nor mal operatin g conditions f or
indoo r switchgear. Prev entiv e action (e.g. suitable v
entilation and proper air conditioning of the building or
housing, use of dehumidif ying equi pment, etc.) must be
taken into consideration with ABB to av oid this
condensation phenomenon and an y re sulting corro
sion or other adv erse eff ects.
F i g u r e 1 : C u r v e f o r d e t e r m i n i n g t h e a l ti t u d e
f a c t o r k i n r e l a t i o n t o th e a l t i t u d e H .
3. Technical data

3.1 Electrical data

Main parameters for panels with circuit breakers
Rated voltage [ k V] 7 . 2 / 12 17.5 24 ( 1 )
Rated power frequency withstand voltage [ k V   1   mi n ] 28 ( 2 ) 38 ( 2 ) 50
Rated lightning impulse withstand voltage [ k V] 75 95 125
Rated frequency [ H z] 50 / 60 50 / 60 50 / 60
Ma i n b u s b a r r a t e d c u r r e n t [A] ...4000 ...4000 ...3150
Circuit-breaker rated current [A] ...4000 ...4000 ...3150
Peak current [ k A] ...125 ...125 ...80
Internal arc withstand current [kA 1 s] ...50 ...50 ...31.5
R a t e d s h o r t t i me w i t h s t a n d c u r r e n t [ k A   3 s] ...50 ...50 ...31.5
(1) 27.6 kV with VD4 according to CSA C22.2 No 31-10 is available
(2) 42 kV (GB/DL)

M a i n p a r a m e t e r s f o r p a n e l s w i t h sw i t c h -d i s c o n n e c t o r N AL F
Rated voltage [ k V] 7 . 2 / 12 17.5 24
R a t e d p o w e r f r e q u e n c y w i t h s t a n d v o l t a [ k V 1 mi n ] 28 38 50
g
R ea t e d l i g h t n i n g i m p u l s e w i t h s t a n d v o l t [ k V] 75 95 125
a ga et e d f r e q u e n c y
R [ H z] 50 / 60 50 / 60 50 / 60
Rated current of busbars [A] ...4000 ...4000 …3150
Rated current of branches [A] ...630 ...630 ...630
Rated breaking current of swit
[A] ...630 ...630 ...630
ch-disconnector (power factor
= a0 t. e7 d) s h o r t t i me w i t h s t a n d c u r r e n
R
[ k A] ...25 ...25 ...25
t ofswitch-disconnector 1 s
Rated short circuit making current [ k A] ...40 ...40 …50
Rated peak withstand current [ k A] ...62.5 ...62.5 ...63
Auxiliary voltage DC [V] 24 / 48 / 110 / 220 24 / 48 / 110 / 220 24 / 48 / 110 / 220
Auxiliary voltage AC [V] 110 / 230 110 / 230 110 / 230

Main parameters for panels with vacuum contactor VSC7/P VSC12/P

Rated voltage [ k V] 7.2 12
Rated insulation voltage [ k V] 7.2 12
Rated power frequency withstand voltage [ k V 1 mi n ] 20 ( 3 ) 28 ( 3 )
Rated lightning impulse withstand voltage [ k V] 60 75
Rated frequency [ H z] 50 / 60 50 / 60
(1)
R a t e d s h o r t t i me w i t h s t a n d c u r r e n t [ k A] ...50 ...50
Peak current [ k A] ...125 ...125
(2)
Internal arc withstand current [kA 1 s] ...50 ...50
Ma x i mu m r a t e d c u r r e n t o f t h e c o n t a c t o r [A] 400 400
(1) ) L i m i t e d b y t h e f u s e s .
(2) ) T h e i n t e r n a l a r c w i t h s t a n d v a l u e s a r e g u a r a n t e e d i n t h e c o m p a r t m e n t s o n t h e s u p p l y s i d e o f t h e f u s e s ( b u s
bars and apparatus) bythe structure of the switchgear and on the load side (feeder) by the limiting properties of
the fuses.
(3) ) V S C 7 / P G f o r 3 2 k V p o w e r f r e q u e n c y w i t h s t a n d v o l t a g e a n d V S C 1 2 / P G f o r 4 2 k V p o w e r f r e q u e n c y w i t h s t a n
d voltage are availableon request in a dedicated panel.

3.2 Resistance to internal arc faults

The fault w ithstand capacit y is as follow T he switchgear panels hav e been tested according
s: to IEC 62271 -200 standard (Annex A, accessibilit y t
yp e A, IAC classif ication FLR) and also to PEHLA
 12 kV - 50 kA 1 s recommendation no. 4. In indiv idual cases, depending
 17. 5 kV - 50 kA 1 s on the conf iguration of the switchgear pan els and/ or
 24 kV - 31.5 kA 1 s the s witchroo m condition s (e.g. lo w ceiling height ),
additional measures ma y be necessar y to ensur e
compliance with criterion 5 .

3
3.3 Dimensions and weights
D i m e n s i o n s o f 1 2 / 1 7 . 5 k V p an e l s
Dimension [mm]
(1)
Height A 2200 / 2 5 9 5
W id t h :
(4) 650
- Feeder panels up to 1250 A ( ≤ 31.5 kA)
- Feeder panels up to 1250 A ( ≥ 31.5 kA) B 800
- Feeder panels 1600 - 2000 A 800 ( 2 )
- Feeder panels above 2000 A 1000
Depth:
1340
- U p t o 2 5 0 0 A , 3 1 . 5 kA
- 3150 A , 4 0 k A 1355
- 4000 A , 4 0 k A C (3) 1390
- 3150 A , 5 0 k A 1390
- 4000 A , 5 0 k A 1455
D 2100
Height of the basic part of panel
E 1495
(1) Height of the low voltage compartment is 705 /
1100 mm.(2) 1000 mm on request.
(3) ) D e e p e r u n i t s a r e a v a i l a b l e o n r e q u e s t .
(4) ) F e e d e r s e q u i p p e d w i t h t h e V S C c o n t a c t o r a r e 6 5 0 m m w i d e u p t o t h e 5 0 k A s h o r t t i m e c u r r e
nt and up to 12 kVrated voltage.

Dimensions of 24 kV panels
Dimension [mm]
(1)
Height A 2325 / 2 7 2 0
W id t h :
- Feeder panels up to 1250 A B 800 ( 2
- Feeder panels above 1250 A 1000
Depth C (3) 1700
(4)
D 2200
Height of the basic part of panel
E 1620
(1) Height of the low voltage compartment is 705 / 1100 mm.
(2) 1000 mm on request.
(3) Deeper units are available on request.
(4) For short-time current up to 25 kA a 1560 mm depth version is available.

W e i g h t o f t h e p a n e l i n c l u d i n g w i t h d r aw a b l e c i r c u i t - b r e a k e r p a r t
Rated current 12 / 17.5 kV 24 kV
...1250 A 800 - 8 5 0 k g 1000 - 1 0 5 0 k g
1600 A 850 - 9 0 0 k g 1200 kg
2000 A 850 - 9 0 0 k g 1200 kg
2500 A 1200 kg 1200 kg
3150 A 1200 kg x
4000 A 1400 kg x

D i m e n s i o n s o f p a n e l w i th t h e sw i t c h -d i s c o n n e c t o r
Dimension 12 / 17.5 kV 24 kV
(1) (1)
Heigh [ m m] A 2200 / 2 5 9 5 2325 / 2 7 2 0
t id t h - O u t g o i n g a n d i n c o m i n
W
[ m m] B 800 ( 4 ) 1000
gpanels:
(2) (3)
Depth [ m m] C 1300 / 1 3 4 0 1700
D 2100 2200
Heigh of the basi par of panel [ m m]
t c t E 1495 1620
Note: The dimensions must by verified according to the relevant order documentation.
Note: Weight of panel including of switch-disconnector (12 and 17.5 / 24 kV) is c
ca 750 / 950 kg.(1) Height of low voltage compartmen is 705 / 1100 mm.
(2) ) T h e d e p t h o f p a n e l w i t h t h e s w i t c h - d i s c o n n e c t o r i n c o m b i n a t i o n w i t h H D 4 c i r c u i t b r e a k e r p a n
els is recommendedto be 1340 mm, in other cases 1300 mm.
(3) ) 1 5 6 0 m m d e p t h v e r s i o n a v a i l a b l e o n r e q u e s t .
(4) ) 6 3 0 A ( m a x . c u r r e n t o f L B S p a n e l l i m i t e d b y c o o r d i n a t e d f u s e s ) .

4
Figure 2: Dimensions of UniGear ZS1 panel.

5
4. Panel design and equipment
measure s
4.1 Basic structure and variants on the switch gear pan els. T hese measures include:
T he basis f or the UniGear panel is the inco ming /
outgoing f eeder panel wi th SF6 or v acuum circui t -
breaker using insertion t echnology. It is div ided into
busbar compart men t I., c ircuit breaker co mpart me
nt II., cable compart ment III. and low v oltage
compart ment IV. f or the s econdary equip ment.
Apar t f rom this, there are v ariants f or all operating
needs.

For busbar sectionalising , two pa nels are necessar y,

the coupling panel with the withdra wable circui t -
breaker part and a bus riser panel (optional with
bu sbar metering and eart hing). In equipment witho ut
busbar sectionalising , a di rect bar connection bet we
en the busbars will be establi she d.
T he UniGear switchgear also includes the v ariant of
incoming / outgoing pan el with the NALF s witc h -
disconnector with the st ationary mounting of the
switch -disconnector. T he panel is div ided into busb ar
compart ment A, s witch - disconnector co mpart me nt
including cables B and low v oltage compart ment f or
the secondary equip me nt D.
Further details about installation and switchge ar
equipment can be obtain ed f rom the relev ant order
documents.

4.2 Enclosure and partitioning

T he enclosure and internal partit ions of the panels
are of 2 mm thick high qualit y galvanized steel. T he
three high voltage compartment s (busbar
compartment,
circuit-breaker compartment and cable connection
compart ment) are equipp ed with top - mo unted an d
secured pressure relief f laps. T hese op en in the
case of ov erpressure due to an internal arc f ault. T
he f ront of the panel is closed of f by pressure
resistant door s which open to an an gle of 130°.
Cable and circuit -breaker compart ments hav e their
own doors, both compart ments can be equipped with
inspection windo ws made of security glass.
Neighbouring panels are p artitioned f rom one anothe
r by th e side walls of each panel and, as a result of t
he design, the air cushion re mains bet wee n these wall
s when the panels are jointe d together.
T he en closure is completed on the roof by top -
mounted pressure relief f laps which, according to the
rated branch conductor current, are made of sheet
steel or expande d metal a nd at the base b y means
of f loor -cov ering 18 (Figure 3) , made of Al sheet.
T he pressure -relief f laps are secured with steel
screws on one longitudin al side and on the other
longitudina l side with plastic screws. In the case of
internal ov erpressure, the plastic screws are th e
rupture point.
Arc f ault curr ent limitation can be achiev ed by
undelayed circuitbreaker release, carried out b y
auxiliar y s witches operate d by the pressure wav e.
The switchgear can be equi pped with Ith li miter: t he
auxiliar y s witches (Figu r e 28 ) are operated by the
pressure relief f laps.
T he necessary saf ety measures to counteract th e
eff ects of an internal arc f ault must be e nsured i
n
relation to the ceiling heig ht. In indiv idual cases,
this ma y require additional op erator protection
6
1. Mounti ng a pressure re lief duct 1 (Figure 124 ) o n
the top of the switchgear, with f urther channels
leading out of the switchgear room in a f orm
appropriate f or the design of the building. T he shock
wav e and arc discharge are channelled off in ducts.
2. Mounting a pressure relief duct with blo w -o ut
apertures located abov e the duct at the ends of the
switchgear and pointing towards the centre of the
switchgear (div erter duct) . T he shock wav e and ar c
discharge then e merge i n an e xtre mel y
attenuate d f orm and in a location which is not critical
f or the operating personnel.

T he rear wall of the busbar compart ment 12 (Figu r

e 3 ) , intermediate wall 19, mounting plate 1 3 wit h
shutters 20/24 and horizontal partition 29, f orm part
of the internal partitioning . T he internal partitioning
makes s af e access to th e circuit -breaker and cab le
compart ments possible ev en when the busbars a
re liv e.
T he low v oltage co mpa rtment f o r the secondar y
equipment is co mpletel y protected f rom the hi
gh v oltage area thanks to its steel -sheet casing.
On the end sides, cov er plates ensure a goo d
appearance and are mec hanically and ther mall y a
rc f ault proof should such an ev ent occur in the e nd
panel.
Doors and cov er plates are thoroughly cleaned
and
treated against corrosion bef ore receiv ing a high
quality double coating of paint. T he f inishing coat is
in the standard RAL 7035 color (special colors by
agreement). Stov ing co mpletes the proce dure an d
prov ides considerable resistance to i mpact and
corrosion. T he circuit -breaker compart ment and cable
connection compart ment d oors are pressure resistant
and can either be f itted wi th screws or manual
closin g syste ms (central handle).

Ventilation o f the
panels
Openings in the outer enclosure are needed
for v entilation in the case of certain rated currents
in the busbars and branch bars.
For incoming air to the circuit -breaker compart men t,
the horizontal partition is prov ided with air -v ents 28
IP4X degree of protection and saf ety in the case of
any release of hot gas du e to an arc f ault is prov
ided by f lap 27 in the horizont al partition 29. For
outgoi ng air, the pressure relief f laps 8 incorporat e v
ents which prov ide the IP4X degree of protection
(Figure 3 ) .
In cases of higher ambient temperature (> 40 °C) it
is necessary to ap pl y derat ing of rated current. It is
necessary to use f orced fan v entilation in 3600 A
and 4000 A panels f or 12 / 1 7.5 kV rated v oltage and
in 3150 A panels f or 24 kV rated v oltage.

7
 I n s t r u c t i o n fo r sw i t c h i n g o f co o l i n g f a n s :
I n c o m e r , 1 2 / 1 7 . 5 k V , 3 6 0 0 A, a m b i e n t t e m p e r a t u r e m a x . 4 0 ° C
FAN 1 FAN 2
Current Note
Circuit Breaker C u r r e n t t r a n s f o r me r s
< 3200 A No - fan is stopp
≥ 3200 A Yes - f a n s t a ret ds o p e r a t i o n

I n c o m e r , 1 2 / 1 7 . 5 k V , 4 0 0 0 A, a m b i e n t t e m p e r a t u r e m a x . 4 0 ° C
FAN 1 FAN 2
Current Note
Circuit Breaker C u r r e n t t r a n s f o r me r s
< 3200 A No No both fans are stopped
≥ 3200 A Yes Yes both fans start operation

I n c o m e r , 2 4 k V , 2 5 0 0 A, a m b i e n t t e m p e r a t u r e m a x . 4 0 ° C
FAN 1 FAN 2
Current Note
Circuit Breaker C u r r e n t t r a n s f o r me r s
< 2200 A No - fan is stopp
≥ 2200 A Yes - f a n s t a ret ds o p e r a t i o n

I n c o m e r , 2 4 k V , 3 1 5 0 A, a m b i e n t t e m p e r a t u r e m a x . 4 0 ° C
FAN 1 FAN 2
Current Note
Circuit Breaker C u r r e n t t r a n s f o r me r s
< 2700 A No - fan is stopp
≥ 2700 A Yes - f a n s t a ret ds o p e r a t i o n

8
F i g u r e 3 : U n i g e a r f e e d e r p a n e l 1 7 . 5 k V , 4 0 k A.

A B u s b a r c o mp a r t m e n t 16 C u r r e n t t r a n s f o r me r
B C i r c u i t - b r e a k e r c o m p a r t me n t 17 V o l t a g e t r a n s f o r me r
C C a b l e c o mp a r t m e n t 18 Floor cover – split
D L o w v o l t a g e c o m p a r t me n t 19 Partition – removable
20 Top shutter
1 S p i n d l e me c h a n i s m 21 T e r mi n a l r a c k
2 Spigot on spindle 22 Control wiring plug connector
3 Hole in spindle for insertion lever 23 Control wiring duct
4 Ventilation grid 24 Lower shutter
5 Earthing switch operating mechanism 25 W it h d r a w a b l e p a r t
6 Operating shaft for earthing switch 26 S p i n d l e me c h a n i s m
7 Slide 27 Back flap
8 Pressure relief flap 28 Ventilation grid
9 Enclosure 29 H o r i zo n t a l p a r t i t i o n , r e mo v a b l e
10 Branch conductor 30 Earthing switch operating mechanis
11 Busbar 31 mo n t r o l w i r i n g d u c t
C
12 Partition 32 Cable sealing end
13 Mo u n t i n g p l a t e 33 C a b l e c l a mp
14 Isolating bushing 34 Ma i n e a r t h i n g b a r
15 Earthing switch

9
 Figure 4: UniGear Digital panel (voltage metering in cable compartment).

A B u s b a r c o mp a r t m e n t 12 Mo u n t i n g p l a t e
B C i r c u i t - b r e a k e r c o m p a r t me n t 13 Isolating bushing
C C a b l e c o mp a r t m e n t 14 Earthing switch
D L o w v o l t a g e c o m p a r t me n t 15 V o l t a g e s e n s o r i n c a b l e c o mp a r t me n
16 t loor cover – split
F
1 S p i n d l e me c h a n i s m 17 Partition – removable
2 Spigot on spindle 18 Top shutter
3 Hole in spindle for insertion lever 19 Control wiring plug connector
4 Earthing switch operating mechanism 20 Control wiring duct
5 Operating shaft for earthing switch 21 Lower shutter
6 Slide 22 W it h d r a w a b l e p a r t
7 Pressure relief flap 23 Current sensor
8 Enclosure 24 H o r i zo n t a l p a r t i t i o n , r e mo v a b l e
9 Branch conductor 25 Cable sealing end
10 Busbar 26 C a b l e c l a mp
11 Partition 27 Ma i n e a r t h i n g b a r

1
F i g u r e 5 : U n i G e a r D i g i t a l p a n e l ( v o l t a g e m e t e r i n g i n b u s b ar c o m p a r t m e n t ) .

A B u s b a r c o mp a r t m e n t 12 Mo u n t i n g p l a t e
B C i r c u i t - b r e a k e r c o m p a r t me n t 13 Isolating bushing
C Ca b l e c o mp a r t m e n t 14 Earthing switch
D L o w v o l t a g e c o m p a r t me n t 15 V o l t a g e s e n s o r i n c a b l e c o mp a r t me n
16 t loor cover – split
F
1 S p i n d l e me c h a n i s m 17 Partition – removable
2 Spigot on spindle 18 Top shutter
3 Hole in spindle for insertion lever 19 Control wiring plug connector
4 Earthing switch operating mechanism 20 Control wiring duct
5 Operating shaft for earthing switch 21 Lower shutter
6 Slide 22 W it h d r a w a b l e p a r t
7 Pressure relief flap 23 Current sensor
8 Enclosure 24 H o r i zo n t a l p a r t i t i o n , r e mo v a b l e
9 Branch conductor 25 Cable sealing end
10 Busbar 26 C a b l e c l a mp
11 Partition 27 Ma i n e a r t h i n g b a r

1011
F i g u r e 6 : P a n e l w i th 1 2 / 1 7 . 5 k V sw i t c h - d i s c o n n e c t o r w i t h f u s e s a n d e a r t h i n g sw i t c h .

A B u s b a r c o mp a r t m e n t 13 Operating shaft for earthing switc

B S w i t c h - d i s c o n n e c t o r a n d c a b l e c o m p a r t me n t 14 S
h lide
D L o w v o l t a g e c o m p a r t me n t 15 Ma i n e a r t h i n g b a r
16 Earthing switch
1 Pressure relief flaps 17 T e r mi n a l r a c k
2 Enclosure 18 Control wire duct
3 Branch conductor 19 I n s u l a t o r o r c u r r e n t t r a n s f o r me r
4 Busbar 20 Cable sealing end
5 Partition 21 Control wire duct
6 Bushing 22 Floor cover - split
7 Position indicator of switch-disconnector 23 C a b l e c l a mp
8 Operating mechanism of switch-disconnector 24 Switch-disconnector
9 Operating shaft of switch-disconnector 25 Insulating partition wall
10 Slide 26 Mo v a b l e i n s u l a t i n g p l a t e
11 Position indicator of earthing switch 27 Fuse or link
12 Operating mechanism of earthing switch 28 Interlocking of earthing switch

1
4.3 Compartments in the panels
T here are six types of electronic instrument
transf ormers f or UniGear Digital:

 KEVA 17,5B2x – v oltage s ensor with ratio

10000:1
 KECA 80C104 – curre nt sensor with
ratio
150mV@80A
 KECA 80C165 – curre nt sensor with ratio
150mV@80A (f or nominal v oltage up to 17,5kV)
 KEVA 24B2x – v oltage sen sor with ratio
10000:1
 KECA 80C184 – curre nt sensor with
ratio
150mV@80A
 KECA 80C216 – curre nt sensor with ratio
150mV@80A (f or nominal v oltage 24kV)

4.3.1 Busbar compartment

T he busbars 11 (Figure 3 ) hav e a f lat cross -section
made of copper and are laid in sections f rom panel to
panel. For higher rated currents (3150, 3600 and 4000
A), the busbars hav e a open D -shaped cross -section
. According to the current rating, either single or
double conf iguration is used. T hey are held in place
b y th e f lat branch conductor 10 (Figure 3 ) and, if
installed, by busbar bushings (chap t er 6.5) . No special
connectio n clamps are neede d.
F i g u r e 7 : Vo l t a g e s e n s o r s i n b u s b a r c o m p a
Busbars and branch condu ctors f or 17.5 and 24 kV ar rtment inUniGear Digital.
e insulated by means of shrink -on sleev es. T he bolt
connections in the 17.5 and 24 kV busbar system a
re cov ered by insulating cov ers (chapter 6.7). T he
busbars f or 12 kV pan els up to 2500 A do not have
cov ers. Open D -shaped busbars 3150, 3600 and
4000 A are insulated and the co nnections are cov ered.
By means of bushing plates and busbar bushings
(chap t er 6.5) , partitions can be created bet we en
panels. T hese partitions are necessary f or higher
rated short-time currents, see table below.

Un Ik Partitions
Every lateral panel; from 12panels additional part
iton in
25 k A t h e mi d d l e ; f r o m 2 1 p a n e l s o n e a d d i t i o n a l p a r t i t i o n i n
each
1 2 / 1 7 . 5 kV third of the switchgear
Every lateral panel and everythird panel
3 1 . 5 kA
4 0 , 5 0 kA Every panel
Every lateral panel; from 12panels additional part
iton in
25 k A t h e mi d d l e ; f r o m 2 1 p a n e l s o n e a d d i t i o n a l p a r t i t i o n i n
24 k V each
third of the switchgear
3 1 . 5 kA Every panel
Ma r i n e / S e i s mi c v e r s i o n
All ratings Every panel

According to customer requirements, this separatio n

into indiv idual panels by means of busbar bushing s
and bushing plates ( c h a p t e r 6 . 5 ) can also be prov
ided in switchgear panels where it is not technical l y
necessary. T op -mounted boxes with busbar earthing
switches, or busbar v oltage transf ormers can b e
placed abov e the panels.

1
4.3.2 Circuit -breaker
compartment
T he circuit -breaker compartment contains all t he
necessary equip ment f or reciprocal operation of th e
withdra wable part and t he panel. Like the busbar
compart ment, it is metalli c ally partitioned on all
sides.

T he tulip isolating contacts 4 (Figure 165 ) , togeth er

with the f ixed isolating contacts, are located in
mounting plate 13 ( F i g u r e 3 ) . T he metal shutters 2/ 4
(Figure 8) , cov ering the i nsertion openings, are al so
included. T he shutters ar e opened b y th e actuatin g
bars of the withdra wable circuit -breaker part, usi ng
the lev er when inserting in to the serv ice position,
and are closed when the latte r is remov ed. In the test /
disconnected position of the withdrawable par t,
partitioning by s eparation is established in the ma in
current circuit. Connection of the control wiring,
required f or test purposes, need not be interrupted
when in the test / disconn e cted position. In the test /
disconnected position, th e withdra wable part is st ill
completel y inside the panel with the door closed. The
ON / OFF pushbutto n loc ated on the circuit -breake r,
and the mechanical indi cators f or ON / OFF a nd
CHARGED / DISCHARGED can be observ ed through
an inspection windo w. If the circuit breaker is i n
serv ice position.
T he switching operations are carried out with the
doors closed. Installation of an additional mechanic al F i g u r e 8 : Vi ew i n t o th e c i r c u i t - b r e a k e r c o m p a r t m e
switching dev ice f or manual operation of the circuit - nt.
breaker in the serv ice position is also possible (Figure
11 ) . T he socket 1 (Figure 8 ) f or the control wiring i s 1 Control wiring socket
2 Top shutter
mounted in the circuit -brea ker compart ment. 3 Duct cover, top right
4 Lower shutter
5 Righ t - h a n d t r a v e l r a i l

F i g u r e 1 0 : W i t h d r aw a b l e p a r t w i t h V D 4 t yp e c i r c u
F i g u r e 9 : C i r c u i t -b r e a k e r c o m p a r t m e it-breaker,pole side.
nt, open.
W it h d r a w a b l e p a r t i n t e s t position, control w
iring plugconnector open
1 Control wiring
plug
2 W it h d r a w a b l e
part
3 Square spi
got

1
 Figure 13: Current sensors KECA 80C165 moun
ted in thecircuit breaker compartment in UniG
ear Digital.

F i g u r e 1 1 : P u s h b u t to n fo r m e c h a n i c a l O N / O F
F b r e a k e r o p e r a t i o n w i t h th e d o o r c l o s e d ( o n r
equest).
Ifthe withdrawable part is in the service position,
operation iscarriedout using the knob which swing
s a push rod extensionout.
1 Me c h a n i c a l p u s h b
utton
2 Turning kn Figure 14: Current sensors KECA 80C104 moun
ob ted in thecircuit breaker compartment in UniG
ear Digital.

