ABB UniGear ZS3.2 Instruction Manual
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ABB UniGear ZS3.2 Instruction Manual

Air-insulated medium voltage switchgear
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UniGear ZS3.2
Air-insulated medium voltage switchgear
Instruction manual
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Summary of Contents for ABB UniGear ZS3.2

  • Page 1 UniGear ZS3.2 Air-insulated medium voltage switchgear Instruction manual...
  • Page 2 Your safety first – always! That's why our instruction manual begins with these recommendations: • Only install switchgear and/or switchboards in enclosed rooms suitable for electrical equipment. • E n s u r e t h a t i n s t a l l a t i o n , o p e r a t i o n a n d m a i n t e n a n c e a r e c a r r i e d o u t b y specialist electricians only.

  • Page 3: Table Of Contents

    Earthing the switchgear this manual – or extracts – to third parties is prohibited. Concluding installation work The data and illustrations are without engagement. Operation of the switchgear Subject to change without notice. Commissioning ABB Xiamen Switchgear Co., Ltd. 6.1.1 Preparatory work...

  • Page 4: General

    Standards and specifications According to VDE 0670 part 1000 and IEC 62271-100, the manufacturer and user may agree on special UniGear ZS3.2 switchgear panels comply with the service conditions which deviate from the normal stand-ards and specifications for factory-as- service conditions. The manufacturer must be...

  • Page 5: Technical Data

    Technical data Electrical data Rated voltage 40.5 Rated power frequency withstand voltage Rated lightning impulse withstand voltage Insulation to: DIN VDE/IEC Chinese GB Rated frequency 50/60 Rated current of busbars ...3150 …3150 Rated current of tee-offs, circuit-breaker ...3150 …3150 Rated peak withstand current ...80 ...80 Rated short-circuit breaking...
  • Page 6 Figure 2/1: Dimensions, without ventilation, front view. Figure 2/2: Dimension, UniGear ZS3.2, …2000 A, section view. Circuit-breaker compartment Low-voltage compartment Busbar compartment Cable connection compartment...

  • Page 7: Switchgear Panel Structure And

    Switchgear panel structure and with-drawable part 50 removed (hinged shutters 35.1/ 35.2 in the closed position), there is protec- equipment installed tion against contact with live parts in busbar com- partment C and cable connection compartment D. Basic structure and variants The necessary safety measures to counteract the (Figures 3/1 to 3/6) effects of an internal arc fault must be ensured in...

  • Page 8: Interlocks/Protection Against Maloperation

    connector 10. led through generously dimensioned and metal covered ducts. The left-hand duct is reserved for As soon as withdrawable part 50 has been slid into the incoming and outgoing control wires, and the the switchgear panel and its interlock yoke 51 has internal wiring in the panel is located on the right- engaged in the test/disconnected position, it is hand side.
  • Page 9 14.1 14.2 54.4 Figure 3/1: UniGear ZS3.2, front view. Earthing switch, operation mechanism 14.1 Hexagonal shaft 54.5 14.2 Slide 54.6 Spindle ON-OFF operating shaft 54.4 Labels for operating advice 54.5 Sight glass 54.6 Ventilation grit below (optional)
  • Page 10 Figure 3/2: UniGear ZS3.2 section view, basic structure of an incoming or outgoing feeder panel, …2000 A. Circuit-breaker compartment Floor cover plate Low-voltage compartment 17.2 Reducer ring Busbar compartment Main earthing bar Cable compartment 20.1 Spout, above Enclosure 20.2 Spout, below...
  • Page 11 35.3 30.1 35.1 35.2 43.1 30.2 19.1 Figure 3/8: Panel of type UniGear ZS