F i g u r e 1 2 : V i ew o f th e p u s h r o d e x t e n s i o n sw u
ng out by
t h e k n o b a t th e f r o n t , w i th t h e w i t h d r aw a b l e c i r c u
i t -b r e a k e r p a r t i n s e r v i c e p o s i t i o n a n d th e d o o r o
pen.
1 Swivelling pus
h rod

1
4.3.3 W ithdraw able
parts
1. W ithdrawable circuit -
breakers
T he withdra wable circuit - breaker f orms a co mplet e
module consistin g of the vacuum circuit -breakers t yp
e VD4 or VM1, SF6 circuit -breaker type HD4
the
withdra wable asse mbl y 1 ( F i g u r e 1 5 ) , isolated
contact arm 3 with contact s yste m 2 (Figure 165 )
and control
wiring plug 1 (Figure 9 ) .
T he withdrawable asse mbly and the circuit -break er
are coupled v ia a mult i -pole control wiring plu g
connector.
T he withdrawabl e as sembl y establishes t he
mechanical connectio n b etween the p anel and t he
circuit-breaker. T he f ixed part is connected to th e
panel by a f orked connecti on, which is f orm co ded o
n both sides. T he mov ing part with the circuit -breaker
is mov ed either manuall y or by a motor b y means of a
spindle, between the ser v ice or test / disconnected
positi ons with the f ront doors closed. Serv ice and
test
/ disconnected positions are set precisely b y means o
f auxiliar y s witches, which register the f inal position
reached and the ang ular position of the spindle. T he
earthing connection between the withdra wable pa rt
and the panel is established by its rollers and trav el
rails 5 (Figure 8 ) , which ar e bolted onto the panel. F i g u r e 1 5 : W i t h d r aw a b l e p a r t w i t h c i r c u i t - b r e
W ithdrawable parts of the same design and electric al a k e r , t yp e V D 4 , o p e r a t i n g m e c h a n i s m s i d e .
parameters are interchan geable. In the case wher e
the withdra wable parts hav e the same dimensions, bu 1 W it h d r a w a b l e a s s e mb l y
t diff erent electrical parame ters, the control wiring
plu g coding prev ents any incorrect connections b
etween the withdra wable part an d the panel.

2. Other withdra wable part

s
T he withdrawable part can also be f itted with
the f ollowing trucks:

 Metering v oltage transf ormers truck with f

uses.
 Earthing truck without ma king capacit y (f or
main
busbar syste m and po wer cables).
 Earthing truck with maki ng capacity (f or
main busbar syste m and po wer cables).
 Power cable testing truck.
 Isolation truck. F i g u r e 1 6 : W i t h d r aw a b l e a s s e m b l y f o r c i r c u i t - b
 Isolation truck with f uses. r e a k e r , w i th a u x i l i a r y sw i t c h e s .

 Shutter lif ting 1 Test position indicator

truck. 2 Service position indicator
3 Square spigot

3. W ithdrawable
contactors
In place of the circuit -break er type, the withdra wab le
part can also be f itted with the VSC typ e v acuum
contactor. VSC is f itted wi th MV f uses 1 (Figure
15 7) and can be used f or rated v oltage up to 12 kV.
All the
data stated in this chapter f or circuit -breakers
also
applies to the contactors.

1
4.3.4 Cable connection compartment 0 ).
T he cable compartment co ntains current transf
ormers
16 (Figure 3) , f ixed and withdra wable v
oltage transf ormers 17, and earthing switch 15,
according to indiv idual operating requirements in each
case.
T he cable compart ment is constructed f or installation
of three current transf ormers. Should all three curre
nt
transf or mers not be required, dummies will b e
installed in their place, usi ng the same i nstallation an
d connection procedures . T he f ixed v oltage transf
ormers
are connected on the primary side with f lexible, f ully
-
insulated cables which are connected to t he
transf o rmers.
T he remov able v oltage transf ormers are f itted wit h
HRC f uses. T he earthing switch can b e used wit h
either a manual or moto r -operated mechanis m. It s
switching position will be i ndicated both mechanicall y
by indication on the shaf t and electrically b y means
of the au xiliar y s witch. T hre e f ixed surge arrestors c
an be mounted inst ead of one position of single -core
cables.

Figure 17: Voltage sensors KEVA 17.5B20 mou

nted in thecable compartment in UniGear Digit
al.

Cable connection of 12 / 17.5 kV p

anels:
In the 650 mm wide panel, up to three parallel plasti c
cables can be connect ed with single -core cab le
protection and push on se aling ends with a ma xi mu
m
2
cross-section of 630 mm . In the 800 or 1000 mm wid
e panel, up to six parallel plastic cables can
be
connected with si ngle -core cable protection and push
-
on sealing ends with a ma xi mu m cross -section of 63
2
0 mm .
Customer requests regar ding connections to bars,
three-core cables, special cables or sealing ends of
diff erent types must be c onsidered during the orde r -
planning stage.
Cable connection of 24 kV panels:
In the 800 mm wide panel, up to three parallel plasti c
cables can be connect ed with single -core cab le
protection and push on se aling ends with a ma xi mu m
2
cross-section of 500 mm . In the 1000 mm wid e
panel,
up to six parallel plastic cables can be connected wi
th
single-core cable protectio n and pushon sealing end s
2
with a ma xi mu m cross -se ction of 500 mm . For mo
re inf ormation regarding cable connection (chap t er 6 . 1

1
there is an easil y accessi ble au xiliar y s witch f or th e
control wiring plug.
Secondary wiring inside th e panel is in a duct on th e
right side of the panel. T he lef t side of the panel is
for the external wiring. T he ducts are cov ered with
steel
sheet 2, 4 (Figure 73 ) . T here are holes f or sliding i n
the ring conductors at th e side of the low v
oltage
compart
ment.
4.3.6 Sw itch -disconnect or and cable compartmen
t in the panel w ith sw itch -disconnector
T he switch -disconnecto r and cable compart ment i s
merged. T he stationa r y s witch -disconnect or is
connected to busbars. The interconnectio n to the
busbar compart ment is carried out by bushings,
which secures the separation of busbar compart ment
f rom all other switchgear co mpartments. T he switc h
- disconnector and cable co mpart ment is also
separat ed f rom other compart ments by metal
partitions. T he switch -disconnector ca n optionally
contain an integrated earthing s witch. T he switching
positions o f the integrated earthing swi tch type E
4.3.5 Low voltage compartment
T he height of the low v oltage compart ment is 705 /
1100 mm (chap t er 3.3) . If the secondary dev ices are
not intended f or door installation, they are mo unted o
n DIN RAILS that enable an y subseq uent changes to
th e wiring. In the lo wer part of the low v oltage
compart ment, there are th ree rows of DIN RAILS o n
the swiv elling DIN RAILS holder and, below these,
can be indicate d by an au xiliar y s witch. T he c losing
and opening of the switch -disconnector is per f ormed
manuall y b y a lev er with the door closed. On request,
the dev ice can be also mounted f or the motor
operation of the switch - disconnector. T he switchdi
sconnector can theref ore be operated both locally and
r emotel y.
T he earthing switch is always operated locall y by th e
operating lev er.
T he switchgear is constructed f or the use of single -
core cables as standard. T he cable compartmen t
usually c ontains suppo rting insulators f or
the f astening of cabl es. On request the cable
compart ment can contai n the instrument curre nt
transf ormers instead of the supporting insulators. If all
three current transf ormers are not required, the
relev ant insulators are installed instead of them.
Cable connection in the panels f or 12 kV, 17.5 kV and
24 kV: In the panel with switch -disconnector plast ic
single-core cable can be connected on each pha se
2
with a cross -section up to 240 mm as standard.
Important note:
In the case of any non st a ndard cable connections a
n agreement must be reac hed bet ween the custo mer
and ABB during the technical preparation stage of the
order.
1
 4.4 Interlock/protection against incorrect operation
4.4.1 Panel internal interlocking
T o prev ent hazardous situations and incorrect
operation, there is a series of interlocks to protect
both personnel and equip ment:
 T he withdra wable part can only be mov ed f rom th
e test / disconnected position (and back) when
the
circuit-breaker and earthing switch are off (i.e. the
switch must be off bef ore hand.) In the
intermediate position, the switch is mechanicall y
interlocked. W hen the circuit -breakers hav e an
electrical release, the interlock is also electrical.
 T he circuit -breaker can only be s witched on whe
n the withdra wable part is in the test or serv
ice
position. In the inter media te position, the s witch
is mechanicall y int erlocked . W hen the circuit -
breakers hav e an electric al release, the interlock
is also electrical.
 If required, prev ention of malf unction of the s
witch can also be achiev ed by means of the
control
terminal (i.e. Relion®).
 In the serv ice or test posit ions, the circuit -breake
r can only be s witched of f manuall y when n o
control
v oltage is applied and it cannot be closed
(electromechanical interloc k).
 Connecting and disconne cting the control wiring
plug 2 (Figure 142 ) is on ly possible in the test / F i g u r e 1 8 : A) C l o s e d p o s i t i o n o f d o o r ’ s h a n d
disconnected position of the withdra wable part. le; B) Notclosed position of door’s handle.
 T he earthing switch 15 ( F i g u r e 3 ) can onl y
be switched on if the withdra wable part is in the
test /
disconnected position or outside of the pane l 4.4.3 Interlocks betw een panels
(mechanical interlock).  T he busb ar earthing switch can only be
 If the earthing switch is on, the withdrawa ble part closed when all the withdra wabl e parts in the
cannot be mov ed f rom the test / relativ e
disconnected busbar section are in t he test / disconnected
position to the serv ice position (mechanica l position (electromechanica l interlock).
interlock).  W hen the busbar earthing switch is closed, the
 Optionally there can be in terlocking on shutters to withdra wable parts in the earthed bus bar
prev ent manual opening. If it is applied then a section
shutter dev ice must be specif cannot be mov ed f rom the test / disconnected
ied. position to the serv ice po sition (electro
 Details of other possib le interlocks, e.g. in mechanical interlock).
connection with a loc king magnet
on the
withdra wabl e part and / o r earthing switch driv e,
can be obtained f rom the relev ant order 4.4.4 Locking devices
documents.
 T he shutters 2/4 ( F i g u r e 8 ) can be
secured independently of each ot her wit h
padlocks when
4.4.2 Door interlocking the withdra wable circuit - breaker part has been
T he panels are equipped with the f ollowing interlocks: remov ed.
 Access to the operating -s haf t 30 (Figure 3) of
 T he apparatus (circuit -breaker or contactor) the earthing switch can be rest ricted with a
can not be racked -in if the apparatus co mpart padlock.
ment  Access to the circuit -breaker racking slot can
door is open. be restricted with a padlock.
 T he apparatus compart ment d oor cannot be  Access to the circuit -breaker compart ment and
opened if the apparatus (circuit -breaker or the cable compart ment can
be restricted with a
contactor) is in serv ice or in an undef ined padlock.
position.
 T he eart hing switch cannot be operated if
the cable compart ment door is open.
 T he cable compartment d oor cannot be opened
if the earthing s witch is ope n - please see
warning
W ARNING
about door’s handle in section 4.4.4 Locking
dev ices.  The locking magnet is n ot installed in the case
of a motor operator; bu s bar earthing sw
itches
Note:
or the w ithdraw able parts are electricall y
W hen the interlocking f or circuit-breaker is used t he locked. The manual emergenc y sw itch is not
n it is necessar y to use the OFF push button on the do locked !
or to prov ide emergency s wit ching OFF.  This interlock is not a vailable fo
r motoroperated w ithdrawable apparatus as
a
mechanical device.
1
 W ARNING
 The door’s handle w hich is an integral part
of doors has to be push to its final close
position
– see (Figure 18 ) of closed and not closed
position of door’s handle.
 In case the door’s han dle is not in its fina
l close position th e doors are not closed yet.
In
this case the interloc k function cannot be
ensured.

4.4.5 Internal interlocking of panel w ith sw itch -

disconnector
T o prev ent hazardous situations and incorrect
operation, there is a series of interlocks to protect
both personnel and equip ment:
 T he switch -disconnector can only be switched on
if the earthing switch is off . T he earthing switch
can
only be s witched on if the switch -disconnector i s
off . T he switch -disconnec tor and earthing s witc h
are mutuall y mechanicall y i nterlocked. F i g u r e 1 9 : Sw i t c h - d i s c o n n e c t o r c o m p a r t m
 T he door of the lower HV cable part of the e n t - o p e n p o s i t i o n . I n s u l a t i n g p l a t e i n th e i
panel can only be opened if the earthing s witch s o l a t i n g d i s t a n c e o f sw i t c h -d i s c o n n e c t o r .
is on.
During the closing of the earthing switch the 1 Position indicator of switch-dis
insulating plate 26 ( F i g u r e 6 ) is auto maticall y connector
2 Switch-disconn
inserted in the isolatin g distance of switch -
ector
disconnector, which increa ses saf ety. T his plate 3 Mo v a b l e i n s u l a t i o n
is automaticall y re mov ed aga in during the plate
opening of the earthing switch. 4 Insulation partitio
 T he earthing switch can only be operated if n wall
the cable compart ment door is closed.
 If the control v oltage is not co nnected, the s
witch- disconnector can be open and
closed only
manuall y. T he manual operation of switch -
disconnector and earthing switch can be prev ented
if the slides 10 and 14 ( F i g u r e 6 ) of the
operating openings are locked up.
 In panels wit h digital control techniques the
protection against incorrect operation is basically
carried out by t he panel s of tware. But the
earthing switch is operated locall y by the operati
ng lev er 1 (Figure 20) . T he mechani cal in
terlocking bet wee n the switch -disconnect or an d
earthing s witch is still in operation.
 Details of other possib le interlocks, e.g. in
connection with a locking magnet on the s witch
-
disconnector, can be obt ained f rom the relev ant
order documents.

W ARNING
The door of the upper HV part of the panel can onl
y be opened if the off -circuit condition of the sw
itch -
disconnecto r is verified. This means that the off -
circuit condition must be unconditionall y verifie d
both on the upper an d low er contacts of
the
sw itch -disconnector.
F i g u r e 2 0 : P r e p a r a t i o n f o r th e o p e r a t i o n o f e a r t
h i n g sw i t c h i n p a n e l w i th t h e sw i t c h - d i s co n n e c t o
r.
Operating lever prepared for the OFF
operation
1 Operating le

1
ver

2
T ypes of interlocks
S t a n d a r d s a f e t y i n t e r l o c k s ( m a n d a t o r y)
T yp e Description C o n d i t i o n to b e fu l f i l l e d
A Apparatus racking-in/out Apparatus in OFF position
1
B Apparatus closing Defined truck position
A A p p a r a t u s r a c k i n g - in Apparatus multi-contact plug plugged
2
B Apparatus multi-contact plug unplugging T r u ck i n t e s t p o s i t i o n
A Earthing switch closing T r u ck i n t e s t p o s i t i o n
3
B A p p a r a t u s r a c k i n g - in Earthing switch in OFF position
A A p p a r a t u s c o mp a r t me n t d o o r o p e n i n g T r u ck i n t e s t p o s i t i o n
4
B A p p a r a t u s r a c k i n g - in A p p a r a t u s c o mp a r t me n t d o o r c l o s e d
A F e e d e r c o mp a r t m e n t d o o r o p e n i n g Earthing switch in ON position
5
B Earthing switch opening C a b l e c o mp a r t m e n t d o o r c l o s e d
Note: Apparatus are circuit-breakers and contactors.

K e ys ( o n r e q u e s t )
6 Apparatus racking-in lock Can only be removed with the truck in the racked-out p
7 Earthing switch closing lock o
C sa int ioonnl y b e r e m o v e d w i t h t h e e a r t h i n g s w i t c h o p e n
8 Earthing switch opening lock Can only be removed with the earthing closed
9 I n s e r t i o n o f t h e a p p a r a t u s r a k i n g - i n / o u t c r a n C a n a l w a ys b e r e mo v e d
k lever
10 I n s e r t i o n o f t h e e a r t h i n g s w i t c h o p e r a t i n g l e v C a n a l w a ys b e r e mo v e d
er

Padlocks
11 A p p a r a t u s c o mp a r t me n t d o o r o p e n i n g
12 C a b l e c o mp a r t m e n t d o o r o p e n i n g
13 Insertion of the apparatus raking-in/out cran
14 kI nl se ev ret ri o n o f t h e e a r t h i n g s w i t c h o p e r a t i n g l e v

15 e
S rh u t t e r s o p e n i n g o r c l o s i n g
It is necessary to use padlocks with 5-8 mm hasp diameter

Locking magnets (on request)

16 Apparatus racking-in/out Ma g n e t e n e r g i ze d
17 Earthing switch ON/OFF Ma g n e t e n e r g i ze d

Ac c e s s o r y d e v i c e s
The device locks the shutters in the closed position when the apparatus is re
18 Shutters fail-safe mo v e d f r o m t h e c o m p a r t me n t . T h e o p e r a t o r c a n n o t o p e n t h e s h u t t e r s m a n u a l l
y. T h e s h u t t e r s c a n o n l y b e
Apparatus-switc op
T hee raapt pe ad rbayt ut hs emua pl tpi a- cr ao tnut sa ct rt upcl ku go ra tnhder se el ar vt ii vc ee st rwui ct ck hs.g e a r u n i t s o c k e t a r e
19 h g e a r u n i t c o mp a t e q u i p p e d w i t h a me c h a n i c a l m a t r i x , t h a t d i s a b l e s a p p a r a t u s r a c k i n g - i n i n t
ibility o a switchgear unit with an
ma t r i x i nhaepappr p
T oa p rr a
i at tues rcaot mp
e d ac rut rmr e en n tt .i s e q u i p p e d w i t h a me c h a n i c a l d e v i c e , t h a t e n a b l e s c i
Circuit-breaker
rcuit-breaker
20 me c h a n i c a l o p e r a
c l o s i n g a n d / o r o p e n i n g d i r e c t l y b y me a n s o f t h e f r o n t o p e r a t i n g me c h a n i s m p u s h
t i n g me c h a n i s m
buttons, keepingthe door closed. The controls can be operated with the circuit-
breakers in the operation and

2
F i g u r e 2 1 : C i r c u i t - b r e a k e r c o m p a r t m e n t d o o r e n a b l i n g d e vi c e ( A) a n d d o o r l o c k i n g p i n (B ) .

F i g u r e 2 2 : C i r c u i t - b r e a k e r t r u c k e n a b l i n g s l o t ( A) .

Figure 23: Circuit-breaker compartment door locking device (B).

2
Figure 24: Cable compartment door enabling device (C).

F i g u r e 2 5 : C a b l e c o m p a r t m e n t d o o r e n a b l i n g s l o t ( C 1 ) a n d e a r t h i n g sw i t c h e n a b l i n g p i n ( C 2 ) .

Figure 26: Cables compartment door locking pin (D).

2
4.5 Plug connector coding
T he control wiring plug connector coding allows
withdra wable parts f or switching dev ices to be
assigned to particular panels. T his ensures, f or
exa mple, that withdra wabl e parts with dif f erent rated
currents or diff erent control wiring circuits can only
be used in the panels the y are intended f or. Coding
pins are f itted in the control wiring s ockets ( F i g u r e 9 )
or control wiring plugs and engage with the
correspondin g bores of the relev ant plug 1 (Figure 9)
or socket 3 when the t wo p arts are connected.
T he plug connector coding is order -related, and is
noted in the relev ant wiring documentation.

F i g u r e 2 7 : C o n t r o l w i ri n g p l u g c o n n e c t o r c o d i
n g , s h ow n f o r a 5 8 - p o l e c o n n e c t o r .
1 Bore for actuating pin of the control wirin
g plug forcontrolling the auxiliary switch
2,4 Centering strikin
g tabs
3 Control wiring so
cket

Coding:
T he correspondin g coding designation f or the control
wiring plug is giv en in bra ckets. T he coding pins ca n
be f itted in the control wiring socket 3 (Figure 27)
and/or in the control wiring plug.

Basic design:
T he number of s ockets
assignment is 1, 8, 10, 20,
and pins can be mi xed
wiring socket 3 and control
is optional, but the basi c
21, 31, 33 and 40. Socket s
as required in the control
wiring plug.

2
4.6 Ith Limiters F i g u r e 3 0 : V a l i d p r o m i c r o sw i t c h o f t yp e M 1
S 6610.
It is additional saf ety f eature on the top of each pane 1 I t h l i mi t e
l. T he micros witch generate s an i mmediate f ault signal r
when the ov erpressure f lap is opened. Reaction time 2 Pressure relief f
is less then 15 ms. T he signal f rom the micros wit ch lap
can be sent directly to trig ger the circui t-breaker
OFF.

F i g u r e 2 8 : Au x i l i a r y I t h l i m i te r sw i t c h . I t m a y b e
n e c e s s a r y t o m o v e t h e a u x i i a r y s w i t c h es i n t o th e
ir service position
w h en t h e l i f t i n g e ye b o l t s h a v e b e e n r
emoved.

It is necessar y to ad just th e centre of the s witch

kno b of the auxiliar y switch to the centre of the
pressure relief f lap’s hole. Correct v alue of the
adjustment of the au xiliar y s witches’ h ei ght in the
presse d positio n according to the particular type of
the switch is indicated in f ollowing pictu res.

F i g u r e 2 9 : V a l i d p r o m i c r o sw i t c h o f t yp e
Crouzet.
1 I t h l i mi t
er
2 Pressure relief
flap

2
 F i g u r e 3 1 : V a l i d f o r m i c r o sw i t c h o f t yp e L X W 3 7 .

2
5. Dispatch and storage

5.1 Condition on delivery

At the time of dispatch, the UniGear panels are f actory
assembled, th e withdra wable parts are in the te st
position and the doors are closed. T he f actory-
assembled panels are ch ecked f or comp leteness i n
terms of the order and simultaneousl y sub jected t o
routine testing (normall y without AC v oltage testing
of the busbars) to IEC publication 62271 -200, and are
theref ore tested f or correct structure and f unction. T
he busbars are not asse mb led. T h e busbar
materia l, f asteners and accessories are packed
separately.

5.2 Packing
Available packing metho ds:
 Polythene f oil - storage time 1/2 year in clean an
d dry env ironment.
 OSB boards - storage time 1/2 year in outdoor
env ironment according to IEC.
 W ood boxes - storage time 1 year in
outdoor env ironment according to IEC.

According to the kind of transport and country of

destination, the panels remain unpacked or are
packed in sea worth y cr ates. A dr ying agent i s
prov ided to protect them against moi sture:

 Panels with basic packing or without packing. Figure 32: Handling by crane.
 Panels with s ea worth y or s imilar packing (incl
uding
packing f or containerised shipments):
-Sealed in polyeth ylen e sh eeting.
-T ransport drying agent bags included.
5.4 Delivery
T he responsibilitie s of the customer when t he
switchgear arriv es at site include, but are not li mite d
to, the f ollowing:

5.3 Transport  Checking the deliv ery f or completeness and

damage (e.g. also f or moisture and its detrimental
T he transport uni ts normall y co mprise i ndiv idual eff ects). In case of doubt, the packing must be
panels and, in exception al cases, small groups of opened and then properl y resealed, inserting ne w
panels. T he panels are each f itted with f our lif ting drying agent bags, when intermediat e storage is
eyebolts. necessary.
 If any quantities are short , or def ects or
T ransport panels upright. T ake the high centre of transport damage are noted, these must be docu
grav ity into account. Only ev er carry out loading mented on
operati ons when it has been ensured that al l the respectiv e shipping d ocument and notif ied to
precautionary measures to protect personnel and the relev ant carrier or f orwarding agent
materials hav e been taken and use the f ollowing: immediatel y in accordance with the relativ e
liability regulations.
 Crane
 Fork-lif t truck and/or manual trolley Note:
jack Alwa ys take photographs to docu ment an y ma jo r
damage.
Loading by crane:
 Fit lif ting ropes of appropriate load capacity wit
h spring catches (eyebolt dia meter: 30 mm)
 Keep an angle of at least 60° f rom the
horizontal f or the ropes leading to the crane hook
 Suspend the unit using AL L f our
eyebolts!
For detailed inf ormation on switchgear
handling,
please ref er to (chap t er
5 . 6) .

2
 choosing the circular slings.
5.5 Intermediate storage
Optimu m int ermediate storage, where this i s Unpacking
necessary, without an y negativ e consequences -Remov e the nails and crate lid and sides.
depends on co mpliance wi th a numb er of mini mu m -Open the compartment door and loosen the bolts f
conditions f or the panels and assembl y materials. ixing the switchgear to the pallet.

1. Panels with basic packi ng or without packing:

 A dry well -v entilated store room with a cli mate i
n accordance with IEC 6227 1-1.
 T he room temperature mus t not f all below –5
°C.
 T here must not be an y other negativ
e
env ironmental inf luences.
 Store the panels upright a nd do not stack panels.
 Panels wit h basic packing - Open the packing, a
t
least partially.
 Panels without packing
- loosely cov er with protec tiv e sheeting.
- ensure that there is suff icient air circulation.
 Check regularly f or any condensation until
installation is started.

2. Panels with sea worth y or si milar packing wit h

internal protectiv e sheeting:

 Store the transport panels:

- protected f rom the weath er.
- in a dry place.
- saf e f rom any da mage.
 Check the packing f or
damage.
 Check the drying agent ( c h a p t e r 5
.2).
- on arriv al of the deliv ery.
- subsequently at regular i nterv als.
 W hen the maxi mu m stora ge period, starting f
rom the date of packing, has been exceeded:
- the protectiv e f unction of the packing can n
o longer be guaranteed.
- take suitable action if intermediate storage is to
continue.

W
ARNING
Do not w alk on the roof of the panels (ruptu re
points in pressure relief devices !). The
pressure
relief devices and/or Ith Limiters could be
damaged.

5.6 Handling
5.6.1 Sw
itchgear
T he switchgear sections a re usually f ixed to woode n
pallets. Handling should be carried out by ov erhead or
mobile cranes. Otherwi s e, use rollers or f ork lif t
trucks. W eights and dimensions of each section are
listed in the shipping do cuments and in the plan t
drawings.
5.6.1.1 Handling w ith overhead crane or mobil e
crane and unpacking - Handling the sw itchgear in
the w ood packing.
T he switchgear must be lif ted by crane and circular
slings. T he slings must b e inserted according to th e
lif ting symbols marked on the crate. W eight and lif
ting opening angle must be taken into account wh en

2
-Lif t the cubicles b y the crane f ollowing th
e instructions below.
-Remov e the pallet.
-Position the unloading shi ms.
-Put the s witchgear on t he loading shi ms using t
he crane.

Af ter unpacking, lif t the panel groups by crane

(Figure 32) . Use the eyebolts an d t he saf ety ropes.
Af ter installation of the panels, remov e the e
yebolt s used f or lif t ing.

W ARNING

 Onl y use a suitable balan ced lifting s ystem.

 Should an accidental fa ult cause a leakage of
SF6, ventilate the room a nd carefull y follow
the
safet y procedures presc ribed in the IEC
1634 Standards.

F i g u r e 3 3 : H a n d l i n g t h e sw i tc h g e a r i n t h e w o o d e n
crate.

2
5.6.1.2 Handling b y roller 5.6.1.3 Handling b y trans pallet or fork li ft trucks
s T o guarantee stability, the switchgear must not b
Lif t the switchgear section by ov erhead or mobi le e lif ted too high. Check the alignment of the f orks.
crane or using jacks; r emov e the wooden pall et
loosening the scre ws f ixing it to the s witchge ar
section base. Put a sturd y metal sheet bet ween th e
rollers and the panel bas e and place the s witchge ar
on the sliding rollers.
W ARNING
Onl y use transpallets or fork lift trucks on a le vel
floor. M ove the sw itchgear section avoiding
any tilting.
W
ARNING
Onl y use rollers on a level floor. M ove
the
sw itchgear section avoiding an y possible
tilting.

Figure 34: Handling by rollers. F i g u r e 3 5 : Sw i t c h i n g h a n d l i n g .

1 Sliding rollers
2 Me t a l s h e e t

5.6.2 Apparatus
T he app aratus can be handled by cran es, f ork lif t
trucks or using the truck prov ided by ABB. For each
piece of apparatus f ollow t he instructions below.

W
ARNING
 W hile handling do not put an y stre ss on
the insulating parts and on the
apparatus
terminals.
 Before handling the app aratus, make sure
that the operating mech anism
F i g u r e 3 6 : L i f t i n g sw i t c h g e a r p a c k e d i n a w o o d e springs are
n crate. discharged and that th e apparatus is in the
open position.

3
5.6.2.1 Handling b y
crane
Circuit-breaker
Hook the lif ting bolts to the r elev ant supports
(Figure 37 ) . W hile handling, pay the utmost attention
not t o put any stress on the insul ating parts or on the
circui t -
breaker terminals ( F i g u r e 3 8 ) . Bef ore putting
into serv ice, remov e all the lif ting eyebolts.

Contactor
T o lif t the contactor use r emov able support sho wn
on
(Figure 39) .

F i g u r e 3 9 : M o u n t i n g th e l i f ti n g e q u
ipment.
Figure 37: Correct han
dling.
5.6.2.2 Handling b y fork -l ift
trucks
Handling by f ork-lif t trucks can be carried out only
af ter the apparatus has been positioned on a sturd y
support. W hile handling, pay the ut most attention no t
to put any stress on the insu lating parts or on t he
circuit-breaker terminals.

W
ARNING
Do not insert the truck forks straight underneath
the apparatus but put t he apparatus on a stur d y
support.

Figure 38: Wrong han

dling. Figure 40: Handling by fork-lift
trucks.

3
5.6.2.3 Handling b y ser vi ce truck Further w
For handling and inserting the apparatus into the arnings
switchgear, use the serv ice truck (Figure 43 ) . W hen mov ing the switchgear on cylinders alwa ys p ut
the cylinders collinear (in parallel) with the f r ont side
In order to handle the circuit -breaker with the relev of the switchgear and al ways keep the s witchgear i n
ant truck, f ollow the instructions below. the v ertical position!
 Hook the lif ting bolts to the circuit -
breaker supports and align it abov e the truck (1).
 Press the handles (2) to wards the circuit -
breaker centre (*) to insert the horizontal check
pins (3).
 Put the circuit -breaker on the truck.
 Push the circuit -breaker towards the circuit
-
breaker compart me nt and insert the truck into th
e Do not tr y to open t he c able or the circuit -breake r
guides until the handles (2) are released (** ) compart ment doors, clos e the earthing s witch or
outwards and t he horizon tal locking pins go into withdra w the circuit breaker if an auxiliary v oltage is
the slots (4), locking the circuit -breaker. not connected to the switchgear! Do not step on the
pressure relief f laps!

W ARNING
 Do no t use the ser vice truck for an y purpos
e other than handling ABB’ s apparatus.
 Fix the circuit -breaker to the truck
before moving it.

F i g u r e 4 4 : ( * ) H a n d l i n g d i r e c t i o n fo r h o r i zo n t a l l
o c k i n g p i n e n t r y, ( * * ) H a n d l i n g d i r e c t i o n f o r e x i t
of the horizontal
locking pins.
Figure 43: Service truck.

3
6. Assembly of the switchgear at site
T o carry out the optimum installation sequence and 1. T he switchgear panels are bolted together in
ensure high quality standards, site installation of the the f ront and rear part to make one unit.
switchgear should onl y b e carried out b y speci all y 2. Further structural data guidelines giv en prov ide a
trained and skilled personnel, or at least by personnel rough calculation of the space required and th e
superv ised and monitored by responsible people. plan f or designing the room f or a switc hgear
In case higher IP is needed please f ollow the project.
instructions described i n manu al 1VLG100101 -
av ailable on request. If seismic resistance is not required, it is not
necessary t o attach each s witchgear panel to the f
loor or f rame, but it suff ices to f ix outside panels in
each row of switchgear on l y.
6.1 General
If seismic resistance is required, it is necessary to
On commence ment of installation on site, the switch -
attach each switchgear pa nel to the f loor or f rame.
room must be co mpletel y f inished, prov ided with
To achiev e seismic resistance the special f ixing syste
lighting and the electricity suppl y, lockable, dry an d
m i s used. T his system pref erably uses a steel f loor
with f acilities f or v entilation. All the necessary
f rame with “C” prof ile shape but m oreov er with an
preparations, such as wall openings, ducts, etc., f or
additio n special f ixing element – please contact ABB
laying the po wer and control cables up to the
f or details.
switchgear must alread y be c o mplete. W here
switchgear panels hav e top -mounted structures for
W hen the f inal building construction documents ar e
earthing switches or instr ument transf ormers, it mu st
drawn up, the binding d ata supplied by ABB f or a
be ensured that the ceilin g height is suf f icient f or
particular case must al wa ys be taken into account!
the opening trav el of t he pressure relief plates. T he
ceiling must be hi gh enou gh to allo w th e asse mbl y
of the pressure relief duct an d/or top mouted VT bo x
Dimension chart of structural data - panels 1
an d earting switch bo x. See ta ble in (chapter 6.7).
2 / 17.5 kV
Compliance with the cond itions f or indoor switchgear
Panel width F [ m m] 650 800 100 0
according to IEC 60694, i ncluding the conditions f or T
Aisle width G [ m m] 1450 1600 180 0
the “minus 5 indoor” te mperature class must b e (1)
Switchgear ro doo width [ m m] 850 1000 120 0
ensured. om r oo
S witchgear ro d
(2) [ m m] 2400 2400 240 0
omheight r

6.2 Foundations Opening in ceilning if transported

ough roof:
thr

T he f ollowing three ba sic met hods of installin g W id t h [ m m] 1000 1000 120 0

switchgear in the s witchro om are identif ied: Lengt [ m m] 1500 1500 150 0
h e i l i n l o a d (3)
C [ k g / m2 ] 1200 1400 140 0
g
M ethod A – installation on C profile for concrete
floor Dimension chart of structural data - pa
As standard, it is recommended to install th e nels 24kV
switchgear on “C” prof ile base irons set into t he Panel width F [ m m] 800 100 0
Tisle width
A G [ m m] 1600 180 0
concrete f loor of the swi tchroom. In this case, th e (1)
panels are f astened using the special bolt blocks (AB Switchgear ro doo width [ m m] 1000 120 0
B deliv ers these on request). o
Sm witchgear r o rd o o h e i g h t
(2)
[ m m] 2525 252 5
om r
M ethod B – installation on anchoring bolts Opening in ceilning if transported thr
Installation directl y on t he lev elled concrete f ough roof:
loor makes much higher dema nds on the f loor lev W id t h [ m m] 1000 120 0
elling, which must, in this case, fulf il the same Lengt [ m m] 1800 180 0
tolerances as the base iron s during meth od A h
Ceilinload
(3)
[ k g / m2 ] 900 850
installation. Fastenin g is carried out b y a nchorin g g
(1) ) P a y a t t e n t i o n t o a p p r o p r i a t e n a t i o n a l
bolts in the c oncrete f loor. standards.
(2) ) A p p l i e s t o l o w v o l t a g e c o m p a r t m e n t s o f s t a n d
ard height.(3) Approximate numbers depending o
M ethod C – installation on bolts for raised floor
n the type of panels.
In this case, f astening of the panels is carried out by
welding outside panels to the steel f loor f r ame in the
places where the f rame is larger than the base of the
switchgear, i. e. on the o utside lateral walls of th e
panel row. T his metho d of installation is not
recommended if seismic re sistance is required.

Generally, the f ollowing procedure f or switchgear

anchoring can be recommended f or any of the
installation methods menti oned:

3
6.2.1 M ethod of installation A – Installation on At tachment of the panels to the “C" shape
C profile for concrete floor base irons
T he general f oundation drawing is giv en in f ollowin T he switchgear is attached to the base irons b
g f igures according to the parameters of the panels. y special bolt blocks, which can be supplied on
 T he “C" shaped base irons can be supplied by ABB request .
together with the s witchg ear. T heir installation
is  Place the indiv idual panels of the switchgear in
sequence onto correctly lev elled and
usually carried out b y personnel on site and installed
should, if possible, be perf ormed under base irons and lev el them according to the
superv ision of an ABB specialist. T he base irons relev ant f oundation drawin gs.
must be installed in the s lab bef ore f inishing  Lev el the panels and then bolt the m together in th
the f loor e f ront and rear part.
 Rest the irons in the sp ecif ied position on  T o attach them to the base irons, insert specially
the concrete f loor as shown in the relev ant f prepared bolt blocks in the f ixing holes in the
oundation bottom of the panels and ti ghten them.
drawing and mark out th e places f or drilling the
holes. T hen drill the holes f or anchoring bolts,
i.e. f or plugs f or f ixing the base irons in the f loor.
T hen put the plugs in the holes and attach the
base irons to the f loor loosely with bolts, without f
inal tightening so that any required lev elling is
possible.
 Caref ully lev el the base i rons both longitudinal l
y and transv ersally ov er the entire length and to t
he
correct height by putti ng strips of suitable
thickness under them and using a lev elling
instrument.

Tolerances for la ying the floor frame are:

- Ev enness tolerance ± 1 mm ov er a measuring leng
th of 1 m
- Straightnes s tolerance 1 mm per 1m, but n ot mor
e than 3 mm ov er the entire length of the f rame.
 Af ter lev elling the base irons, tighten bolts 13. T
he adjusted position of the base irons on the F i g u r e 4 5 : F i x i n g t o th e f l o o r - M e t h o d A - I n s t a l l a
concrete tion on Cprofile for conrete floor.
f loor must not be changed during this operation!
Check again and, if necessary, correct an y
dev iations.
 W eld Indiv idual parts of the base irons
together inside the “C" prof ile at the seams so that
there is
a mutual conductiv e conne
ction.
 T ake any necessar y meas ures f or perf ect
earthing of the base irons with galv anized steel
strips with
mini mu m di me nsions of 30 x 4 mm. T wo earthing
connections are reco mmended f or a panel ro w
longer than approx. 5 pane ls.
 W hen the f loor top cov ering is applied, caref
ully backf ill the f loor f rame, le av ing no gaps. T
he top
edge of the f loor f rame should be 2 mm abov e th
e f inished f loor surf ace; the tolerance of this v
alue is within the limits of 0 to 5 mm. T his f
acilitates erection and align ment of the switchgear
pa nels. In some c ases, this me ans th at the
material t hickness of an additional f loor cov ering
to be f itted la ter must be taken into accou nt
separately.
 T he base irons must no t be subjecte d to an
y harmf ul impact or pressur e, particularl y during
the
installation phase. If these conditions are not
respected, problems du ring assembl y of the
switchgear and possibl y wi th mov ement of the
withdra wable parts, as wel l as opening and
closing of the doors cannot be ruled out.

3
6.2.2 M ethod of installation B – Installation on
anchoring bolts
T he general f oundation drawing is giv en in f ollowin
g according to the paramet ers of the units.
 Clean the switchgear instal lation area caref ully
 On the slab, v isibly trace the perimeter of all the
units making up t he s wit chgear according to
the
relev ant drawing, taking the mini mu m wall
and obstacle clearances into a ccount
 Lev el the f loor both longitudinally and
transv ersally, ev enness tolerance is ± 1 mm ov er
a 
measuring length of 1 m
 Drill the f loor at the intended f ixing
points, ref erring to the slab drilling drawings. T o
make the
holes, use a hammer drill with a bit according t
o the steel plugs used
 Insert the plugs in t he hol es and put the i ndiv
idual panels on the traced per imeters of the
units to
create the switchgear
 Lev el the units and then bolt them together in
the f ront and rear part
 Fix the units with bolts wi th special washers (th
e coupling material is suppli ed on request)
 In the case of a metal f loor, use the attachment
according to the f igure. To make the holes, use
a place wher e
drill with a suitable bit f or the type of f ixing to
be made (through or thread ed hole)
F i g u r e 4 6 : F i x i n g t o th e f l o o r - M e t h o d B - I n s t a
llation onanchoring bolts.
6.2.3 M ethod of installation C – Installation on
bolts for raised floor
T he general f oundation drawing is giv en in (Figure 48)
- (Figure 72 ) according to the parameters of the
panels. In most cases, the f loating f loor is created
by a steel structure in which the welded steel f rame i s
installed. A f rame prod uced using suitable ste el
prof iles is used. ABB does not supply this f rame.
- Ev enness tolerance ± 1 mm ov er a measuring leng
th of 1 m.
- Straightness tolerance 1 mm per 1 m.
Clean the installation area.
 Af ter installation of the f rame, take an y necessar y
measures f or perf ect earthing of the f rame
with
galv anized steel strips wit h min. di mensio ns 30 x
4mm. T wo earthing conne ctions are reco mmende
d f or a panel row longer than approx . 5 panels.
 Place the panels on the f rame according to
the relev ant f oundation drawings, taking the mini
mu m
wall and obstacle clearanc es into
account.
 Lev el the panels and then bolt the m together in th
e f ront and rear part.
 Carry out attach ment b y welding the
outside panels to the steel f loor f rame in the
the f rame juts out f rom the switchgear botto m,
i.e. on the outside lateral wal ls of the unit row. T his
method of installation i s not recommen ded if
seismic resistance is requi red.
 In the case o f a metal f loor, use
attachment according to the f igure. To make the
holes, use a
drill with a suitable bit f or the type of f ixing to be
made (through or thread ed hole).
F i g u r e 4 7 : F i x i n g t o th e f l o o r - M e t h o d C - I n s t a
llation onbolts for raised floor.
3
F i g u r e 4 8 : U n i G e a r 1 2 / 1 7 . 5 k V u p t o t h e n o m i n a l c u r r e n t o f T - o f f s 2 5 0 0 A. G u i d e l i n e s t r u c t u r a l d a t a f
o r f o u n d a t i o n fr a m e o n c o n c r e t e f l o o r . I t i s n o t v a l i d fo r t h e p a n e l w i th sw i t c h -d i s c o n n e c t o r .
C T yp i c a l p a n e l d e p t h C = 1 3 4 0 m m – h o w e v e r a l w a ys c o n s i d e r a
nnota tion 2)G W id t h o f o p e r a t i n g a i s l e
FT Panel width
TB Door width = FT + 200 mm
TH Door height = panel height + 200 mm

1 Rear cover
2 Door
3 Side end cover
4 Screw
5 Steel dowel

1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m.
2) D i me n s i o n mu s t b e v e r i f i e d i n d o c u me n t a t i o n o f t h e r e l e v a n t o r d e r .

3
F i g u r e 4 9 : U n i G e a r 1 2 / 1 7 . 5 k V f o r t h e n o m i n a l c u r r e n t o f T - o f f s 3 1 5 0 / 4 0 0 0 A a n d / o r 5 0 k A. G u i d e l i n
e s t r u c t u r a l d a t a f o r f o u n d a t i o n f r a m e o n c o n c r e t e f l o o r . I t i s n o t v a l i d fo r t h e p a n e l w i t h sw i t c h - d i s
connector.
C T yp i c a l p a n e l d e p t h C = 1 3 9 0 m m – h o w e v e r a l w a ys c o n s i d e r a
nnotation 2)G W id t h o f o p e r a t i n g a i s l e
FT Panel width
TB Door width = FT + 200 mm
TH Door height = panel height + 200 mm

1 Rear cover
2 Door
3 Side end cover
4 Screw
5 Steel dowel

1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m.
2) D i me n s i o n mu s t b e v e r i f i e d i n d o c u me n t a t i o n o f t h e r e l e v a n t o r d e r .

3
F i g u r e 5 0 : U n i G e a r 2 4 k V . G u i d e l i n e s t r u c t u r a l d a t a f o r fo u n d a t i o n f r a m e o n c o n c r e t e f l o o r I t i s n
o t v a l i d f o r th e p a n e l w i t h sw i t c h - d i s c o n n e c t o r .
C T yp i c a l p a n e l d e p t h C = 1 7 0 0 m m ( F o r s h o r t - t i me c u r r e n t u p t o 2 5 k A , 1 5 6 0 m m d e p t h v e r s i o n i s a v a i l a
ble)
- h o w e v e r a l w a ys c o n s i d e r a n n o t
ation 2)G W id t h o f o p e r a t i n g a i s l e ( c
h a p t e r 6 . 2 ) FT Panel width
(chap t er 6. 2 )
TB Door width = FT + 200 mm
TH Door height = panel height + 200 mm

1 Rear cover
2 Door
3 Side end cover
4 Screw
5 Steel dowel

1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m.
2) D i me n s i o n mu s t b e v e r i f i e d i n d o c u me n t a t i o n o f t h e r e l e v a n t o r d e r .

3
F i g u r e 5 1 : U n i G e a r 1 2 / 1 7 . 5 k V w i t h N AL s w i t c h - d i s c o n n e c t o r . G u i d e l i n e s t r u c t u r a l d a ta f o r f o u n d a t
ion frame on concretefloor.
C T yp i c a l p a n e l d e p t h C = 1 3 4 0 m m – h o w e v e r a l w a ys c o n s i d e r a
nnotation 2)G W id t h o f o p e r a t i n g a i s l e
FT Panel width
TB Door width = FT + 200 mm
TH Door height = panel height + 200 mm

1 Rear cover
2 Door
3 Side end cover
4 Screw
5 Steel dowel

1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m.
2) D i me n s i o n mu s t b e v e r i f e d i n d o c u me n t a t i o n o f t h e r e l e v a n t o r d e r .

3
Fig ur e 5 2 : U n i G e a r 2 4 k V w i th N AL sw i t c h - d i s c o n n e c t o r . G u i d e l i n e s t r u c t u r a l d a t a f o r f o u n d a t i o n f r a m
e on concrete floor.
C T yp i c a l p a n e l d e p t h C = 1 7 0 0 m m – h o w e v e r a l w a ys c o n s i d e r a
nnotation 2)G W id t h o f o p e r a t i n g a i s l e ( c h a p t e r 6 .2)
FT P a n e l w i d t h (chap t er 6. 2 )
TB Door width = FT + 200 mm
TH Door heigh = panel height + 200 mm

1 Rear cover
2 Door
3 Side end cover
4 Screw
5 Steel dowel

1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m.
2) D i me n s i o n mu s t b e v e r i f i e d i n d o c u me n t a t i o n o f t h e r e l e v a n t o r d e r .

4
F i g u r e 5 3 : E x a m p l e o f 1 2 / 1 7. 5 k V sw i t c h g e a r f o r 2 5 0 0 A o n f o u n d a t i o n f r a m e o n c o n c r e t e f l o o r . P a n
e l w i th e x a m p l e s o f g a s d u c t i n c l u d i n g c h i m n e ys o r p r e s s u r e r e l i e f t o t h e o u t s i d e .
A T yp i c a l p a n e l d e p t h A = 1 3 4 0 m m – h o w e v e r a l w a ys c o n s i d e r a n n o t a t i o n 2 )
1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m
2) D i me n s i o n mu s t b e v e r i f i e d a c c o r d i n g t o d o c u m e n t a t i o n o f t h e r e l e v a n t o r d e r

F i g u r e 5 4 : E x a m p l e o f 1 2 / 1 7. 5 k V sw i t c h g e a r f o r 3 1 5 0 / 4 0 0 0 A o n f o u n d a t i o n f r a m e o n c o n c r e t
e f l o o r . P a n e l w i t h e x a m p l e s o f g a s d u c t i n c l u d i n g c h i m n e ys o r p r e s s u r e r e l i e f t o t h e o u t s i d e .
B T yp i c a l p a n e l d e p t h B = 1 3 4 0 m m – h o w e v e r a l w a ys o n s i d e r a n n o t a t i o n 2 )
1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m
2) D i me n s i o n mu s t b e v e r i f i e d a c c o r d i n g t o d o c u m e n t a t i o n o f t h e r e l e v a n t o r d e r

4
F i g u r e 5 5 : E x a m p l e o f 1 2 / 1 7. 5 k V , 4 0 / 5 0 k A s w i t c h g e a r o n f o u n d a t i o n f r a m e o n c o n c r e t e f l o o r . P a n
e l w i th e x a m p l e s o f g a s d u c t i n c l u d i n g c h i m n e ys o r p r e s s u r e r e l i e f t o t h e o u t s i d e .

C T yp i c a l p a n e l d e p t h C = 1 3 9 0 m m – h o w e v e r a l w a ys c o n s i d e r a n n o t a t i o n 2 ) .
1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m.
2) D i me n s i o n mu s t b e v e r i f i e d a c c o r d i n g t o d o c u m e n t a t i o n o f t h e r e l e v a n t o r d e r .

F i g u r e 5 6 : E x a m p l e o f 2 4 k V , 2 5 k A sw i t c h g e a r o n fo u n d a ti o n f r a m e o n c o n c r e t e f l o o r . P a n e l w i t h e
x a m p l e s o f g a s d u c t i n c l u d i n g c h i m n e ys o r p r e s s u r e r e l i e f t o t h e o u t s i d e .
D T yp i c a l p a n e l d e p t h D = 1 5 6 0 m m – h o w e v e r a l w a ys c o n s i d e r a
nnotation 2).1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m
m.
2) D i me n s i o n mu s t b e v e r i f i e d a c c o r d i n g t o d o c u m e n t a t i o n o f t h e r e l e v a n t o r d e r .

4
F i g u r e 5 7 : E x a m p l e o f 2 4 k V , 3 1 . 5 k A s w i t c h g e a r o n fo u n d a t i o n f r a m e o n c o n c r e t e f l o o r. P a n e l w i t h e
x a m p l e s o f g a s d u c t i n c l u d i n g c h i m n e ys o r p r e s s u r e r e l i e f t o t h e o u t s i d e .
E T yp i c a l p a n e l d e p t h E = 1 7 0 0 m m ( F o r s h o r t - t i me c u r r e n t u p t o 2 5 k A a 1 5 6 0 m m d e p t h v e r s i o n i s a v a i l
able)
– h o w e v e r a l w a ys c o n s i d e r a n n o t a t i o n 2 ) .
1) Mi n i mu m d i me n s i o n s ; r e c o m me n d e d s p a c e 5 0 0 m m .
2) D i me n s i o n mu s t b e v e r i f i e d a c c o r d i n g t o d o c u m e n t a t i o n o f t h e r e l e v a n t o r d e r .

4
Figure 58: Guideline structural data for a raised false floor.
A L a r g e r d i me n s i o n i s v a l i d f o r t h e c u b i c l e w i t h c i r c u i t b r e a k e r H D 4 i n c l u d i n g c o m
b i n a t i o n w i t h t h e m, i n o t h e r c a s e s s m a l l e r d i me n s i o n s a r e v a l i d – h o w e v e r a l w a
ys c o n s i d e r a n n o t a t i o n 2 ) .
G W id t h o f o p e r a t i n g a i s l e
FT Panel width
TB Door width = FT + 200 mm
TH Door height = panel height + 200 mm

1) Mi n . d i me n s i o n s .
x) Ma x . d i m e n s i o n s .
2) D i me n s i o n mu s t b e v e r i f i e d i n d o c u me n t a t i o n o f t h e r e l e v a n t o r d e r .
3) I n c a s e o f r e a r a c c e s s o r i n s p e c t i o n w i n d o w o n t h e r e a r c o v e r mi n . r e c o m me n d e d d i s t a n c e f r o m t h e w a
l l i s 5 0 0 mm.

Structural data for a raised false floor

Un [ k V ] P a n e l d e p t h A2 ) B C 1)
12 / 17.5 up to 2500 A 1340 / 130 1235 135
12 / 17.5 - 3150 / 4000 A 1 3 9 00/ 1 3 5 1235 185
1 2 / 1 7 . 5 - 4 0 / 5 0 kA 0
1390 1235 185
24 1700 / 1560 / 1520 1590 / 1450 140

4
F i g u r e 5 9 : 1 2 / 1 7 . 5 k V u p t o 4 0 k A – 6 5 0 / 8 0 0 / 1 0 0 0 m m w i d e p a n e l s – A) An c h o r i n g b o l t s B ) C p r o f i l e f o r
concrete floor.

An c h o r i n g b o l t s fi x i n g s ys t e m
FT width [mm] A [mm] B [mm]
650 440 450
800 590 600
1000 790 800

F i g u r e 6 0 : 1 2 / 1 7 . 5 k V , 5 0 k A, 1 2 5 0 - 2 0 0 0 A, 8 0 0 m m w i d e p a n e l s - A) An c h o r i n g b o l t s B ) C p r o f i l e f o r c o n
crete floor.

4
F i g u r e 6 1 : 1 2 / 1 7 . 5 k V , 5 0 k A, 2 5 0 0 - 3 6 0 0 A, 1 0 0 0 m m w i d e p a n e l s - A) An c h o r i n g b o l t s B) C p r o f i l e fo r c o
ncrete floor.

F i g u r e 6 2 : 1 2 / 1 7 . 5 k V , 5 0 k A, 4 0 0 0 A, 1 0 0 0 m m w i d e p a n e l s - A) An c h o r i n g b o l t s B ) C p ro f i l e f o r c o n c r e t
e floor.

4
F i g u r e 6 3 : 2 4 k V , 2 5 k A, 8 0 0 m m w i d e p a n e l s - A) An c h o r i n g b o l t s B ) C p r o fi l e f o r c o n c r e t e f l o o r .

F i g u r e 6 4 : 2 4 k V , 2 5 k A, 1 0 0 0 m m w i d e p a n e l s - A) An c h o r i n g b o l t s B ) C p r o fi l e f o r c o n c r e t e f l o o r .

4
F i g u r e 6 5 : 2 4 k V , 3 1 . 5 k A – 8 0 0 m m w i d e p a n e l s - A) An c h o r i n g b o l t s B ) C p r o f i l e fo r c o n c r e t e f l o o r .

F i g u r e 6 6 : 2 4 k V , 3 1 . 5 k A – 1 0 0 0 m m w i d e p a n e l s - A) An c h o r i n g b o l t s B ) C p r o f i l e f o r co n c r e t e f l o o r .

4
F i g u r e 6 7 : 1 2 / 1 7 . 5 k V c u b i c l e w i t h sw i t c h - d i s c o n n e c t o r - A) An c h o r i n g b o l t s B ) C p r o f i l e f o r c o n c r e t e
floor.

F i g u r e 6 8 : 2 4 k V – c u b i c l e w it h Sw i t c h -d i s c o n n e c t o r - A) A n c h o r i n g b o l t s B ) C p r o f i l e f o r c o n c r e t e f l o o
r.

4
F i g u r e 6 9 : An c h o r i n g b o l t s F i g u r e 7 0 : C p r o fi l e f o r c o n c r e t e f l o o r

Figure 71: Through hole on metal structure. Figure 72: Threaded hole on metal structure.

5
6.3 Assembly of the switchgear panels
Use screws of tensile class 8.8. T he ma xi mu m Any tighteni ng torques tha t dev iate f rom those in th
recommended tightening t orques based on each e general tables (e.g. f or contact syste ms or dev ice
type of connection are giv en in the f ollowing tables: terminals) must be taken into account as stated i n
the detailed technical docu mentation.
It is recommended that th e threads and head cont a
T i g h t e n i n g t o r q u e s f o r c o p p er b a r s o r c o m b i n ct surf aces of bolts should be lightly oiled or greased
ed busbarconnections to achiev e the precise tightening torque (column Oil o r
Max. recommended tightening torq
grease in table).
(2)
Thread uW
e N
(1)
it m
hout (ƞ=0.14 Oil of grease (ƞ=0.
) 10) T he preparation work f or installation is as f
M5 2.5 -
ollows:
(3)
M6 1 8
M8
(3) 02 2  Remov e withdra wable par ts 1 (Figure 145 ) f
M1 55 04 rom the switchgear panels and
store them wit h
M10 08 06
2 5 9
suitable protection.
M1 20 17
6 0 0  Dismantle lif ting
T i g h t. t o r q u e s f o r c o p p e r b a r c o n n e c t i o n s c o m eyebolts.
bined withepoxy insulators
 T ransport the switchgear panels to the
prepared
installation point f ollowing the sequence shown o n
the switchgear plan.
 Remov e cov ers 2 and 4 (Figure 73 ) f rom
Max. recommended tightening torq the v ertical control wiring duct s at th e f ront lef t
Thread
(2)
uW
e N
(1) of the
it m
hout (ƞ=0.14 Oil of grease (ƞ=0.
panel.
M8 ) 1 10) 1
M1 53 22
0
M1 24 63
2
M1 5
11 69
6
M2 0
22 0
18
0 0 0
T i g h t. t o r q u e s f o r c o p p e r b a r c o n n e c t i o n s c o m
b i n e d w i t h AB B C T s

(2) Max. recommended tightening torq

Thread uW
e N
(1)
it m
hout (ƞ=0.14 Oil of grease (ƞ=0.
M1 ) 7 10) 5

T i g h t. t o r q u e s f o r c o p p e r b a r o r c a b l e c o n
n e c t i o n s c o m b i n e d w i t h AB B V T s

(2) Max. recommended tightening torq

Thread uW
e N
(1)
it m
hout (ƞ=0.14 Oil of grease (ƞ=0.
M1 ) 2 10) 1

T i g h t e n i n g t o r q u e s f o r c o p p er c o n t a c t p i n s i n
side epoxyspout

(2) Max. recommended tightening torq

Thread uW
e N
(1)
it m
hout (ƞ=0.14 Oil of grease (ƞ=0.
M1 ) 4 10) 3
0
M2 6
25 7
20
Note: Thread and head contact surface lubricated.[/
IndexValue]
(1) ) T h e r e c o m m e n d e d m a x i m u m t i g h t e n i n g t o r q u e s a r e
based on acoefficient of friction for the thread of 0.14 (
without lubrication) or0.10 (with lubrication).
(2) ) T h e t i g h t e n i n g t o r q u e s a r e r e c o m m e n d e d f o r s c r e w
s IS O 4 0 1 4 -
4 0 1 8 a n d IS O 4 7 6 2 ( t e n s i l e c l a s s 8 . 8 ) . If u s i n g o t h e r t y p e
s of screwsplease contact ABB for clarification.
(3) ) A p p l i c a b l e o n l y f o r f i x i n g o f s u b s i d i a r y c o v e r s F i g u r e 7 3 : V i ew i n to t h e h i g h v o l t a g e a r e a a t t h e f r
or terminalconnections. ont.
1 Blocking adjustable pin
2 Duct cover for external control cables
3 H o r i zo n t a l p a r t i t i o n , r e mo v a b l e
4 Duct cover for external control cables

5
6.4 Procedure for setting-up the doors
releases the blocking sto p and it is possible t o
Instructions f rom the standpoint of the saf ety at
open the door.
work: T he relev ant work and adjust ments must be
carri ed out by trained specialists f amiliar with the i
nsta llation , taking into account all r elev ant saf ety
regulation s according to IEC and o ther relev ant prof
essional bodies, and other local and works regulations
a nd instructions.
T he switchgear doors are alwa ys mounted and set u
p at the f actory. It is always necessary to reset these
doors on site and to do this bef ore commissioning th
e switchgear. During settin g -up, the s witching stati on
must be connected to the control v oltage, otherwise it
will not be possible to operate the withdrawable part
with circuit -breaker / con tactor and earthing switc
h. T he working method:

a) The circuit -breaker compartment door:

 Loosen (but do not dis ma ntle) 2 lock scre ws

M6
(Figure 74 ) on the lateral side of the door - this
releases the blocking sto p and it is possible t o
open the door.
 W ithdraw thewithdra wa ble part with circuit
- breaker / contactor f rom th e circuit -
breaker
compart ment onto the se rv ice truck and mov e it
outside of the switchgear.
 Dismount the l ef t lateral cov er of the
control cables (Figure 75).
 W ithdraw the lef t lateral cov er of the control
cables f rom the circuit -breaker compart ment
outside of
the switchgear (Figure 76).
 Loosen (but do not dismantle) all M8 screws at all
hinges (Figure 77).
 T he setting -up of the door position is based
on rotating the door in the opening on an axis of
the
middle hinge (the second hinge from the bottom
edge of d oor in the case of a door with 4 hinges).
 Set up the door in the position in which its upper
edge is parallel with the gap between the circuit -
breaker compart ment and the low v oltage
compart ment (Figure 78).
 T ighten the upper hing e and check the
correct f unction of the door including the
insertion of
blocking lev er in the door slot with the blocking
stop.
 If the door closes correctly, tighten all scre ws
at all hinges to a torque of 20 Nm.
 Set up the blocking stop so that its lower edge is
in the range of 29.8 -30.3 mm abov e the lev el
of
the lo wer edge of the sl ot in the door dra w bar
when the door handle is in the closed position
(Figure 79 ) (Figure 80) . T he required position of
the stop can be set up by insertion of the jig
OCA0071, drw.No. 1VL76 1 1226P0101.
 Check that the door closes correctly.
 Mount the lef t lateral cover of the control cables.
T he screw tightening torq ue must not e xceed 2,
5
Nm.
 Insert the withdra wable p art with ci rcuit-breaker
/ contactor in the circuit -breaker compart ment
an d
leav e in the test / disconnected
position.
 Close the door and v erif y the door
blocking f unction by operation wit h the withdra
wable part.

b) The cable compartment door:

 Loosen (but do not d is ma ntle) 2 M6 lock scre

ws
(Figure 74 ) on the lateral side of the door - this
5
 W ithdraw the withdrawa b le part with
measuring v oltage transf ormers (if the switchgear
is equipped
with the m) f rom the cable compart ment outside
of the switchgear (Figure 81) .
 Dismount the l ef t lateral cov er of the
control cables (Figure 82 ) .
 W ithdraw the lef t lateral cov er of the control
cables f rom the cable co mpar tment
outside of the
switchgear (Figure
84) .
 Loosen (but do not dismantle) all M8 screws at
all hinges (Figure 77).
 T he setting u p of the door position is based
o n rotating the door in the opening on an axis
of the
middle hinge (the second hinge from the
bottom edge of door in the case of a door with 4
hinges).
 Set up the door in the position in which its
upper edge of door will be parall el with the upp er
edge of
the separating cov er (Figure
83) .
 T ighten the upper hinge and check the
correct door f unction including the
insertion of the
blocking lev er in the door slot with the blocking
stop.
 If the door close s correctly, tighten all scre ws
at all hinges to a torque of 20 Nm.
 Set up the blocking stop so that its lower edge
is in the range of 29.8 -30.3 mm abov e the lev
el of
the lo wer edge of the sl ot in the door dra w bar
when the door handle is closed (Figure 79),
(Figure 80) . T he required stop position can be
set up by insertion of the jig OCA0071, dr w.No .
1VL7611226P0101.
 Check that the door closes correctly.
 Mount the lef t lateral cover of the control cables.
T he screw tightening torq ue must not e xceed
2. 5
N
m.
 Insert the withdra wable part with measurin
g v oltage transf ormers (if the switchgear is
equipped
with the m) in the cable co mpart
ment.
 Close the door and v erif y the door
blocking f unction by operation wit h the earthing
switch.

5
 F i g u r e 7 4 : S c r ew s o n l a t e r a l s i d e o f d o o r . Figure 76: CB compartment without lateral cover.

Figure 75: Lateral cover of control cables. F i g u r e 7 7 : M 8 s c r ew s .

5
Figure 78: Correct position of CB compartment d Figure 80: Setting up right position.
oor.

F i g u r e 8 1 : W i t h d r aw a b l e p a r t w i t h m e a s u r i
Figure 79: Setting up right position. ng voltagetransformers.

5
 Figure 82: Lateral cover of control cable F i g u r e 8 4 : C a b l e c o m p a r t m e n t w i th o u t l a t e r a l c o v
s in cablecompartment. er.

Figure 83: Correct position of cable compartme

nt door.

5
 er
6.5 Installation of the bushing 4 nr. 3 Rubber partition (busbar s
upport)
Bef ore f ixing the panels side by side (according to 5 n r . 1 2 M8 n u
the general drawings) bushing s (12 ÷ 24 kV) must be f t
ixed (f or switchgear with busbar partitioning only). 6 nr. 1 bushing pl
ate

6.5.1 Bu shing of 12 / 17.5 kV

panels
Lower bus -tie s yste
m
Insert bushing 1 f or the lower rear bus -tie into
bushing plate 5 f rom the right side in contrast to the
procedure f or the other two bushings.

Figure 85: 12 / 17.5 kV panels - fixing b

ushings.
1 nr. 1 bushi
ng
2 nr. 8 8x30 scr
ews
3 n r . 8 M8 w a s h
er
4 nr. 3 Rubber partition (busbar
support)

Figure 86: 12 / 17.5 kV panlels - fixing b

ushings.
1 nr. 1 bushi
ng
2 nr. 8 8x30 scr
ews
3 n r . 8 M8 w a s h

5
6.5.2 Bushing of 24 kV
panels
Assembl y procedure f or bushings – main (upp
er) busbar syste m:
Insert bushing 1 f or the lower bus bar into bushin g
plate 5 f rom the right side, and f or the middle and
upper busbar f rom the lef t side.

Lower bus -tie s yste

m:
Insert bushing 1 f or the lower rear bus -tie into
bushing plate 5 f rom the right side in cont rast to the
procedure f or the other two bushings.

F i g u r e 8 7 : 2 4 k V p a n e l - fi x i n g b u
shings.
1 nr. 1 bush
ing
2 nr. 8 10x25 sc
rews
3 n r . 8 M1 0 w a s
her
5 n r . 1 2 M1 0
nut
6 nr. 1 bushing
plate

F i g u r e 8 8 : 2 4 k V p a n e l - fi x i n g b u
shings.
1 nr. 1 bush
ing
2 nr. 8 10x25 sc
rews
3 n r . 8 M1 0 w a s
her
4 nr. 3 Rubber partition (busbar
support)
5 n r . 1 2 M1 0
nut
6 nr. 1 bushing
plate

5
6.6 Fixing of the panels

W ARNING
Before fixing the panels side by side be sure that
the bushings are fixed a ccording to (chapter 6. 5) .

Fit and screw do wn the sid e cov

ers.
Align the switchgear pan els on the f loor f rame for
correct positioning and v e rtical alignment (dev iations
of the panel edges f rom the v ertical must not exceed
2 mm, especiall y at the f ront) and bolt the pane ls
together (Figure 89 ) . It is adv isable to start f rom the
centre when assembling s witchgear with more than 10
panels.

T he junction points wher e the panels should be f ix ar

e as f ollows:

 Nr.6 in the f ront

side
 Nr.4 in the middle part
 Nr.5 in the rear side
T he nuts are already f ixe d on the right side of the
panel (except in the middle part); on the lef t side there
is the an empt y space where t he screws are to b
e f ixed. T he screws needed are:
 10 x 30 scre ws (co mplete with M10
washer)

F i g u r e 8 9 : V i ew o f th e f i x i n g p
oints.

5
6.7 Installation of the busbars
6.7.1 Preparation of the material
 Clean the insulation on the busbar sections with a
sof t, dry cloth, and check f or any
insulation
damage. Re mov e greasy o r adhesiv e
dirt.
 Busbar connections:
– T he silv er -plated surf aces of the
connections
must be cleane d with a metal -f ree non -wov
en
cleaning cloth and thinly and ev enly coated with
SYN -setral-EK 339 grease
– T he non silv er -plated surf aces of the
connections are either brushed with a wire brush,
preserv ing the grease f ilm, or cleaned with a
metal -f ree non -wov en cle aning cloth and ev
enly
greased with a thin coat of SYN -setral-EK 339
 Prepare insulating cov ers 2 (Figure 90 ) and lids 3
to suit the relev ant busbar connections and pull
them on the busbar. (For insulated busbars only)

F i g u r e 9 0 : 1 2 / 1 7 . 5 k V p a n e l s , i n s t a l a t i o n o f th e b u s b a r s . T h e l ow e r p i c t u r e s h o w s th e i n s t a l l a t i o n a t
th e b u s b a r e n d s .
1 Busbar bushing
2 Insulating cover
3 Lid
4,7 S u p p o r t f o r c o v e r ( a t e n d p a n e l s o n l y)
5 W as h e r , I S O 7 0 8 9
6 W as h e r , 2 5 mm d i a m e t e r

6
F i g u r e 9 1 : 2 4 k V p a n e l s - Ar r a n g e m e n t o f t h e b u s b a r a n d b r a n c h c o n d u c t o r s a t t h e b u sb a r e n d s . I n c
o n t i n u o u s b u s b a r s , t h e c o n n e c t i o n s a r e s i m i l a r , b u t w i t h o u t t h e l i d h o l d e r a n d w i t h o u t th e s p a c e r
p l a t e . D u r i n g a s s e m b l y, c u t o u t t h e
i n s u l a t i n g c o v e r a n d l i d to f i t t h e c r o s s - s e c t i o n o f t h e f e e d e r
bar of busbar.

F i g u r e 9 2 : 2 4 k V p a n e l s , 1 2 5 0 A b r a n c h c u r r e n t a n d 1 6 0 0 o r 2 5 0 0 A b u s b a r c u r r e n t - Ar r a n g e m e n
t of the busbar and
b r a n c h c o n d u c t o r s a t t h e b u sb a r e n d s . I n c o n t i n u o u s b u s b a r s , t h e c o n n e c t i o n s a r e s i m i l a r , b u t w i
th o u t t h e l i d h o l d e r 2 a n d w i th o u t t h e s p a c e r p l a t e 1 3 .

F i g u r e 9 3 : 2 4 k V p a n e l s 2 5 0 0 A b r a n c h a n d b u s b a r c u r r e n t - Ar r a n g e m e n t o f t h e b u s b a r a n d b r a n c
h c o n d u c t o r s a t t h e b u s b a r e n d s . I n c o n ti n u o u s b u s b a r s , t h e c o n n e c t i o n s a r e s i m i l a r , b u t w i th o u
t t h e l i d h o l d e r 2 a n d w i t h o u t th e s p a c e r p l a t e 1 3 .
1,7 Lid for insulating
cover
2 Lid hold
er
3, 4 10mm spring wa
sher
5 Insulating c
over
6 Branch condu
ctor
8 Busbar sect
ion
9) W as h e r I S O 7 0
89
10 M1 0 h e x a g o n s o c k e t h e a d
screw
11 M1 0 n u
t
12 W as h e r 2 5 m m d i a m
eter
13 Spacer plate (only for 2500 A branch an

6
 d busbarcurrent)

6
6.7.2 Busbar compartment access
Access to the busbar compartment is possible either
f rom the top of the panel af ter dismounting the
pressure relief plate 8 ( F i g u r e 3 ) bef ore the
mounting of the gas duct, or f rom the f ront of the
circuit -breaker compart ment.
Af ter circ uit-breaker has been withdra wn f rom t he
panel, it is possible to dismount the horizont al
partition 1 (Figure 95 ) by u nscrewing 4 scre ws holdin
g the partition f rom the inside. Af ter that, the
partition
can be dismantled and taken o ut of the panel,
which
makes access to busbar s f rom the circuit -breaker
compart ment possible.
F i g u r e 9 5 : Ac c e s s i n g b u s b a r c o m p
artment.
1 H o r i zo n t a l p a r t
ition
2, 3 Cov
er
6.7.3 Busbars installation
 Install the busbars panel by panel according to the
rating of the switchgear. Screw on the indiv idual
busbar elements one abo v e the other (depending
on the syste m la yout) a nd in line with the f lat
branch conductor. For the tightening torque please
ref er to the (chap t er 6.3) . Use tightening material
supplied by ABB.
 Bolt one holder to each end of the busbars to
support insulating cov er. T he screws f or
holder
must be tightened wit h a lower torque (f or
insulated busbars only).
 Position insulating cov ers and lids ov er the
relev ant bolted joint, and slide the lid onto the
cov er until it clicks into place (f or insulated
busbars only).
Note:
Busbar connection is c arried out with “ stabiliz ed
connecti ons”. T his mean s that the quali t y of the
copper busbar connection s does not deteriorate
according to the operating time and theref ore it is n
ot necessary to inspect tight ness of busbar
connection s regularly. But this is on condi tio n that
corre ct assembl y is carried out as described abov
e and especially that all connect ions are tightened
with th e prescribed torque according to the table.
W e recommend onl y che cking tightness of busba
r connections during inspect ions (chap t er 9. 3 )
Figure 96: Washer before tightening.
F i g u r e 9 7 : W a s h e r a f t e r t i g h te n i n g .
6
 Busbars for 12 / 17.5 kV panels
Busbars are made of copper and hav e a f lat cross -
section f or rated current up to 2500 A. For 3150, 36
00 and 4000 A, the busbars hav e a double D -shaped
cross-section . Branch conductors alwa ys hav e a f lat
cross-section.
12 / 17.5 kV bushings are made of epoxy resi n
castings and are arranged as a single casting f or al l
three phases. For bustie panels the bushings are
single and are arranged in the lo we r part of the pane
l.
Bushings are held in bus hing plates. For 12 kV, t he
busbars are bare ( witho ut insulation) and witho ut
insulating cov ers up to 2500 A.
3150, 3600 and 4000 A o pen D -shaped busbars ar e
insulated by shrink f itting sheaths and are f itted with
insulating cov ers. For 17.5 kV, the busbars are
insulated and f itted with c ov ers ov er the whole curre
nt range.

F i g u r e 9 8 : 1 2 k V p a n e l s - T -o f f 6 3 0 - 1 2 5 0 A, b u s b a r s 1 2 5 0 A.
1 nr. 4 10x35 screws
2 n r . 8 M1 0 w a s h e r s
3 n r . 4 M1 0 n u t s

F i g u r e 9 9 : 1 2 / 1 7 . 5 k V p a n e l s - T - o f f 6 3 0 - 1 2 5 0 A, b u s b a r s 1 6 0 0 , 2 0 0 0 , 2 5 0 0 A.
1 nr. 4 10x60 screws
2 nr. 8 M1 0 w a s h e r s
3 nr. 4 M1 0 n u t s
4 nr. 1 s p a c e r ( 1 5 m m)

6
F i g u r e 1 0 0 : 1 2 / 1 7 . 5 k V p a n e l s - T - o f f 6 3 0 , 1 2 5 0 A, b u s b a r s 3 1 5 0 , 3 6 0 0 , 4 0 0 0 A.
1 nr. 4 10x60 screws
2 nr. 8 M1 0 w a s h e r s
3 nr. 4 M1 0 n u t s
4 nr. 1 s p a c e r ( 1 5 m m)

F i g u r e 1 0 1 : 1 2 / 1 7 . 5 k V p a n e l s - T - o f f 6 3 0 , 1 2 5 0 A, b u s b a r s 3 1 5 0 , 3 6 0 0 , 4 0 0 0 A, o p e n D .
1 nr. 4 10x60 screws
2 nr. 8 M1 0 w a s h e r s
3 nr. 4 M1 0 n u t s
4 nr. 1 s p a c e r ( 1 5 m m)

6
 F i g u r e 1 0 2 : 1 2 / 1 7 . 5 k V p a n e l s - T - o f f 1 6 0 0 , 2 0 0 0 , 2 5 0 0 A, b u s b a r s 1 6 0 0 , 2 0 0 0 , 2 5 0 0 A.
1 nr. 4 10x60 screws
2 nr. 8 M1 0 w a s h e r s
3 nr. 1 s p a c e r ( 5 m m)
4 nr. 4 M1 0 n u t s

F i g u r e 1 0 3 : 1 2 / 1 7 . 5 k V p a n e l s - T - o f f 1 6 0 0 - 4 0 0 0 A, b u s b a r s 3 1 5 0 , 3 6 0 0 , 4 0 0 0 A.
1 nr. 4 10x60 screws
2 nr. 8 M1 0 w a s h e r s
3 nr. 1 s p a c e r ( 5 m m)
4 nr. 4 M1 0 n u t s

6
F i g u r e 1 0 4 : 1 2 / 1 7 . 5 k V p a n e l s - T - o f f 6 3 0 , 1 2 5 0 A, b u s b a r s 3 1 5 0 , 3 6 0 0 , 4 0 0 0 A, o p e n D .
1 nr. 4 10x60 screws
2 nr. 8 M1 0 w a s h e r s
3 nr. 1 s p a c e r ( 5 m m)
4 nr. 4 M1 0 n u t s

Busbars for 24 kV panels be connected to the busbar. Busbars f or 24 kV

Busbars and branches are made of copper and both
hav e a f lat cross -section. T he bushings are diff
erent f rom the 12 / 17.5 kV v ersions. T hey are single
f or each phase and hav e an electrode inside, which
mus t
panels are insulated by means o f shrink f itting
sheaths and the connection points are cov ered by
insulating cov ers.

F i g u r e 1 0 5 : 2 4 k V p a n e l s - T -o f f 1 2 5 0 A, b u s b a r s 1 2 5 0 A.
1 nr. 4 10x35 screws
2 n r . 8 M1 0 w a s h e r s
3 n r . 4 M1 0 n u t s

6
 F i g u r e 1 0 6 : 2 4 k V p a n e l s - T -o f f 1 2 5 0 A, b u s b a r s 2 5 0 0 A.
1 nr.4 10x60 screws
2 n r . 8 M1 0 w a s h e r s
3 n r . 4 M1 0 n u t s

F i g u r e 1 0 7 : 2 4 k V p a n e l s - T -o f f 2 5 0 0 A, b u s b a r s 2 5 0 0 A.
1 nr.4 10x60 screws
2 n r . 8 M1 0 w a s h e r s
3 n r . 4 M1 0 n u t s

6
F i g u r e 1 0 8 : 2 4 k V p a n e l s - T -o f f 3 1 5 0 A, b u s b a r
s 3 1 5 0 A.
1 nr.4 10x60 scr
ews
2 n r . 8 M1 0 w a s h
ers
3 n r . 4 M1 0 n u
ts

Important note:
The contact springs 2 m ust be inserted during th
e
installation of busbars. These contact springs
make the connection bet w een the busbar 4 and t
he metal tube 5 and prevent damage caused by
parti al discharges inside the bushing on live b usba
rs (Figure 109) .

Important note: F i g u r e 1 0 9 : 2 4 k V p a n e l s - d et a i l o f th e b u s b a r
Alw a ys check that there is good contact betw een b u s h i n g , s e c t i o n a l v i ew .
the metal tube 5 in the b ushing and the busbars
via contact spring 2. Ensure that the contact 1 Busbar bushing
2 Contact spring
spring i s in the correct position ! ( F i g u r e 1 0 9 ) 3 Busbar support for double conductor
4 Busbar
5 Me t a l t u b e

6
 6.8 Installation of the top-mounted boxes
For ease of transportation top mounted bo xes ar e
deliv ered separate f rom the panel in pre -assemble d
sections.
6.8.1 Voltage transformer for busbar metering
 T op-mounted box 1 ( F i g u r e 1 1 5 ) with scre w f
ixin
to (Figure 111 ) (Figure 113 ) . Howev er, if
necessary, the additional spacer plate 2 ( F i g u
re
111 ) and threaded plate 9 (Figure 113 ) , as well a s
the screw f ixin g material f rom the “ top -
mounted box f or metering” set of bags must be
used. Insulating cov er 2 ( F i g u r e 8 7 ) must be
g placed into position as is described in (chap t er
6. 5) .


material in the set of bags “ T op -mounted bo x f or
metering” must be mo unted on the busbar  Intermediate bo x ( F i g u r e 1 1 5 ) ( F i g u r e 1 1 6
compart ment. ) wit h
In panels without busbar bushing plate 5 ( F i g u r e the screw f ixin g material f rom the “top- mounted
87 ) , the partition bet ween the bu sbar compart box f or metering” set of bags must be mounted on
ment the low v oltage compartment. Conduction tube
and the topmounted bo x is necessary. T hey must be positioned an d ins erted in reducer rings.
are  Secondary circuits f rom t he v oltage transf
installed at the f actory in the top-mounted bo ormers must be led to the ter min al strips and
connected
x.
according to the cable core markings and circui t
As f ar as equipment wit h busbar partitioning i s
diagram.
concerned (i.e. with bush ing plate 5), the spac e
between the busbar co mpartment and the top -
mounted bo x must re main open f or pressure relief
.
 Connecting bars 1 with br anch conductors 5 at
the junction point must be scr ewed together
accordin g

Figure 110: Panels 12 / 17.5 kV - Bar connection to the top-mounting box. The figure shows the arran
gement in panels thebusbar ends.

7
Figure 111: Panels 12 / 17.5 kV - Bar connection to the top-mounting box. The figure shows the arran
gement in panels thebusbar ends.
1 Connection bar
2 Spacer plate, 8 mm thick
3 Tapped plate
4 Spacer plate, 5 mm thick
5 Branch conductor

Figure 112: Panels 12 / 17.5 kV - Bar connection to the top-mounted box.

7
 F i g u r e 1 1 3 : P a n e l s 2 4 k V - B o l t e d b u s b a r j o i n t f o r to p - m o u n t e d b o x , s h ow n fo r l e f t - h a n d b u s b a r
e n d . I n c o n ti n u o u s b u s b a r s t h e c o n n e c t i o n i s s i m i l a r , b u t w i t h o u t th e l i d h o l d e r a n d w i t h o u t th e
spacer plate.
1 Connection bar 12 Busbar section
5 Branch conductor 13 Lid holder
6 Lid for insulating 14 W as h e r 3 mm
cover 15 M1 0 h e x a g o n s o c k e t h e a d s c r e w
7 Spacer plate 16 10 mm spring washer
8 W as h e r 2 mm 17 Spacer plate, 10 mm thick
9 Threaded plate
10 Insulating cover
11 Cylinder screw

Figure 114: Panels 24 kV - Bar connection to the top-mounted box.

7
F i g u r e 1 1 5 : P a n e l s 1 2 / 1 7 . 5 k V - Top - m o u n t e d b o x w i t h vo l t a g e t r a n s f o r m e r s f o r b u s b a r m e t e r i n g .
The figure shows thearrangement in panels without the busbar bushings plate.
1 T o p mo u n t e d b o x w i t h v o l t a g e t r a n s f o r me r
2 Conductor tube
3 Partitioning
4 Reducer ring
5 I n t e r me d i a t e b o x

F i g u r e 1 1 6 : 2 4 k V p a n e l s - Ar r a n g e m e n t o f t h e b u s b a r a n d b r a n c h c o n d u c t o r s a t t h e b u sb a r e n d s . I n c
o n t i n u o u s b u s b a r s , t h e c o n n e c t i o n s a r e s i m i l a r , b u t w i t h o u t t h e l i d h o l d e r a n d w i t h o u t th e s p a c e r p l
ate.
1 T o p - mo u n t e d b o x
2 Conductor tube
3 Reducer ring
4 I n t e r me d i a t e b o x
5 Pressure relief flap
6 Connection bar
7 Bushing plate

7
 6.8.2 Earthing sw itch for busbar earthing
 T op-mounted box 1 (Figur e 117) with scre w f ixin
g material f rom the “ top - mo unted bo x f or earth
ing”
set of bags must be mounted on th e
compart ment. busbar
Operating mecha nism bo x 3 with scre w f
material f rom the “t op - mo unted bo x f or earthing”
set of bags must be mou nted on the lo w v oltage
compart ment.
 Pre-mounted single parts of hexagonal shaf t
2 must be re mov ed. Please pay attention to
the
sequence and angling of the parts!
 T he hexagonal shaf t f rom the operatin
g mechanis m bo x must be pushed through into
the
bev el gear of the earthing switch. T he sequence
and angles of the part mus t be restored!
 Connecting bars 4 ( F i g u r e 1 1 9 ) with the
branch conductors at the junction point must be
scre wed
together according to ( F i g u r e 1 1 1 ) , (Figure
113) . Howev er, if necessary, a dditio nal spacer
plate 2 (Figure 111 ) and threaded plate 9 (Figure
113 ) , as well as the scre w f ixing material f rom the
“t op - mounted bo x f or earthing” set of bags must
be used.
 Insulating cov er 10 ( F i g u r e 1 1 3 ) must be
brought into position as described in (chap t er 6. 7) .
F i g u r e 1 1 7 : B u s b a r e a r t h i n g sw i t c h .
1 T o p - mo u n t e d b o x
2 Conductor tube
3 Operating mechanism box
7
Note:
T he auxiliary s witch es f or the earthing s witch a re
adjusted at the f actory. Correct operation is onl y
guaranteed if the working elements on the he xagona l
shaf t are correctly mounted. During f inal installation
of the earthing s witch and o perating mech anis m on
sit e, it ma y be necessary to ma ke precise adjustment
of the auxiliar y s witches. In th is case, the f ollowing
is importa nt:
 T he auxiliary switch OFF 1 (Figure 118 ) must be
operated bef ore slide 3 has uncov ered half of
the
opening in f ront of the hexagonal shaf t and bef
ore the lower edge of the slide has touched the
anchor of locking magnet 4.
 T he auxiliary s witch ON 2 must be operat ed bef
ore the toggle spring of the earthing switch
has
reached its dead centre po
int.
 T he push -rod of the auxilia ry s witch must still hav
e about 0.5 mm to go to the end position in
the
operated position.
F i g u r e 1 1 8 : P a n e l s 1 2 / 1 7 . 5 k V - Top - m o u n t e d b o x w i t h e ar t h i n g sw i t c h f o r b u s b a r e a r t h i n g .
1 Auxiliary switch OFF
2 Auxiliary switch ON
3 Slide
4 Locking magnet

F i g u r e 1 1 9 : P a n e l s 2 4 k V - T o p - m o u n t e d b o x w i t h e a r t h i n g sw i t c h fo r b u s b a r e a r t h i n g . t h e a r r a n g e m e
nt is the same as thefigure above.
1 T o p - mo u n t e d b o x
2 Conductor tube
3 Operating mechanism box
4 Connection bar

7
 6.8.3 Ultra fast earthing sw itch UFES
For more inf ormation s ee document 1VLG1001
28 Manual f or installation of UFES into UniGear ZS1.

F i g u r e 1 2 0 : T o p - m o u n t e d b o x w i t h U F E S.
1 UFES
2 T o p - mo u n t e d b o x
3 Conductor tube
4 Reducer ring
5 I n t e r me d i a t e b o x

6.8.4 Anti -ferrore sonan t resistor for voltag e

transformers open delta connection
W hen using a f erroresonance resistor f or VT s open
delta connection is necesary to ad just the position of
this resistor during site installation.
T he f erroresonance resis tor is placed on the top of
switchgear on the CB relief f lap f or the
transportation (Figure 121) . W hen mov ing the resistor
f rom relief f lap to LV comp artment (LVC ) please f
ollow pictogra m
(Figure 122 ) on the top of LVC. T he resistor has to be
f ixed by means of screws on the top of the
LVC
(Figure 123) .
Assemble resistor prior t o instalation of preassur e
relief gas duct. Pay att ention to the resistor’s wire s
whilst installing ga s duct. Figure 121: Transport position of anti-fer
roresonantresistor.

Figure 122: Pictogram on the top of LVC. Figure 123: Correct position of anti-ferroresona
nt resistor.

7
6.9 Pressure relief ducts
T he pressure relief duct is supplied dismantled in
single compone nts. T he rear and f ront wa ll
correspond, as f ar as length is concerned, with the
appropriate panel widt h.
T he screw f ixing material i s contained in the
“pressure reli ef duct” set of bags. Riv et nuts are
already prov ided in the metal shee ts.
Detailed instructions f or gas e xhaust duct asse mb ly
are described in doc ument Asse mbl y manu al
1VLM000034.

Note:
T he rear pressure relief f lap must be mounte d
according to ( F i g u r e 1 2 4 ) . Details regar
ding connection to the wall a nd a discharge grating f
or pressure relief outside the switchroo m will be agree
d on with the custo mer. Figure 126: Fixing points on th
e rear.

Figure 124: Schematic diagram of the pressure

relief duct.
1 Pressure relief F i g u r e 1 2 7 : As s e m b l y o f p r e s s u r e r e l i e v e f l a p s
duct w i th o u t g as d u c t .

2) If the switchgear is equipped with a press

ure reliefduct, the pressure relief flap for th
e c a b l e c o n n e c t i o n c o m p a r t me n t i s f i x e d t o t h e r e
Note:
ar side of the panel and will opento the front (into th T his side of the preassure relief f laps has to be f
e duct) in case of an arc fault. ixed by plastic scre ws. T he mar ked screws must be
plastic .

6.9.1 Gas duct w ith

outlet
Once the panels are bolted up, and busbars are
installed, it is possible to start f ixing the gas duct o n
the top of the switc hgear. Ev ery panel has three f ixin
g points in the f ront part (Figure 125 ) and three f ixin g
points on the rear part (Figure 126) .

F i g u r e 1 2 8 : As s e m b l y o f p r e s s u r e r e l i e v e f l a p
s w i th g a s d u c t .

Note:
If a gas duct is used turn of f the cable compart me
nt f lap according to f igure. The marked screws must b e
plastic.
Figure 125: Fixing points on th
e front

7
 6.9.2 Gas duct w ith top chimne
ys
In order to mount the gas duct with top chimne ys
please f ollow the appropriate instructions. T he
diff erence between the two solut ions is that in t his
case there are no side e xits, but th e gas generat
ed f rom an internal the arc exits f rom the duc t throu
gh the top chimne ys l ocated on the top part of the gas
duct on each panel.
On the top of the gas duct there are two openin gs
(Figure 130) ; f or each opening the perf orated metal
plate must be f ixed with 6 spacers (Figure 131 ) .
Note:
For UniGear ZS1 24 kV; 31 ,5 kA with gas duct with to
p chimne ys f or a duct heigh t of 500 mm it is
necessar y to use a def lector. Insert t he def lector
onto gus duct - open side in direction of LVC. For f
ixation us e connecting parts include d in gas duct
asse mbl y. Def lector is designed to div ert hot gas
away of rear part of panel to shield a staff behind the
panel. It is not necessar y to apl y the def lector in
case of placing panels directly to wall. No access f rom
rear s ide.

F i g u r e 1 2 9 : O p e n i n g s o n to p o f t h e g a
s duct.

Figure 132: Defle

ctor.

Figure 130: Net and spacers of top ch

i m n e ys .

Figure 131: Top cover of top chi

mneys.

7
6.10 Cable connection
6.10.1 Pow er
cables
T he standard method f or entry of power cables in t
he switchgear is shown in ( F i g u r e 1 3 3 ) . T he cables
are conv eyed f rom below thro ugh f loor cov ering 2,
which is div ided at the cable entry point.
T he cables go through rubber reducer rings 3, whi ch
can be adapted to the re quired cable dia meter in a
range f rom 27 to 62 mm. Cables are f astened in th e
panel by means of cable clamps mounted on cabl e
strips, which are part of the panel f loor cov ering.
T he clamps make it possible to f asten cables with
diameters bet ween 35 a nd 54 mm.

F i g u r e 1 3 4 : V i ew i n t o c a b l e c o n n e c t i o n c o m p a r t
F i g u r e 1 3 3 : P a r t i a l v i ew o f th e c a b l e c o m p ment, max.six parallel cables possible.
artment,prepared here for connection of 1 Earthing switch position indicator
triple cables. 2 Cable connection bar
1 Ma i n e a r t h i n g 3 C a b l e c l a mp
bar 4 Reducer ring
2 Floor cover, s 5 Floor cover, split
plit
3 Reducer ri
ng
4 Earthing connecti
on pin
Important note:
The cable connection bars are equipped w ith
holes for M 16 screw s.
Cable termi nation kits are mou nted on the cab le
cores according to the manuf acturer’s instructions. It
is possible to use cable te rmination kits f rom dif f
erent manuf acturers (e.g. Pr ys mian, Raych em etc.),
but it i s necessary to keep the sa me length of the
cable ends, including cable ter minatio n kits, which is
giv en by t he distance of cable connecting bars
(Figure 133 ) f rom the panel f loor cov ering.
T hese bars hav e diff erent v ersions, which diff er in
their number of parallel cables and the v alues of
rated and short -circuit currents.
T he bars are equipped with holes f or M16 screws.
The earthing of cable screens is carried out on the stri p -
holding cable cla mps. T he cable strip is connected t
o the earth potential.
It is also possible to place the remov able arrangeme
nt of v oltage transf ormers in the cable compart
ment . T hese can be f itted with HV f uses sim ilar to
those in the measuring panel.
T hree f ixed mounted surge arresters can also be
installed here. In both ca ses the nu mber of parall el
cables that can be installe d is reduced - (see t able ) .

7
 C o n n e c t i o n o f c a b l e s i n t yp i c a l p a n e l s
Rated Panel wid Max. number of par Max. cross sectio Range of ca Range of redu
volage [k th [ m m ] allelcables in p n ofcables bleclamp [ cerring [m
V] hase [mm2] mm] m]
(1)
650 3
≤ 17. 800 630 35 - 54 27 - 62
5 6 (2)
100 0
800 3
(1) 500 35 - 54 27 - 62
24
1000 6
(2)

(1) ) I n c a s e s where there are removable voltage transformers on the truck, or surge arresters are used, the number of p
arallel cables is reducedto a max. of 2 per phase.
(2) ) I n c a s e s where there are removable voltage transformers on the truck, or surge arresters are used, the number of p
arallel cables is reducedto a max. of 4 per phase.

C a b l e c o n n e c t i o n i n th e p a n el w i th sw i t c h -d i s c o n n e c t o r
Rated Panel wid Max. number of par Max. cross sectio Range of cab Range of redu
volage [kV] th [ m m ] allelcables in p n ofcables [m leclamp [m cerring [m
≤ 17.5 800 hase 1 m 2 ] 240 m ]35 - 54 m 27
] - 62
24 1000 1 240 35 - 54 27 - 62

Important note:
Connection w ith single -core plastic insulate d
cables is presumed in t ypical panels. In the case of
an y at ypical cable conne ctions or of special cable s
(e.g. three -core cables, cables w ith paper or
special insulation etc.), an agreemen t must b e
reached betw een the customer and ABB.

Mounting procedure f or po wer cables (Figure 134 ) :

 It is possible to achiev e more space - see
chapter 6.7.2.
 Power cables must be ins erted, cut to length
and stripped.
 Reducer rings 4 must b e adapted to the
cable diameter and f itted onto th e cable.
 Cable termination kits must be prepared and
mounted on cable cores according to
manuf acturer’s instructions.
 Cable e yes must be con nected to the pr
epared connection bars 2 with stra i n relief .
 Earthing of cables must be connected.
 Indiv idual parts of the floor cov ering must be
mounted.
 Reducer rings 4 must be mov ed down so that nut
s in the rings f it into the corresponding recesses
in
the f loor cov erings. In this wa y, the cabl
e passages are sealed.
 Cables must be f astened into the prepared
cable clamps 3 (the ma xi mum tig
htening torqu e
applicable to the clamp scr ews is 9 +2 N m).

8
Figure 135: Dimension of power cable connection of Unigear 12 / 17.5 kV panels.
D T yp i c a l p a n e l d e p t h 1 3 4 0 ( 1 3 9 0 ) m m. D i me n s i o n mu s t b e v e r i f i e d a c c o r d i n g t o t h e r e l e v a n t o r d e r d o c
umentation.

1 Cable connection bar

2 Reducer ring
3 C a b l e c l a mp

Dimensions of power cable connections 12 / 17,5 kV

Max. number of cables per
phase A [mm] B [mm] C [mm]
I n [ A] Width [mm] I t h [ k A]
single core triple co
re
630 3 3 840 -
1000 650 31. 535
5
1250 3 3 480 180
1250 40 / 50 465
1600 800
2000
1600 31.5 / 40 / 50 440
2000 6 6 460 100
2500 1000
3150
4000 40 / 50 455

8
 Figure 136: Dimension of power cable connection of Unigear 24 kV, 25 kA panels.
D T yp i c a l p a n e l d e p t h 1 7 0 0 m m ( 1 5 6 0 m m v e r s i o n i s a v a i l a b l e b u t d i m e n s i o n mu s t b e v e r i f i
e d a c c o r d i n g t o t h e r e l e v a n t o r d e r d o c u me n t a t i o n )

1 Cable connection bar

2 Reducer ring

Dimension of power cable connection 24 kV, 25 kA

Max. number of cables per phas
I n [ A] Width [mm] I t h [ k A] A [mm] B [mm] C [mm]
es i n g l e c o r e triple core
1000
800
1250
3 3 497 608 180

1000
2000
1250 25 6 6 432 645 100

8
Figure 137: Dimension of power cable connection of Unigear 24 kV, 31.5 kA panels.
D T yp i c a l p a n e l d e p t h 1 7 0 0 m m ( F o r s h o r t - t i me c u r r e n t u p t o 2 5 k A a 1 5 6 0 m m d e p t h v e r s i o n i s a v a i l a b l e .
B u t d i m e n s i o n mu s t b e v e r i f i e d a c c o r d i n g t o t h e r e l e v a n t o r d e r d o c u me n t a t i o n )

1 Cable connection bar

3 C a b l e c l a mp

Dimensions of power cable connections 24 kV, 31.5 kA

Max. number of cables per phase
I n [ A] Width [mm] I t h [ k A] A [mm] B [mm] C [mm]
single core triple core
IF 800 6 6 465 700 100
Up to 1250 31.
IFM 800 2 2 460 740 118
IF 1000 5 5 425 770 120
Up to 3150 31.
IFM 1000 6 6 415 690 100

8
 F i g u r e 1 3 8 : D i m e n s i o n o f c a b l e c o n n e c t i o n i n p a n e l s o f Un i g e a r sw i t c h g e a r w i t h 1 2 / 1 7 . 5 k V sw i t c h d i s
connector.
D T yp i c a l p a n e l d e p t h i s 1 3 4 0 ( 1 3 9 0 ) m m. T h e d i m e n s i o n m u s t b e v e r i f i e d a c c o r d i n g t o t h e r e l e v a n t o
rder documentation.

1 Cable connection bar

2 Reducer ring
3 C a b l e c l a mp

F i g u r e 1 3 9 : D i m e n s i o n o f c a b l e c o n n e c t i o n i n p a n e l s o f Un i g e a r sw i t c h g e a r w i t h 2 4 k V sw i t c h d i s c o n n
ector.
D T yp i c a l p a n e l d e p t h i s 1 7 0 0 m m. T h e d i me n s i o n mu s t b e v e r i f i e d a c c o r d i n g t o t h e r e l e v a n t o r d e r d o c u
mentation.

1 Cable connection bar

2 Reducer ring
3 C a b l e c l a mp

8
6.10.2 Control cables
T he control cables are conv eyed into the pa nel 6.12 Installation of
through the control wiring duct 23 (Figure 3 ) on the
lef t hand panel side. Moun ting procedure: interconnecting bundles
 Insert the cables into the control wiring duct on th e T he interconnecting bundles are supplied rolled up i
lef thand side. T he duct is cov ered by cov ers 2, n the lo w v oltage co mpart ment or in the accessori
4
(Figure 73). es. T hey are marked and f itted with f errules or
 Fasten the control cables at the top end of the connectors at both ends. Openings are prov ided in
duct, strip the insulation and conv ey cable control the side wa lls of the low v oltage compart ment f or
cores into the low v oltage compart ment, af ter the these lines to be looped through f rom panel to panel.
terminal strip f rame has been swung up ( F i g u r e
140 ) .
 Connect control cables to the ter minal stri

p according to the circuit diagram.
Make the con trol wiring connections to ad
6.13 Final erection work
jacent panels using bushing.

 Check painted areas of the switchgear f or

possible damage, touching u p wher e required
 Check bolt connections and tighten wher
e required, in particular all those carried out
during
on-site erection of the busbars and earthing
syste m
 Af ter the lif ting eyebolts hav e been remov ed,
the Ith limiter auxiliar y s witch (if deliv ered)
must be
mounted and ad just
ed:
- T he auxiliary s witch hold er is f ixed b y scre ws
in the panel
- T he auxiliary s witch hol der must be
positioned horizontally
- T he control pin of the auxiliar y s witch must
be mov ed to the centre of the hole in the
F i g u r e 1 4 0 : L i f t -u p t e r m i n a l fr a m e s w u n g u p fo r c o
pressure
nnectionworks. relief f
lap
- Adjust the au xiliar y s witc
h
- If the auxilia ry s witch is mounted and adjuste d
according to the abov e instructions, checking
during regular inspections is not necessary
 Clean the switchgear thoro ughly
 Remov e all f oreign bodies f rom the panels
 Correctly replace all co v erings, etc. remov ed
during erection and conne
ction
 In the enclosure, an y re maining openings must b
e closed if they are no longe r needed
 Check the isolating co ntacts and interlocking
mechanis ms f or smooth motion, and grease
again
with S YN -setral-EK 339 wh ere
necessary
 W ithdrawable circuit -breaker parts must be
Figure 141: Fixed terminal inserted and the control wi rings connected
f ra m e .
 Panels doors must be prop erly closed

6.11 Earthing the switchgear

Connect main earthing bar 6 with co nnections 2
prov ided in ev ery panel (Figure 133) .
Ensure protection f or the wiring con nection of the f
loor f rame or the erected raised f alse f loor.
Connect the earthing c onductor f rom the eart h
electrode, pref erably via a remov able bolted
connection f or testing purposes, to the main earthi
ng
bar 6 of the switchgear.

8
 7. Operation of the switchgear
Note on safet y at w
ork
All relativ e work and ope rating procedures must b e
caref ully carried out b y trained specialists f amilia r
with the installation, ta king into account all t he
relativ e saf ety regulations according to the IEC and
other relev ant prof essional bodies, as well as a ny
local and work regulations and instructions.

W ARNING: T he withdrawable part must not be stopped in any

Do not w alk on the top surfaces of the sw intermedi ate position in th e trav el range betwe en th e
itchgear panels as the y contain r upture points for serv ice and test / disconnected position!
pressu re
relief w hich could be damaged
!

7.1 Switching operations

W
ARNING
Carr y out sw itching operations w ith the front
doors
closed
!

7.1.1 W ithdraw able

apparatus
Manual insertion f rom the test / disconnected
position to the serv ice position:

 Connect control wiring plu g 2 (Figure

142 ) .
 Close the f ront
door.
 Ensure that the apparatus is in the OFF position.
 Fit hand crank 1 (Figure 144 ) on square spigot 3
(Figure 16 ) of the spindle mechanis m 26 ( F i g u
re
3 ) , af ter opening the aperture f or them by
turning slide 2 (Figure 143 ) .
 T urn the crank clockwise (approx. 20 turns at 12
- 17.5 kV and 30 at 24 k V) until the stop is
reached
and the withdrawa ble part is in the serv
ice position.
 Observ e the position
indicator.
 Remov e hand
crank.
It must be noted that the spring loaded pin head 1
(Figure 16 ) will lie co mple tely on the rear side of the
panel door when the hand crank is mov ed f rom
square spigot of spindle mechan ism. T his ensures that
th e rear part of the pin head has been shif ted onto the
hexagonal cap of the spindle and prev ents
unintentional wrenching o f the spindle during panel
serv ice. W renching ma y lead to the circuitbreake r
blocking.

Note:

8
Figure 142: Control wiring plug connector block
ed to
p r e v e n t d i s c o n n e c t i o n w i t h th e w i t h d r aw a b l e
part in theservice position.
1 Interlock
2 Control wiring plug
3 Control wiring socket

Figure 143: Before inserting the hand crank, it is

n e c e s s a r y t o o p e n t h e a p e r a t u r e f o r i t - tu r n t
h e s l i d e b y u s i n g th e k e y.
1 Double bit key
2 Slide

8
 breakers.

Motorized mov ement of the withdra wable part:

F i g u r e 1 4 4 : M o v e m e n t o f t h e w i t h d r aw a b l e p a r
t b e tw e e n t h e t e s t / d i s c o n n e c t e d p o s i t i o n a n d t
h e s e r v i c e p o s i t i o n , c l o c kw i s e u p t o t h e s t o p t o
th e s e r v i c e p o s i t i o n a n d a n t i - c l o c kw i s e f o r th e
test / disconnected position.
1 Hand cra
nk

Manual withdra wal f rom t he serv ice position into

the test / disconnected position:

 Ensure that the apparatus is in the OFF position.

 Rev erse the procedure described abov e f
or
insertion into the serv ice position.

Important note:
Insertion and w ithdraw al of circuit -breakers
(and
other w ithdraw able parts) mu st be gradual, in
order to avoid an y shoc ks w hich could deform
the mechanical interlock. If the operations are
prevented, do not force the interlocks and che ck
that the operating seque nce is correct. The forc e
normall y applied to the insertion / w ithdraw in g
lever i s 260 N. In an y c ase, the maximum appli ed
force must never exceed 400 N. Please also refer t
o the technical documentation of the circuit -
breakers fo r installation operations.

Caution:
The insertion and w ithdraw al must alw ays
be carried out w ith the apparatus open ! Do not
u se
force to move w ithdraw able parts w ith locking
magnet Y0 or RL2 in the event of an auxiliary
voltage drop. If this occurs, the y are locked
along
the w hole travel range betw een the service
and
test positions. To rem ove the interlock, consult
the technical documentation of the circuit -
8
 Brief ly operate the electri cal control f or
insertion or withdra wal (the wi
thdrawable part then
automaticall y mov es into th e opposite position).
 Observ e the position
indicator.
Not
e:
W hen the driv e motor is faulty, the withdra wable part
can be mov ed using the emergenc y manual operatio
n. If the driv e motor f ails during mov ement of the
withdra wable part, the withdra wable pa rt must be
mov ed into a limit positio n using emergenc y manu al
operation. E mergenc y man ual operation is carried
ou t with hand crank 1 (Figure 144 ) on spindle
mechanis m
26 (Figure 3) , in a si mi lar wa y to op eration of a
withdra wable circuit -break er with manual s yste ms.
-Switch of f the auxiliary power ( m.c.b.), since t
he
motor would other wise be braked
electrically.
-T urn hand crank in the r equired direction. W hen the
withdra wable part mov es, the motor tur ns. In thi s
case, the motor f unctions like a generator, i.e. it ca n
lead to reserv e v oltages in the terminals. T he
moto r
f use must not be ch anged f rom the specif ied type
an d
rated v alue, otherwise the behav iour of the
permanent magnet motor could be irre v e rsibly
damaged!

Caution
In emergenc y manual operation of a
motorized
w ithdraw able circuit -breaker part, the
interlock w ith the earthing sw itch is not effective !

W ithdrawal f rom the test / disconnected position ont

o the serv ice truck:

 Open the door of the circuit-breaker compart

ment.
 Release control wiring plug 2 (Figure 142 )
and
place it in the storage position on the withdra wable
part.
 Position serv ice truck 4 ( F i g u r e 1 4 6 ) with
guide pin
1 (Figure 147 ) of the adju stable bench top at th
e
correct height f acing the panel f ront, and
allo w catch pin 2 to engage.
 Mov e sliding handles 2 ( (Figure 145 ) in
wards against the springs t o release withdra
wable part 1 ,
draw the withdra wable pa rt out onto the serv
ice truck and secure it in the catches on the truck.
 Press release lev er 1 ( F i g u r e 1 4 6 ) (at the
f ront underneath the bench top) and release the
serv ice
truck f rom the switchgear panel.
 Secure the position of the shutters with
padlock.
Insertion f rom the serv ice truck into the test /
disconnected position:
 Carry out the procedur e described abov e f
or withdra wal in rev erse order.
8
 F i g u r e 1 4 5 : S e r v i c e t r u c k e n g a g e d w i th t h e sw i t c F i g u r e 1 4 6 : W i th d r aw ab l e p ar t s t a n d i n g o n s e r v
hgear ice truckand secured in the catches.
p a n e l . W i t h d r aw a b l e p a r t r e l e a s e d f o r w i t h d r aw
a l w i t h t h e h a n d l e s s l i d i nw a r d s . 1 Release lever for catch pin
2 Catch (connected to sliding handle)
1 W it h d r a w a b l e p a r t 3 Height adjuster
2 Sliding handle 4 Service truck
3 Service truck

Figure 148: Shutters secured with padlock t

F i g u r e 1 4 7 : P o s i t i o n i n g th e s e r v i c e t r u c k w i t o preventunauthorized operation.
h t h e g u i d e pin s o n t h e a d j u s t a b l e h e i g h t b e n c
h top at the correct 1 Locking of lower shutter
h e i g h t fo r a p p r o a c h t o t h e sw i t c h g e a r p a n e l , a n 2 Locking of upper shutter
d engagingthe catch.
1 Guide pin
2 Catch pin

9
7.1.2 Circuit -breaker - t ype VD4
Charging the stored energ y spring s yste m:
 Charging of the circuit -breaker is carried
out automaticall y b y the c harging
motor. If the
charging motor should f ail , the charging
procedure can be carried out or comp leted manuall
y.
 If mechanical charging is necessary open the door
with the withdra wable pa rt in the test position
,
insert charging lev er 3 int o the recess and pu
mp f or approx. 25 strokes until the charged
condition i s indicated.
 On breakers where th e charging lev er is
integrated, take the lev er and pump 10 ti mes.
 W hen the charged con dition is reached, the
charging mecha nis m is a utomaticall y disen
gaged,
and any f urther strokes of the lev er hav e no eff
ect (Figure 149) . Pu mping is eff ectiv e if the lev er
is mov ed ov er an angle of 90°.

Opening and closing the ci rcuit -breaker:

 Opening and closing operations with th
e withdra wable part in the serv ice position
should
only be perf ormed wi th the door
closed.
 Operate the local or remot e electrical control.
 Observ e the switch position indicator. T
F i g u r e 1 4 9 : M a n u a l o p e r a t i o n o f w i t h d r aw a b l
he e p a r t w i th V D 4 c i r c u i t - b r e a k e r .
switching operation cou nter 4 f or the circuit
- 1 Me c h a n i c a l s w i t c h p o s i t i o n i n d i c a t o r
breaker auto maticall y incr eases b y one unit wit h 2 Charging condition indicator
each operating c ycle. An additional control 3 Charging lever
mechanis m f itted in the do or of the circuit - 4 Me c h a n i c a l o p e r a t i n g c yc l e c o u n t e r
breaker compart ment enables me c hanical
operation of the
circuit-breaker with the d oor closed and with the
withdra wable part in either
position.
 Press the relev ant mecha nical pushbutton, hav
ing prev iously turned knob 2 ( F i g u r e 1 1 ) anti-
clock wise
to the stop if the withd rawable part is in the
serv ice position.
 Observ e the switch position indicator. For f
urther details regarding operations and
maintenance of
VD4 circuit -breakers, see instruction manuals BA
460-06, BA 414-06

9
 7.1.3 Circuit -breaker - t ype VM 1
T he maintenance -f ree VM1 circuit -breaker applies a
combination of moulded - in v acuum interrupters, a
magnetic actuator and an electronic controller witho ut
auxiliar y s witches and with sensors. Bef ore
connecting the primar y v oltage:
 Connect the auxiliar y v oltage. OFF comma
nd (closed – circuit release) and the closing lock -
out
must be energized bef ore the circuit -breaker can
be closed. T he auxilia ry v oltage has been
established when the (Re ady) LED 5 (Figure 150 )
lights up.
 Carry out the closi ng a nd opening test of
the circuit-breaker by pressi n g pushbuttons 6
and 7
(Figure 150).
 Closing: B y re mote c ontro l v ia closing contacts
or locally b y pressing ON pus hbutton 6.
 Opening: By re mote contro l v ia closing contacts
or locally b y pressing OFF pu sh button 7.
 Opening on f ailure of the auxili ary po wer suppl
y: Electrical opening is still possible within the f
irst
200 s. Af ter a period of 2 00 s, e mergenc y
manual opening is necessary to i nsert emergenc y
manual
F i g u r e 1 5 0 : W i th d r aw ab l e p ar t w i t h VM 1 t yp e
circuit-breaker - operating mechanism sid
e.
1 Me c h a n i c a l o p e r a t i n g c yc l e c o u n t e r
2 Me c h a n i c a l s w i t c h p o s i t i o n i n d i c a t o r
3 C a t c h f o r e m e r g e n c y ma n u a l o p e r a t i n g l e v e r
4 Front cover plate
5 “ R e a d y” d i s p l a y
6 ON pushbutton
7 OFF pushbutton
9
operating lev er 1 (Figure 151 ) onto the spigot of
the emergenc y shaf t 3 ( F i g u r e 1 5 0 ) in the f ront
plate and turn it anticlock wise to open the circuit -
breaker. Just bef ore the f inal stop is reached, a
slight resistance on the e me rgenc y s haf t has to
be ov ercome.
 Closing on f ailure of the auxiliar y po wer suppl
y: Closing is not appropriate and not possible.
 Af ter each operating cycle (ON -OFF), the
operating c ycle counter 1 (Figure 150)
increases
by on e f ull digit. On ter mination of a switchin g
operation, the position indicator 2 in the windo w of
the f ront plate displays the related switch position.
 Anti-pumping s yste m: T he circuit -
breaker controller ensures that ci rcuit -breaker
closing is
locked when an openi ng c ommand is activ e. W
hen closing on a subsequent o pening command, f
urther closing with the closing command still activ
e is locked. T he closing command must be giv en
again f or the next closing operation.
For details, ref er to manual BA 433/E.
F i g u r e 1 5 1 : E m e r g e n c y m a n u a l sw i t c h - o f f .
1 R e c e s s f o r e me r g e n c y ma n u a l o p e n i n g l e v e r
2 E me r g e n c y ma n u a l o p e n i n g l e v e r
7.1.4 Circuit -breaker - t ype closing release, the opera tion can also be carried o
HD4 ut by means of a control circuit. T he indicator 2 shows
Manual operation f or spring that closing has been acco mplished.
charging:
T o manually charge the closing springs, f ully insert Circuit-breaker opening:
charging lev er into seat 3 ( F i g u r e 1 5 2 ) and turn it For manual opening, press pushbutton 1 (Figure 153) .
unti l the yello w indicator 2 app e ars. W hen there is a shunt op ening release, the operati
Electrica l operation f or spring on can also be carried out wi th remote control b y
charging: mean s of a control circuit. T he indicator 2 shows that
T he circuit -breaker can b e f itted with the f ollowin g opening has been acco mplished . An additional contro
accessories f or electrical operation: l mechanis m f itted in the door of the circuit -breaker
 Geared motor f or automatic charging of the compart ment enables me chanical operation of the
closing springs. circuit-breaker with the door closed and with th e
 Shunt closing release. withdra wable part in either position.
 Shunt opening release.  Press the relev ant mecha nical pushbutton, hav
ing prev iously turned knob 2 ( F i g u r e 1 1 ) anti-
T he geared motor aut o mat ically r echarges the clock wise
spring s af ter each closing operation until the yello w to the stop, if the wit hd rawable part is i n
indicat or the serv ice position.
2 appears. Should ther e be no v oltage during  Observ e the switch position
charging, the geared mo tor stops and then starts
recharging the springs automaticall y when the v indicator.
oltage is on again. In an y cas e, it is al wa ys possible Detailed inf ormation about installation an d
to complete the charging o pe ration manuall y.
maintenance can be f ound in instruction manu al
647016.
Circuit-breaker closing:
T his operation can only be carried out with the closin
g springs completel y charge d. For manual closing pre
ss pushbutton 4 (Fi g u r e 1 5 3 ) . W hen there is a
shunt

F i g u r e 1 5 2 : H D 4 t yp e c i r c u i t - b r e a k e r - s i d e v i ew . Figure 153: Operating and signalling parts of H

D4 circuit-breaker.
1 Control wiring plug
2 Signaling device 1 Opening pushbutton
3 S h a f t f o r ma n u a l c l o s i n g s p r i n g c h a r g i n g 2 Operation counter
4 W it h d r a w a b l e a s s e mb l y 3 Circuit-breaker open/closed indicator
4 Closing pushbutton

9
 7.1.3 W ithdraw able metering
parts
Handling of the withdra wable metering part in th e
metering pa nel is as d escribed in (chap t er 7. 1) ,
without, ho wev er, the switching operations an d
interlocking f unctions. W ithdrawable metering parts
in incoming and outgoing f eeder panels are mov ed in
to the cable compart ment usi ng a ramp. T hey reach
the ir serv ice position immediate ly and engage i n the
pan e l earthing by two locking pins at the sides. T he
v oltage transf ormers used correspond to the type
used in th e metering panel, and theref ore HRC f uses
can also be used along with the v oltag e transf ormers.
F i g u r e 1 5 4 : W i th d r aw ab l e p ar t w i t h m e t e r i
ng panel.
1 Cast resin tube (with fuse car
tridge)
2 Voltage transfo
r me r
Figure 155: Mini circuit breakers of transforme
r secondarycircuits.
9
7.1.6 Vacuum contactor - VSC
T he VSC v acuum contactor is ideal f or controlling
AC installations requiring a high number of
operations. T he contactors basically consist of a mould
ed resi n monoblock, housing the v acuum interrupters,
mov ing apparatus, control electromagnet, multiv oltage
control f eeder and auxiliary acce ssories. T he
monoblock is also the support f or assembl y of
the f use -holder f rame. Closing of the main contacts is
carried out by the control electro magnet. Opening is
carried out b y a special opposing spring . T he
contactor can be equipped with electrical o r
mechanical latchi ng. T he f uses are positioned in
special supports to be connected in series between
the contactor and the user. T he supports can house f
uses in complian ce with DIN or BS standards. For
details, please ref e r to manual 6497011.
F i g u r e 1 5 6 : V S C t yp e v a c u u m c o n t a c t o r - f r
o n t v i ew .
1 Signalling device O
N/OFF
2 O p e r a t i n g c yc l e c o
unter
F i g u r e 1 5 7 : V S C t yp e v a c u u m c o n t a c t o r - p
ole side.
1 MV f u s e
s
7.1.7 Earthing sw itch - type EK6 and ST -
E
T he earthing switch has a snap closing mechanis m
which is independen t of the rotation of the driv e shaft.
An earthing switch 15 ( F i g u r e 3 ) allocated to a
circuit- breaker is only enabl ed f or switching whe
n withdra wa ble part 1 (Fig ure 145) is in the test /
disconnected position or r emov ed f rom the s witchge
ar panel. Only turn earthing switches on when the
doo rs are closed.
Manual opening an d closin
g:
Press slide 2 ( F i g u r e 1 5 8 ) down wards onto the
operating lev er recess socket. (W hen the switch is
closed, it is already in this position! )
Caution:
 During emergenc y manua l operation of a motor
- operated earthing sw itch, the interlock is
not
functional
!
 On emergenc y manual operation, coupling w
ith the motor operator is automaticall y
released .
To disengage the coupling to the motor
operator, first turn the l ever further in the pre -
selected direction up to the relative stop
(turning through a small angle). On the next
operation w ith the motor operator after its
function has been restored, the coupling
automaticall y re-engages .

Caution:
If the operation is pre vented, do not force t
he
interlock and check that the operation sequence i s
correct. F it operating lever 1 (Figure 159) ont o
hexagonal shaft 2 ( F i g u r e 1 5 8 ) ,w hich is
now released for operation.
Note:
T he lev er may onl y be f itted temporaril y to carry ou
t an emergenc y manual s wit ching operation. T he
power to the motor operator mu st be switc hed of f f or
the duration of any breakdo wn .

Note:
Position operating lev er 1 (Figure 159 ) to poi nt up or
down on the he xagonal sh af t so that there is suff
icient room f or mov ement of the operating lev er ev en
if space is limited at the side s.
 T urn the lev er clockwise th rough approx. 180°
until the stop is reached to clos e the earthing s
witch, or
anti-clockwise u ntil the sto p is reached to open th
e earthing switch
 Observ e the mechanical/e lectrical switch
position indicator
 Remov e operating lev er 1. Slide 2 (Figure
158)
remains open if the earthing switch is in the close
d
position. Make s u re that the operating lev er is
turned right up to the stop in the opening process,
to ensure that the earthing switch is in its def ined
limit position. T he manu al operating mechanis m
can also be f itted with a locking magnet

Opening and closing with motor operator (EK6 onl y) :

T he earthing switch can also be f itted with a mot or
operator. Brief ly operate the electrical control for
opening or closing. T he earthing switch is the n
switched auto maticall y into the opposite position.
Figure 158: Preparation for operation of branch
e a r t h i n g sw i t c h - p r e s s t h e s l i d e d o w nw a r d s .
Emergenc y manual opera
tion: 1 H e x a g o n a l s h a f t o f E S o p e r a t i n g me
If a f ault should occur in the motor operator, th e chanism
2 Slid
earthing switch ca n be s wi tched to emerg enc y manu
e
al operation with lev er 1, in a si milar wa y to manuall y
operated earthing switch es .

9
 Figure 159: Preparation for operation of bran F i g u r e 1 6 0 : S h u t t e r l i f t i n g t ru c k i n c i r c u
c h e a r t h i n g sw i t c h - o p e r a t i n g l e v e r p r e p a r e d f it-breakercompartment.
o r sw i t c h i n g o n / o f f .
1 Shutter lifting truck
1 Operating le 2 Isolated operation rod
ver

7.1.8 Busbar earthing sw itch

T o earth the busbars, EK6 earthing s witches are als
o used. T heir operating mec hanism is identical to that
of the branch earthing s witch es. T he conditions f or
panel to panel interlocking of the busbar earthing
switches (chap ter 4.4 ) .

7.1.9 Shutter lifting truck

Shutter lif ting truck (optional accessories) can b e
used f or access to spouts af ter remov ing the circuit -
breaker f rom the circuit -breaker compart ment:
 Place the shutter lif itng truck 1 (Fig u r e 1 6 0 )
into the rails f or the circuit -breaker truck in
circuit -
breaker compart
ment
 Push the shutter lif ting tru ck in using the
isolated operation rod 2 ( F i g u r e 1 6 0 ) and open
the shutters
f or access to
spouts
 Rotate the operation rod to lock the truck and pull
the truck out when f inished Actuating bars must be
bolted in the top position (f or operation of the
bottom shutters) or i n t he botto m position (f or
operation of the top shutters), as required.
Figure 161: Opening shutters.

Caution:
Never operate shutter lift ing truck onl y b y
hand.

9
 f uses will be required, the current -carrying bars will b
e inserted in holders instead of the MV f uses to
maintai n the same location of the e arthing switch.

Notice:
T he switch -disconnector and earthi ng switch can onl
y be operated with the s wi tchgear panel door
closed. T he switch -disconnector and earthing s witch
are mutuall y mechanicall y inte rlocked.

Range of fuses
Un [ k V ] In min. [ A ] In max. [ A ]
7.2 6 200
12 6 125
17.5 6 160
24 6 125

Figure 162: Isolated operati

on rod.

7.1.10 N ALF sw itch -

disconnectors
T he NALF switch -disconnectors, combining a s witc h - F i g u r e 1 6 3 : P r e p a r a t i o n f o r th e o p e r a t i o n o
f earthing
disconnector with f uses and E type earthing s witch es sw i t c h i n p a n e l w i t h t h e sw i t ch - d i s c o n n e c t o r
are intended f or indoor use in switchboards. T he o p e r a t i n g l e v e r p r e p a r e d f o r t h e O N o p er a t i o
switch -disconnectors can open and close loaded an d n.
unloaded ind uctiv e and capacitiv e circuits. In the
1 Lockable operating handle –
open position the dev ice has a visible isolating padlock
distance. 2 Position indicator of earthin
T he switch -disconnectors are used in co mbination wi g switch
th power f uses as short -circuit protection. T his 3 Operating shaft for the earthin
g switch
combination e xcludes t wo -phase po wer suppl y,
because the interruption of any f use link causes the
opening of the switch -di sconnector by its trippin
g
syste
m.
T he E type earthing switc hes are constructed with a
snap closing mechanis m. T hey can close and car r y
short-circuit currents.

Operating mechanis m of the switch -disconnector for

use in UniGear switchgear:

Operating mechanis m A – with t wo

springs.
T he opening spring is alwa ys charged bef ore
the
closing of the switch -disc onnector. T his means, th at
the closed switch -discon nector alwa ys has store d F i g u r e 1 6 4 : P r e p a r a t i o n f o r th e o p e r a t i o n o
energy in the opening spri ng and the opening f ollows f earthing
immediatel y with th e ma nual lev er, opening shunt sw i t c h i n p a n e l w i t h t h e sw i t ch - d i s c o n n e c t o r
release or f use tripping mechanism. T his mec hanis operatinglever prepared for the OFF operati
on.
m f acilitates remote opening and in combination with
th e motor o perating mechanis m makes co mpletel y 1 Operating le
re mo te control possible. ver

T he E type earthing switc h is always operated local

ly by the operating lev er 1 (Figure 164) .

T o secure the protection of connected MV equip me nt

the UniGear s witchgear wi th switch -disc onnector use
s CEF mediu m v oltage f uses. T he UniGear switchgear
9
with NALF s witch -disconne ctor can be equipped with
a range of f uses according to the f ollowing table.

In cases that the s witc h -disconnector without

MV

9
Closing and opening of NALF switch -disconnector. approx. 1s. If f aster opening is required, it is
 T he switch -disconnector can only be switched on necessary to equip the mechanis m A with an
if the earthing switch is ope n . opening coil.
 Put operating lev er 1 ( F i g u r e 1 6 4 ) in
position pointing up or do wn on t he groov ed
shaf t of the
switch -disconnector so tha t there is suf f icient
room f or mov ement of the operating lev er ev en if
space is limited at sides. Caution:
 T urn the lev er clockwise through approx. 180° t The operating lever ma y onl y be fitted temporari l y
o charge the opening spring. to carr y out an emer genc y manual sw
 T urn the lev er anti -clockwi se to charge the itching operation – RISK OF INJURY.
closing spring and to close the swi tch-
disconnector.
 T urn the lev er clockwise through approx. 20°
to open the switch-disconnec tor.
 Observ e switch positioning indicator 7 (Figure 6 ) .

Caution:
Until the latch of the o pening or closing sprin g
actuates, the lever w ill be return ed back into the
starting position through the spring action.
Proceed w ith caution during this operation t o
prevent the slipping of l ever from hand - RISK O F
INJURY.

Closing and opening of integrated E type earthin g

switch.
 T he earthing switch can on ly be s witched on if
the switch -disconnector is ope n and opening
spring is
charged.
 Put operating lev er 1 ( F i g u r e 1 6 4 ) in
position pointing lef t or up on the groov ed
shaf t of the
earthing switch so that th ere is suff icient room f o
r mov ement of the operating lev er ev en if space is
limited at the sides.
 T urn the lev er clockwise through approx. 90°
until the stop is reached to close the earthing
switch.
 T urn the lev er anti -clockwise through approx. 90
° until the stop is reache d to ope n the
earthing
switch.
 Observ e switch positioning indicator 7 (Figure 6 ) .
Closing and opening of NALF switch -disconnecto r wit
h the motor operating mecha nism.
T he switch -disconnector can also be equipped wi th
the UEMC 40 K3 motor op erating mechanis m.
 Brief ly operate the control buttons f or closing
or opening. T he switch -disco nnector is then
switched
automaticall y or the s prings of the switch -
disconnector are charged.

Emergenc y manual operati on

If a f ault should occur in t he motor operatin g
mechanis m, t he s witch -dis connector can be s witc he d
manuall y with the opera ting lev er 1 (Figure 1 6 4)
directly on the shaf t of the switch -disconnector.

Notice:
 Af ter the manual operati on the motor
operating mechanis m will not be synchronous
with the
switch -disconnector, whic h means t hat it must b e
manipulated t wice to rea ch synchr onization, e.g .
opening – closing.
 W e recommend using a p rotectiv e circuit -
breaker in the suppl y circuit o f the motor
operatin g
mechanis m. T he opening time of mechanis m A
operated with mot or operating mechanis m

9
 is

1
7.2 Test procedure
7.2.1 Testing the off -circuit condition 7.2.2 Current and voltage tests
In switchgear panels whi ch are not equipped with T he testing and earthing module is av ailable for
capacitiv e v oltage indication, checking the of f -circuit carrying o ut curre nt and v oltage tests. It is als o
condition is carried out with a HV t ester on t he suitable f or supplying primar y current to an y curre nt
isolating contacts in the isolating tulips, af ter the transf ormers which ma y be f itted during
correspondin g upper shutter or lower shutter has been measure ments in the p rotection circuit and, f or
opened. Shutter opening c an be carried out b y mean exa mple, f or application of a test v oltage during
s of a module. If the p anels are equipped wit h insulating tests.
capacitiv e v oltage indication, this can be used to
check the of f -circuit condition. In this case, procee d  Isolate and secure the wor king area in accordance
with the IEC saf ety regulat ions.
according to the manuf acturer’s instructions or the
 For primar y current sup ply, f ix the
indicators. (Optionally, s witchgear can be equipp ed connecting cable of the est transf ormer to the
with v arious types of indicators f rom diff erents contact pins.
manuf acturers). In case of any doubt about correct  For AC v oltage tests, ball is required on the
operation of capacitiv e voltage indication, the off - contact pin. T he bore in the ball is used f
or
circuit condition must be checked using a HV te ste connection of the v oltage supply.
r.  For current tests, f or example of small connecte
d generators, the short -circ uit bridge must be f
Checking the of f -circuit condition must al wa ys b e ixe d
carried out in compliance with the relev ant saf ety onto the contact pins.
regulations and local oper ating conditions!
Note:
W ith v oltage tests at power f requency withstan
d v oltage and/or impulse v oltage, carr y out the f
ollowin g procedure:
Disconnect any v oltage transf ormers and surge
arresters and cov er them with an insulating plate.

F i g u r e 1 6 5 : W i th d r aw ab l e p ar t d u r i n g i n s e r t i o
n i n to t h e s e r v i c e p o s i t i o n , s h u t t e r s n o t ye t f u
lly open.
1 Top shutter
2 C o n t a c t s ys t e m
3 Isolation tulip
F i g u r e 1 6 6 : V i ew i n s i d e t h e ci r c u i t - b r e a k e r c o m p a
4 C o n t a c t a r m, w i t h i n s u l a t i n g s l e e v e
rtment,
w i t h d r aw a b l e p a r t r e m o v e d , s h u t t e r s o p e n .
1 Isolating tulip
2 Isolating contact
3 Lo w e r s h u t t e r

1
 7.2.3 Pow er cable Note:
test Pictures show the shutters l if ting truck f or panel 12
T he power cable test can be carried out by AC kV 650mm. Shutters lif ting truck f or other conf
v oltage, DCv oltage or AC v oltage applicable f or v ery igurations ma y be slightl y dif f erent but f unctionalit y is
low f requency (VLF)testin g at 0,1Hz. For ma xi mu m preserv ed.
cable test v oltage see table onthe next page.

General
Voltage applied during cable testing can da ma ge
v oltage transf ormers,surge arrestors if f itted. It is
theref ore necessary todisc onnect them f rom the circu
it bef ore perf orming cable test.T he below described
procedure shall be used to c arry outcable test on the
power cables with out disco nnecting thecables f rom th
e switchgear.

Caution:
Al l the operations below must be carried out b
y
qualified and skilled personnel w ith in -
depth know ledge of the panel and apparatus.

Procedure described below must be f ollowed t

o accesscable test points

 Switch OFF the circuit bre

aker.
 Rack out the cir cuit breaker f rom serv ice to
test
position.
 Open CB door.
 W ithdraw the circuit breaker f rom the panel
(see Figure 167: Modified shutters lifting truck ins
par. 7.1.1). erted in CBcompartment.
 De-energise the cable.
 Switch ON the earthing s wi tch (see par.
7.1.7).
 T est the off -circuit condition (see par.
7.2.1).
 Disconnect v oltage transformers, surge arr
estors
if f
itted.
 Insert modif ied shutters lif ting truck inside t he
CB comparte ment.
 Push modif ied shutters lif ting truck to serv
ice position b y insulating oper ating handle. T he
lo wer
(cable connection) shutter shall open. Cable test
points (contact pins) shall be accessible. Shutters
lif ting truck manipulation is described in par. 7.1.9.
 Connect the cable test equipmen t to the test
points (contact pins in the CB comparte ment – 2
(Figure
166 ) ) and to the main e arth
busbar.
 Swith OFF earthing s witch. (see par.
7.1.7).
 Carry out the cable test as required.

1
F i g u r e 1 6 8 : S h u t t e r s l i f ti n g tr u c k w i th a l l Figure 169: Modified shutters lifting tr
actuatingelements. u c k a f t e r d e m o u n t i n g o f b o t to m a c t u a t i
ng elements.

1
Power cable test - Maximum applied voltage
Rated voltage of theswitchgear Ur
[kV] 12 17.5 24

Rated power-frequencycable test volta

g e , m a x . d u r a t i o n 1 mi n U c t ( A C ) [ k V] 22.4 30.4 40

Rated DC cable test

v o l t a g e , ma x . D u r a t i o n 1 5 mi n U c t ( D C ) [ k V] 36 36 48

Rated AC cable test

voltage applicable for VLFtesting at 0.1 H
z, [ k V r ms ] 19.2 26.1 36
ma x . d u r a t i o n 60 mi n U c t (A C - V L F )

Note: The test circuit is designed for a maximum applied voltage in thetable.

Caution:
The test circuit is designed for a maximum applied
voltage of table below .

T o restore normal operating

conditions:
 De-energise cable conn ection. Switch -ON the
earthing switch.
 T est the off -circuit condition (see in par.
7.2.1).
 Disconnect the cable test equipment.
 Connect v oltage transf ormers, surge arr estors
if
f itted.
 Switch -OFF earthing s witc
h.
 Insert the circuit breaker into CB compart ment.
 Close CB door.
 If needed rack -in the cir cuit breaker f rom test
to
serv ice position.
 If needed switch -ON cir cuit breaker.

Caution:
Af ter t esting, the test connections ma y retain
a
lethal electrical charge a fter the test equipment i s
sw itched OFF. Discharge the test points using a
safet y ground (e.g. earthing sw itch to earthed ON
position) and ensure that the test connections are
dead before disconn ecting the cable te st
equipment. In all cases, ensure that the test points
are reall y dead.

1
7.3 Service trucks
Instead of earthing, short -circuiting and testing wit h
module 9 (Figure 171 ) it i s possible to use the serv ice
trucks. T hese trucks are div ided into f our diff erent
types:
Earthing truck w ithout making capacit
y earthing) or botto m (po we r cable earthing) ter minal
T hese trucks carry out the same f unction as th e
earthing switches without making capacit y. T heref ore
they do not hav e any capa city to earth the liv e
circuits under f ault conditions. T hey are used to ensure
f ixed additional earthing, as required by the plant serv
ice and maintenance proced ures, as a f urther saf ety
measure f or personnel. T he use o f these trucks
anticipates remov al of the switching dev ice f rom the
switchgear (circuit -break er or contactor) and its
replacement with th e truck . T he panels preset f or
use of earthing trucks are f itted with a ke y lock which,
if activ ated, prev ents their ra cking-in. T his truck
is av ailable in two v ersions:
 Main busbar s yste m earthi
ng.
 Power cable earthing.
During the racking -in phas e, the main busbar earthin
g truck only lif ts the top shutter and earths the
contacts connected to the top branches (and theref ore
to the main busbar syste m) b y the switchgear
structure. During the racking -in phas e, the po wer
cable earthin g truck only lif ts the bottom shutter and
earths th e contacts connected to t he bottom bra
nches (an d theref ore to the power cables) by the s
witchge ar structure. T hese trucks can also be used in
the bus -tie panels. In this case, they earth the two si
des of the main busbar s yste m.
Figure 170: Earthing trolley without short circui
t sw i t c h i n g c a p a b i l i t y.
1 C o n t a c t s ys t
em
2 Contact ar
ms
3 Actuating b
ars
4 Earthing con
tact
5 E a r t h i n g mo d u l e w i t h o u t s h o r t c i r c u i t
switchingcapability
Earthing truck w ith making capacit
y
T hese trucks carry out the same f unction as th e
earthing switches with ma king capacity. T hey consi st
of circuit -breakers only f itted with top (main busb ar
s. T he contacts wi thout ter minals are short -circuited b
y means of a copper bar an d connected to earth b y
th e apparatus truck. T hey ke ep all the ch aracteristics
of the circuit -breakers, such as f ull making capacit y
an d opening of the liv e circuits under f ault
conditions . T hey are used to ensure extre mel y ef f
ectiv e earthing on circuits stressed by a f ault. T hey
allow opening and closing operations to be carried out
rapidl y wit h remote electric control.
T he use of these trucks anticipates remov al of the
switching dev ice f rom the switchgear (circuit -breaker
or contactor) and its replacement with the truck. T he
panels preset f or use of earthing trucks are f itted
with a key lock which, if activ ated, prev ents their
racking - in. T his truck is av ailable in two v ersions:
 Main busbar s yste m earthi
ng.
 Power cable earthing.
During the racking -in phas e, the main busbar earthin
g truck only lif ts the top shut ter and presets the
contact s connected to the top branc hes (and theref
ore the mai n busbar syste m) f or closing to earth by
the contro l.
During the racking -in phas e, the po wer cable earthin
g truck only lif ts the bottom shutter and presets the
contact connected to t he bottom bra nches (a nd
theref ore to the power ca bles) f or closing to earth by
the control. T hese trucks can also be used i n bus -tie
panels. In this case, they earth the two sides of the
main busbar s yste m.
Pow er cable test
truck
T hese trucks allow the in sulation tests to be carrie d
out on the power cables without accessing the f eeder
panel or disconnecting the cables f rom t he s witchgea
r. T he use of these trucks anticipates remov al of the
switching dev ice f rom the switchgear (circuit -breaker
or contactor) and its replacement with the truck.
During the racking -in phase, the truck only lif ts the
bottom shutter and, b y the co nnectors it is f itted wit
h, allows connection of the test apparatus cables. T his
truck can onl y be used i n the inco ming / outgoin g
panels.
Isolation truck
T he isolation truck allows the switchgear top and
bottom contacts to be con nected directly. Connec tio n
is made e xtre mel y saf e by using the poles of the
HD4 circuit-breakers to insulat e the connection bars f
ro m the external env ironment. In the incoming /
outgoing panels, it connects the main busbar syste m
to t he power cables, whereas in the bus -tie pane ls, it
connects to the two sides of the busbar system.
T his truck is used in the UniGear s witchgear to ma ke
incoming / outgoing panel s without circuit -breakers in
radial networks, to make cable connections betwee n
two s witchgear panels pla ced in f ront o f each
other,
and f or constructing interconnection panels
and
creating bus-tie-riser pane ls with double insulation (i
n this case, both the panels are made f rom bus -ties,
the f irst f itted with a circuit -breaker and the other
with a n isolation truck).
1
Earthing and short -circui ting w ith earthing
module
(Figure 171)
 Isolate the area to be earthed and secure it
against reconnection.
 Caref ully f ollow all saf ety regulations.
 Remov e the withdra wable c ircuit-breaker part f
rom
the relev ant switchgear panel.
 Secure the shutter in f ront of the liv e contact
pins by means of the padlock. Screw on the
earthing
module 9 actuating bars 4 as f ollows: T o the top
position f or opening of bottom shutter and to the
bottom position f or openin g of top shutter.
 Further screw on t he eart hing module 9
insulating plate 1 with three re mov able bushings
as f ollows:
- Contact arms 3 in the bottom position f or
earthing of cable output f eeder.
- Contact arms 3 in the to p posi tion f or earthing
of busbars.
 Insert the earthing mod ule 9 into the test /
disconnected position an d then mov e it into
the
serv ice position with the hand crank (Figure
193).
 Using a high v oltage tester, check that the contact
pins 6 of the earthing module are def initely off
-
circuit.
 W ithdraw the earthing module back into the test /
disconnected position (cha pter 7.1) .
 Mount a co mplete sh ort circuit link 7 on th
e earthing module 9. Connect one end of
earthing
cable 10 under one of three screws M12, with
which sh ort circuit link 7 is connected to cont act
pins 6. Connect the second end of this cable to the
earthing terminal in the p a nel.
 Insert the earthing module 9 with short -circuit link
7 mounted and earthing cable 10 returned f rom the
test / disconnected pos ition into the serv ice
position in the panel with hand crank. For saf ety
reasons, insert the module only with the circuit-
breaker compart ment doo r closed and with door
catches locked.
 Display earthing warning label on the s
witchgear panel door.
 Secure neighboring areas to prev ent inadv
ertent contact with liv e parts (e.g. f eeder cables).
T he procedure f or remov ing earthing is the sa me, onl
y in rev erse order.

Figure 171: Testing and earthing module.

Actuating bars, removable
- top position for bottom shutte
- bottom position for top s
h u t t e r C o n t a c t a r ms , r e m o
vable
- bottom position for cable area
- top position for busbar area
I n s u l a t i n g p l a t e w i t h a l t e r n a t i v e mo u n t i n g p o s i t i o n s f o r c a b l e o r b u s b a r e a r t h i n g ( t u r n t h r o u g h 1
8 0 ° f o r b u s b a r e a r t h i n g ) . C o n t a c t s ys t e ms , r e p l a c e a b l e f o r d i f f e r e n t c o n t a c t p i n d i a m e t e r s o n t h e
switchgear.
B a l l h a n d l e s , r e mo v a b l e , f o r v o l t a g e t e s t s .
Short-circuiting connection - can be replaced with ball handles.

1 I n s u l a t i n g p l a t e w i t h 3 r e mo v a b l e b u s h i n g h s
2 C o n t a c t s ys t e ms
3 C o n t a c t a r ms ( 3 p c s . )
4 Actuating bars (1 pair)
5 Bushings
6 Contact pin
7 S h o r t - c i r c u i t i n g c o n n e c t i o n , c o mp l e t e
8 Ball handles (3 pcs.)
9 T e s t i n g a n d e a r t h i n g mo d u l e w i t h ma n u a l m e c h a n i s m
10 Earthing cable

1
8. Commissioning
8.1 Preparatory work
In preparation f or commis sioning, the f ollowing wor k
must be carried out:
 Check the general condition of the switchgear f
or any da mage or def ects.
 Visually inspect the switching dev
ices, withdra wable parts, isolat ing contacts,
insulating
parts, etc.
 Check connection of the main eart hing bar to the
installation earthing conductor (f ollowing the
appropriate saf ety regulati
ons).
 Check the paint work f or da mage and,
where necessary, touch up as d e scribed in
(chap t er 9. 5) .
 Remov e all residues of materials, f oreign
bodies and tools f rom the switchg ear.
 Clean the switchgear, rubbing down insulating
parts with a sof t, dry, c lean, non -f raying
cloth.
Remov e any greas y or sti cky dirt as described
in
(chap t er 9. 4) .
 Correctly re mount all cov ers etc. remov ed
during assembl y and testing proc edures.
 T ransport caps on heavy dut y v acuum circuit
- breakers if applicable - must be remov ed.
 Lif ting eyebolts on high current v
acuum circuitbreaker s must be re mov ed if still f
itted.
 Preparatory works f or SF6 circuit -breakers: F i g u r e 1 7 2 : W i th d r aw ab l e p ar t w i t h V D 4 t yp e h i g
-Clean the insulating parts with clean dr y h currentcircuit- breaker, pole side.
cloth
-Check that the upper and lower ter minals are 1 T r a n s p o r t c a p s ( t o b e r e m o v e d o n c o m mi s i o n i
ng)
clean and f ree of any def ormation caused b y 2 L i f t i n g e y e b o l t ( t o b e r e m o v e d o n c o m mi s s i o n i
shocks receiv ed during transport and storage ng)
-It is adv isable to check the SF6 gas pressure
 In switchgear pa nels with an additional v
entilation syste m f or high current circuit -breakers
(required
f or ambient te mperature higher than > 40 °C
and/or higher f requency 60 Hz - according to
(chap t er 2.3 ) and (Figure 172) , (Figure 173 ) , f lap
hanging in partition must rest loosely against leaf
spring (with the centrif ugal f an at a standstill,
if f itted). T his i s not standard.

To check:

 Insert a suitable scre wdr iv er through opening

4
(Figure 173 ) in horizontal partition 1 and into
bracket 3 on f lap
5. F i g u r e 1 7 3 : F i t ti n g o f h o r i z o n t a l p a r t i t i o n w i t h
 Swing f lap 5 up wards and allow it to r est loosel a d d i t i o n a l v e n t i l a t i o n fo r h i g h c u r r e n t c i r c u i t -
y again on leaf spring 2. breakers, required due
to increased ambient temperature (>40 °C) and/o
 If the f lap is in the lo cked position, use
the screwdriv er to press leaf spring 2 do wn r i n c r e a s e d f r e q u e n c y ( 6 0 H z ) a c c o r d i n g to s e c t i o
wards b y n 2.3. The internal
f l a p i s s h ow n i n th e s e r v i c e p o s i t i o n ( o p e n ). S i d e
approx. 5 mm to release t he lock bef ore swingin g
v i ew , b u t w i t h o u t t h e w i n d v a n e w i th mi c r o - sw i t c h
the f lap. required with a
 If any centrif ugal f ans controlled in relation fan. Not standard.
to primar y current are f itted, also check that
these 1 H o r i zo n t a l p a r t i t i o n
function correctly. 2 Leaf spring
3 Bracket
On motorized withdra wabl e parts, check the direction 4 Inspection aperture
5 Flap
of rotation of the trav el motor. For any other matter s 6 Centrifugal fan
regarding operation of the withdra wable circ uit -
breaker part and testing f acilities f or the withdrawabl
e part.

1
Figure 174: Horizontal partition with additiona
l ventilationfacilities. Checking unimpeded mo
vement of the internal
flap.
1 Inspection opening

8.2 Measurements and tests

T ests at site are mandatory prior to energization of
the switchgear.
T he main purpose of site tests in general is to mak
e sure the switchge ar is re ady f or en ergization,
not to repeat the f actory testin g and conf irm the f
actor y results. For manuf acturer’s recommendati o n of
test scope and method plea se contact ABB’s Serv ice
Department. Af ter perf orming the t ests, make su re
that all normal serv ice conditions are restored.

W ARNING
 The check is only succ essful if all the
above tests have been passed s uccessfull y.
 If the inspection gi ves negative results,do
not put the apparatus into service but, if
necessar y,
contact ABB’s Customer Service Department.
 Onl y energise the sw itchgear w ith all the
w ithdraw able parts in the test position and w
ith
the circuit-breaker open.

1
9. Maintenance
9.1 Maintenance strategies
Preventi ve maintenanc e is maintenance carried ou t
at predetermined interv als or according to prescribe d
criteria, aimed at redu cing the f ailure risk or
perf ormance degradation of the equipment. T his
method is based o n sched uled activ ities perf ormed o
n the out -of -serv ice equipme nt including: v isual
checks, apparatus cleaning, mechanical co mpo nents
lubrication, worn parts rep lacement and routine test
s.
Risk-based maintenance is mainten ance carried o ut
by integrating anal ysis, measure ment and periodi c
test activ ities with stand a rd prev entiv e maintenanc
e. T he gathered inf ormation is v iewed in the context
of the env ironmental, operati on and process condition
of the equipment in the s yst em. T he aim is to perf
orm the asset condition and risk assessment and def
ine the appropriat e mai ntena nce tasks. Please ref er
to next chapt ers f or details of prev entiv e and risk -
based maintenance progra ms.
Note:
W hen carrying out all maintenance work, th e
regulations in the country of installation must be
strictly co mplie d with. Mai ntenance work ma y onl y b e
perf ormed in a caref ul manner by train ed personn
el f amiliar with the charac teristics of the indiv idual
switchgear, in accordance with all relev ant IEC saf
ety regulations and those of other technical authorities
, and with other ov er -riding instructions . It i s
recommended that ABB serv ice personnel be called in
to perf orm the serv icing and repair work detailed
below. T he inspection and serv icing interv als f or
some of the equipment / co mpo nents (e.g. parts sub
jects to wear) are determined b y f ixed criteria, such
as switching f requency, lengt h of serv ice and number of
short-circuit breaking oper ations. On the other hand
, f or other parts the length of the interv als may depen
d, f or example, on the diff erent modes of operation in
indiv idual cases, the degree of loading, and also
env ironmental inf luences (including pollution an d
aggressiv e air).

T he f ollowing operating instructions must also b

e f ollowed, together with thi s instruction manual in th e
indiv idual cases concerned:
W ARNING - Alw ays follo w 7 safety
steps:  Vacuum circuit -breaker: t ype VD4
(1VCP000001).
 Clearl y identif y the w ork
 Vacuum circuit -breaker: t ype VD4 - high
location current.
 Disconnect and secure against  Vacuum circuit-breaker with magnetic actuator:
reconnection type V M1.
 Protect against an y other live  Gas circuit-breaker: type H D4.
parts  Vacuum contactor: t ype VS
 Take special precautions w hen close to C.
bare  Switch -disconnector NAL -
conductors catalogue.
 Check the installation is  Switch -disconnector - in stallation, serv ice
dead and
maintenance instruction manual.
 Carr y out earthing and s hort  Operating mechanis ms of the circuit -breakers
circuiting with high v oltage - catalogue.
 Issue a permit to w  Motor operator UEMC 40 K3 - installation, serv ice
and maintenance instruct ion manual (f or
ork panels
with NALFE earthing s witc h).

Intervals for inspection, servicing and repairs

9.2 Preventive maintenance
Maintenance serv es to preserv e trouble -f ree
operation and achiev e the longest possible working lif e
of the switchgear. It co mprises t he f ollowing closel y
relate d activ ities:
Inspection: Determination of the actual condition.
Serv icing: Measures to preserv e the specif ied
condition.
Repair: Measures to re st ore the specif ied
condition.
T ime interv als f or mainten ance work to be carried o
ut alwa ys depend on the o perating conditions of the
switchgear, and mainl y on the mode of operation, th
e number of rated and sh ort -circuit current switchi ng
operations, ambie nt te mp erature, pollution etc . W e
recommend carr ying out t he maintenance work at t
he f ollowing interv als:

Activity performe According to sectio T i me i n t e r v a l i n y e a r A c c o r d i n g t o n u mb e r o f s w i t c h i n g o p e r a t i

d n 9.3 s ons
Inspection 4 (1)
(3)
Servicing 9.4 4 (2) 10 000
Repair 9.5 As required As require
d
1
 (1) In more demanding service conditions, we recommend reducing this in
terval suitably.(2) According to the results of the inspection.
(3) See the instruction manuals of the circuit-breakers.
Earthing switch - maximum two closing operations at 100 % of the rated short-circuit making current
r e q u i r e i n s p e c t i o n . No - l o a d p e r m i s s i b l e o p e r a t i o n s t i l l i n s p e c t i o n a n d m a i n t e n a n c e i s r e q u i r e d : 1 0
00 or 4 years

1

9.3 Inspection
Inspection is pri maril y to carry o ut a v isual check f
or grime, corrosion and moist ure:
 Af ter remov al of the bulkhead f rom the circuit -
breaker compart ment, t he main busbars ar e
v isible.
 Visually check that the top monoblocks 4 (Figure
178 ) , where the tulip isolating contact is housed,

 Eff ects of high temperature on the main circuits.

 T races of partial discharge on the insulating
material parts.
 T races of leakage current on the insulating
material parts.
 Surf aces of the contact systems.
Howev er, inspection must also include correct
mechanical / el ectrical operation of the f ollowing
parts: switching dev ices, actuating, interlocking,
protection and signalling d ev ices.

Special conditions
On panels with additional v entilation dev ices due
to increased ambient te mpera ture (chap t er 2. 3) .

 Check f lap 27 (Figure 3 ) f or correct operation, als

o
(Figur e 173 ) .
 T he centrif ugal f an (if f itted) does not require an
y special maintenance. Its working lif e –
depending
on the serv ice conditions, and one signif icant
parameter being the room temperature - is approx.
between 20,000 a nd 30,00 0 operating hours.

Checking readiness f or operation can be carried

out as f ollows:
 Load-dependent f unctional test with controllable
primar y current supply of the relativ e
instrument
transf ormer. On current
rise:
-to appro x. 70 % of the rated ins trument
transf ormer current, the f an must start.
-to 80 % of the rated instrument transf
ormer
current, the f an must hav e reached the r equired
mini mu m air f low. Correspondin g monitorin g
(signalling) by the wind v ane with micros witch.
 Basic checking with te mporary operation of
the centrif ugal f an with an e xternal po wer
suppl y of
230 V AC.
 In both cases, check f or unimpeded nor mal ru
nning of the f an and listen f or any unusual bearing
noise.
Remov e any dirt on the f an
rotor.
 Check unimpeded operati on of the wind v ane
and micros witch b y starting the f an sev eral times.
 T he wiring to remov able horizontal partition
29
(Figure 3 ) can be disconnected behind the right -
hand side duct cov er. Follow the circuit diagram
and caref ully reconnect the wiring again on
completio n.

Caution:
W ith regard to the sw itching devices, their
separate Instruction manuals should be follow ed.

Visual inspection of busbar compartment

 By gaining access f rom the circuit -
breaker compart ment, re mov e bulkhead 3
(Figure 178 ) ,
unscrewing 7 x M8 scre
ws.

1
 are f ully intact and do not show an y sign
of damage.
 Visually check that the in sulating cov ering of
the main busbars and the insulating joining cov
er of
the busbars are f ully inta ct and do not sho w
an y sign of damage.

Cleaning and checking the auxiliar y connections

 Open the miniature circuit -breakers 1 (Figure 175)

positioned inside the lo w v oltage compart ment t
o
remov e the auxiliar y po wer supply to the panel.
 Carry out a v isual inspec tion on all the
cabling, terminal bo xes 2 and che ck f or any
presence of
dirt.
 Manuall y check correct in sertion of the cabling
in the terminal bo x.

F i g u r e 1 7 5 : Au x i l i a r y c o n n e c t i o n s .
1 Circuit breaker
2 T e r mi n a l s

Testing interlock conditions

Carry out a v isual inspection of the mechanical
parts of the interlocks (key locks 1 , door interlocks
1 , f ail saf e 2) and check f or any presence of humidity
and signs of corrosion on the mov ing parts.

F i g u r e 1 7 6 : T e s t i n g i n t e r l o c k c o n d i ti o n s - 1 k e y l
ocks.

1

F i g u r e 1 7 7 : T e s t i n g i n t e r l o c k c o n d i ti o n
s - 1 doorinterlocks, 2 fail safe.
1. T he withdrawable part mu st only be mov able f rom
the test / disconnected position into the serv ice
position when the circuit -breaker is open and the
earthing switch is open . Check the f ollowing
conditions indiv idually:
 W ith the circuit -breaker closed, insertion of the
withdra wable part toward s the serv ice
position
must be locked af ter onl y h alf a turn of the crank
in the clockwis e direction, an d it must not be
possibl e to switch on the trav el motor on motor-
operated withdra wable parts.
 W ith the earthing switch closed, insertion of the
withdra wable part toward s the serv ice
position
must be locked af ter onl y two clock wise turns of
the crank, and it must not be possible to s witch o
n the trav el motor on motor- operated parts.
Use no f orce! Also see the note in (chap t er 7. 1 ) !
2. T he withdrawable part mu st only be mov able f rom
the serv ice position into the test / disconnected
position with the circuit-br eaker open
Check this condition as f
ollows:
 W ith the circuit -breaker closed, withdra wal
mov ement of the withdrawable part must be locked
af ter only half a turn of the crank in anti -clock
wise direction, and it must not be possible to s
witch on the trav el motor on moto r -operated
withdra wable parts.
3. Closing of the circuit -breaker must onl y be
possible wh en the withd rawable part is in th e
def ined test / disconnected position or serv ice
position. T he control wiring plug 2 (Figure 142)
must prev iously hav e been inserted
Check this condition as f
ollows:
 It must not be possible to close the circuit -breaker
with the withdra wable part in any position bet
ween
the test / disconnected position and the serv ice
position. Enabling of switching when th e
withdra wable part mov es i nto the serv ice position
is carried out electricall y by operati on of auxiliar y
switch (Figure 1 6 ) in the withdra wable asse mbl y,
and slightly earlier mecha nically - this corresponds
to a position approxi matel y half a turn of the
crank bef ore the stop.
 For mov ement into the test / disconnected
position, the sa me e nablin g conditions appl y i n
the
same wa y, in this case by means of auxiliar y
switch (Figure 16 ) in the withdrawable asse mbl y.
4. It must onl y be possible to open the circuit -breake
r (manuall y) when the with drawable p art is in th e
serv ice position or test / disconnected position and
the control v oltage ha s f ailed. Check this
condition.
5. W ithdrawable parts with order -related locking
magnet Y0 ma y not be mov ed in case of control
power f ailure, or when there is no control power.
Do not f orcibly mov e locked withdra wable parts!
T he locking magnet Y0 is only present o n manuall
y operated withdra wable par ts. Releasing the
locking magnet Y0:
 Remov e f ront plate.
 Disengage locking magn et Y0 b y pulling th e
magnet ar
mature.
 W hile doing so, turn crank (Figure 193 ) about one
half turn (either direction of rotation is
permissible). T he locking magnet is only activ e in
the test position and serv ice position. In
intermediate positions it h as no eff ect.
6. Disconnection of the control wiring plug 2 ( F i g u r
e
142 ) as well as later inse rtion must be locked in
the withdra wable part ser v ice position. Check this
condition
7. Operation of the earthing switch must onl y b e
possible when withdra wabl e part 1 ( F i g u r e 1 4 5
) is in the test / disconnected position or the
remov ed position (subject to any ad ditional electro
-magnetic interlocks in indiv idual cases).
Check this condition:
 W ith the withdra wable part in the test /
disconnected position, it must be possible to press
slide 2 (Figure 158) , in f ront of the earthing switch
operating shaf t 1, downwards to the opening
position. T he earthing switch can then be
operated.
 W ith the slide pressed down, it must also be
impossible to start the t rav el motor on motor
-
driv en withdrawable
parts.
 If the slide is pressed down sli ghtl y when th e
trav el motor is running, the motor must the
n
automaticall y s witch of f immediatel y. T he
selected trav el direction is continued by pressing
the button It is onl y possible to pre ss slide 2
(Figure 158 ) down f ully with a running trav el
motor when the latter is in the start-up phase.
 W hen the withdra wable part is mov ed in wards
towards the serv ice posi tion, pressing do wn
of
slide 2 (Figure 158 ) must be locked af ter only one
and a half clockwise turns on the crank.
1
9.4 Servicing
W hen, during an inspection as per (chap t er 9.3) , th e 9.4.2 M aintenance in cable compartment
need to carry out cleaning operations is noted, Checking tightening of the cable busbar connections
proceed as f ollows:
 Open the cable co mpar tment door; the
 Clean the surf aces: cable busbar connections are v isible.
Remov e any dry dust d eposits which are  Using a dyn a mo metric spa nner, check tightness
not of all the scre ws. Ref er to t he table on page 51
f or
strongly adherent using a sof t dry
cloth. the tightening v alues.
Remov e an y more adheri ng dirt with ET HANOL
F 25 M. Note
 Clean the insulating s urf aces and the conductiv T he cable compartment d oor cannot be opened if
e components with ET HANOL F 25 M. the earthing switch is open.
 Af ter cleaning, rinse with clean water and dr
y caref ully.
 Should any partial dis charges occur as a
consequence of the condensation phenomenon, a
temporar y re med y which is of ten eff ectiv e is
applica tion of a thin la yer of silicone ov er the
surf ace inv olv ed. For a permanent re me d y to thi s
type of unusual proble m, contact the ABB serv ice
department.

9.4.1 M aintenance in busbar compartment

Checking of the tightening main busbars
 By accessing throu gh the circuit -
breaker compart ment, re mov e the bulkhead 3 ( F i
gure 178)
unscrewing 7 x M8 scre
ws.
 Af ter the remov al of the bulkhead f rom the circuit
- breaker compart ment, t he main busbars ar
e
v
isible.
 Using a dyn a mo metric spa nner, c heck tightness
of all the screws. R ef er to the (chap t er 6.3 ) f or
the
tightening v
alues.

F i g u r e 1 7 9 : I n t e r n a l v i ew o f th e c a b l e c o n n e c t i o n
c o m p a r t m e n t , w i th a m a x i m u m n u m b e r o f s i x
cables inparallel.
1 Earthing switch position indicator
2 Cable busbar connection
3 Fairlead
4 Slotted bottom plate

F i g u r e 1 7 8 : V i ew o f t h e b u s b a r c o m p a r t m e n
t, shownwithout insulating covers.
1 Busbars
2 Branch conductor
3 B u l k h e a d , r e mo v a b l e
4 Tulip isolating contact

1
Earthing sw itches – type EK6; ST -E
Cleaning the kinematics to prev ent f aults on
the signallin g contacts
 Carry out a v isual inspection of the kinematics
and check f or any presence of dirt, hu midit y and
signs
of corrosion on the mov ing parts.
 Manuall y check c orrect ch angeov er of the
earthing switch signalling contacts ( F i g u r e 1 8 1 )
.
 Remov e any dep osits of dust using a dry cloth
that does not leav e any de posits on the
treated
surf aces (do not use woollen cloths).
 If necessary, grease the mechanical mov ing
parts by appl ying a thin layer of mechanical
grease f or
mov ing parts.
Figure 182: Removable circuit-breaker plate.
 Carry out a v isual inspection on the toothed
wheel and pinion 2 (Figure 180 ) and check any
presence
of dirt, humidity and sig ns of corrosion on Instrument transformers
the mov ing parts. Cleaning and checking of the current transf ormers.

 Open the cable compart me nt door.

 Remov e the circuit -break er plate ( F i g u r e 1 8 2 )
to
get larger access.
 Visually check the conn ections of the current
transf ormers.
 Using a dynamo metric spanner, check the
tightness of all the scre ws. Ref er to the table i
n
(chap t er 6. 3 ) f or the tightening v alues.

Cleaning and checking of the v oltage transf ormers an

d anti-f erroresonance circuit.
Fixed v ersion v oltage transf ormers:

 Open the cable compart me nt door.

 Remov e the circuit -break er plate ( F i g u r e 1 8 2 )
to
F i g u r e 1 8 0 : M a n u a l e a r t h i n g sw i t c h o p e r a t i n g m e get larger access.
chanism.  Visually check the v oltage transf
ormer connections.
1 Drive shaft  Using a d yna mo metric sp anner check tightness
2 Auxiliary contact of all the scre ws. Ref er to t he table in (chap t er
6.3)
f or the tightening v alues.
 Carry out a v isual inspection of the transf
ormers and check f or any presence of dirt.
 Remov e any dep osits of dust using a dry cloth
that does not leav e any de posits on the
treated
surf aces (do not use woollen cloths).

Voltage transf ormers in remov able v ersion:

 Open the cable compart me nt door.

 Manuall y withdra w the VT truck.
 Carry out a v isual inspection of the transf ormers
and check f or any presence of dirt.
 Remov e any dep osits of dust using a dry cloth
that does not le av e any de posits on the
treated
surf aces (do not use woollen cloths).
F i g u r e 1 8 1 : C h a n g e o v e r o f t h e e a r t h i n g sw i t c h
signallingcontacts. Voltage transf ormers in wit hdrawable v ersion:

 Open the cable compart me nt door.

 Manuall y withdra w the VT truck.
 Carry out a v isual inspection of the transf ormers
and check f or any pres ence of dirt.
 Remov e any dep osits of dust using a dry cloth
that does not leav e any de posits on the
treated
surf aces (do not use woollen cloths).

1
Cleaning and checking the anti-f erroresonance circuit.
 Open the miniature cir cuit -breakers 1 (Figure
175)
positioned inside the lo w v oltage compart ment t
o that does not leav e any de posits on the
remov e the auxiliar y po wer supply to the panel.
 Carry o ut a v isual in spection on the
anti - f erroresonanc e resistors and
check f or any
presence of dirt.
 Manuall y check correct ins ertion of the cabling.
9.4.3 M aintenance in circuit -breaker compartment
Lubrication of the isolating contacts:
 Remov e any dep osits of dust using a dry cloth
treated
surf a ces (do not use woollen cloths).
 If necessary, grease the mechanical mov ing
parts by appl ying a thin layer of mechanical
grease f or
mov ing parts.

F i g u r e 1 8 3 : An t i - f e r r o r e s o n a n c e r e s i s t o r .

Cleaning and checking of the f uses.

 W ith the VT truck withdra wn, manuall y ho ok up
the f uses contained in the re sin tube of the v
oltage
transf ormers.
 Carry ou t a v isual inspection on the f uses
and check f or any presence of dirt.
 Remov e any dep osits of dust using a dry cloth
that does not leav e any de posits on the
treated
surf aces (do not use woollen cloths).

F i g u r e 1 8 4 : W i th d r aw ab l e p ar t w i t h m e a s u r e m e n t
panel.
1 Resin tube (with fuse)
2 Fuse
3 V o l t a g e t r a n s f o r me r

10
9.5 Repairs
9.5.1 Repair on sw itchgear assembli es
9.5.1.1 Repair of surf ace damage:
 Carry out repair work i mmediatel y af ter a def
ect has been discov ered.
 Completel y re mov e all rust f rom da
maged paintwork areas on steel sheet and
other steel
parts by mechanical mean s, e.g. with a wire brush.
 Lightly grind the surrou nding paint coat
and caref ully degrease the
entire area. T hen
immediatel y appl y an anti - rust primer and, af ter
an appropriate hardening time, appl y the top coat.
Only use suitable and co mpatible paint products.
 Apply the top c oat in stand ard RAL 7035 colour,
or the relev ant special colour.
 Caref ully re mov e any whit e rust on alu miniu
m/zinc surf aces with a wire brus h or cleaning
pad, e.g.
Scotch-Brite, and clean loosely adhering particle s
with a dr y, non -f raying cloth. Next treat the
cleaned parts with zinc sp ray or zinc po wder
paint and, f inally, treat with alu miniu m spra y f or
colour matching.
 Caref ully remov e any whi te rust f rom passiv
ated operating parts and rust f ormation on
phosphatise d
parts with a wire brush or metal -f ree cleanin g
pad, e.g. Scotch -Brite, and clean with a dry cloth.
T hen grease ev enly ( with mech anical grease f or
mov ing parts).
Replacement of the conta ct pins when t he surf ace is
damaged. Af ter an y requi red replacement of contact
pins, the latter should be retight ened using the socket
head bolts - see table ( c h a p t e r 6 . 3 ) .
F i g u r e 1 8 6 : V i ew o f i n s i d e c i r c u i t - b r e a k e r c o
m p a r t m e n t , w i t h d r aw a b l e p a r t r e m o v e d , s h u t t
ers open.
1 Isolating tulip
2 Isolating contact
3 Lo w e r s h u t t e r
9.5.1.2 Repair on earthing switch signaling contact
T he auxiliar y s witches of the interchangeabl e grou p s
are adjusted at the f actory. W hen f inal installation of
the ea rthing switch and operator takes place on site, it
ma y be necessar y to carry out f urther precise
adjust ment of the au xiliar y s witch. In this case, th
e f ollowing should be taken i nto account:
 T here must be a run -on of 0.5 mm in the f
ully operated position b ef ore the plunger reaches
the
stop (f or saf ety
reasons).
 Auxiliar y li mit s witch 4 ( F i g u r e 1 8 7 ) f or
earthing switch ON must be ope rated in the
range of
mov ement of the lev er 5° - 10° bef ore the end
position.
 Auxiliar y li mit s witch 1 f or earthing switch OF
F must be:
- operated on earthing switches with manual
mechanis ms during the op ening mov ement of
slide
2 bef ore half of the hexagonal shaf t has
become v isible, or 1 mm bef ore th e tab of the
slide makes contact with the ar matur e o f the
de -energised
locking magnet.
- operated on earthing switches with motor
operator (no slide 2 f itted) immediatel y af ter the
toggle spring mechanis m has passed the dead
centre position during rotat ion to the OFF position.
 In cases where there has bee n an internal arc is
necessary to repair a nd clean the whole
substation.
F i g u r e 1 8 7 : M a n u a l e a r t h i n g sw i t c h o p e r a t i n g m
echanismwith auxiliary contacts, side protecti
on removed.
1 Q8S1 auxiliary contact – earthing switch OFF
2 Sliding closure
3 Cam plate, adjustable
4 Q8S2 auxiliary contact – earthing switch ON
10
F i g u r e 1 8 8 : E a r t h i n g sw i t c h m o t o r o p e r a t o r w i t
h auxiliarycontacts installed, protections rem
oved.
1 Locking d
isk
2 C a
m
3 Q8S2 auxiliary contact – earthing sw
itch OFF
4 Q8S1 auxiliary contact – earthing s
witch ON

9.5.2 Repairs on w ithdraw able

parts
W hen f unctional tests are carried out on withdrawabl
e parts, compliance with t he conditions listed below
should also be checked. T he f ollowing operating
instructions must also be f ollowed, together with thi s
instruction manual in the i ndiv idual cases conce rned:

 Vacuum circuit -breaker: t ype

VD4
 Vacuum circuit -breaker: t ype VD4 - high
current
 Vacuum circuit -breaker with magnetic actuator:
type V M1
 Gas circuit -breaker: type H
D4
 Vacuum contactor: t ype VS
C
 Operating mechanis ms of the circuit -breakers
with
high v oltage - catalogue

10
9.6 Risk-Based maintenance
ABB supports UniGear us ers with opti mized and co st
eff ectiv e strategies to ensure that the correct action s
are imple mented at the rig ht time. Asset ma nagers ar
e f ully support ed in mov ing f rom conv entional
approaches (‘Correcti v e maintenance’ and ‘Prev entive
maintenance’) to adv anced strategies (‘Risk -base d
maintenance’ and ‘Con diti on -based maintenanc e’).
In this wa y, the serv ice ac tiv ity is no longer driv en
by
predef ined timef rames, observ ations and past
experiences, but takes into account the act ual
condition of the equip me nt, the required reliabilit y
lev el and the expetation f or lif e time extension.
T his assessment is perf ormed b y trained technician s
as part of risk -based maintenance progra ms or is
carried out automaticall y b y on -line monitorin g
syste ms f or condition -based maintenance solutions .
Please ref er to brochure 1VCP000427 - Maintenan ce
by ABB f or more details on Risk -Based maintenance.

9.7 Spare parts, auxillary

materials and lubricants
Spare parts
A spare parts list is av ailable on request f or
procurement of spare parts. It basically include s
mov ing parts and parts subject to wear. W hen parts
are required, the serial number of the rel ev ant
switchgear or s witching dev ice should al wa ys be
quoted.

Au xiliar y materials, lubri

cants

 Lubricant - SYN-setral-EK 339

 Halogen-f ree cleansers (optional) - ET HANOL F
25
M (f or general cleaning);
 T ouch -up pain (optional) - Standard colour
RAL 7035.

10
9.8 Operating accessories

Figure 189: Charging lever (f Figure 190: Double bit key (to u Figure 191: Manual emergency
o r H D 4 t yp e c i r c u i t - b r e a k e r ) se thecentral locking devic e a operating lever (to remove vol
n d th e s c r e w t a g e t o V M 1 t yp e c i r c u i t - b r e a k
t yp e d o o r l o c k ) er)

Figure 192: Operating lev Figure 193: Crank handle (to m Figure 194: Operating lev
e r ( f o r e a r t h i n g sw i t c h ) o v e t h e w i t h d r aw a b l e p a r t i n s i d e r ( f o r sw i t c h -d i s c o n n e c t o
e th e p a n e l ) r)

10
10. Product quality and environmental
protection
T he UniGear panels are produced in compliance wit h T he duty of compan y i s to f acilitate subsequent
the require ments of inter national standar ds f or th e recycling or disposal at the end of product lif e.
quality manag ement s ystem and env ironment al
manage ment s yste m. In these f ields, the lev el of During dis posal of the product, it is alwa ys necessar
excellence achiev ed is documented b y quali ty y to act in accordance with local legal require ments
certif icates according to ISO 9001 and by the EMS in f orce.
according to ISO 14 001.
T he f ollowing methods of disposal are possible:
End of life of product Disposal can either be c arried out ther mall y in a n
ABB is committed to co mp lying with the relev ant incineration plant or by sto ring on a waste site.
legal and other require ments f or env ironmental
protecti on according to the ISO 14 00 1 standard.

R aw m a t e r i a l R e c o m m e n d e d m e t h o d o f d i sp o s a l
Me t a l m a t e r i a l ( F e , Cu, A l , A g , Z n , W , o t h e r S e p a r a t i o i n a n d r e c yc l i n g
s) T h e r mo p l a s t R e c yc l i n g o r d i s p o s a l
Epoxy resin S e p a r a t i o n o f me t a l a n d t h e d i s p o s a l o f r e s t
Rubber Disposal
O i l a s d i e l e c t r i c ( t r a n s f o r me r o i l ) D r a i n i n g f o r e q u i p me n t a n d f u r t h e r r e c yc l i l n g o r d i s p o s
SF6 gas D i as lc h a r g i n g f r o m e q u i p me n t a n d f u r t h e r r e c yc l i n g o r d i s i
P a c k i n g ma t e r i a l - wood posal R e c yc l i n g o r d i s p o
P a c k i n g ma t e r i a l - f o i l R e c yc l i ns g
a lo r d i s p o
sal

10
1VLM000363 - A, EN - Inst ruction manual - 2015.1 1 (Unigear ZS1)
(gs)

Y o u r s a l e s c o n t a c t : w w w . a b b . co m / c
ontacts
M o r e p r o d u c t i n f o r m at i o n : w w w . a b b . c o m / p r
oductguide

T h e d a t a a n d i l lu s t r a t i o n s a r e n o t b i n d i n g . W e r e s e r v e t
h e r i g h t t o m a k e c h a n g e s wi t h o u t n o t i c e i n t h e c o
u r s e o f t e c h n i c a l d e v e lo p m e n t o f t h e p r o d u c t .

© Copyright 2015 A
BB.All rights reser
ved.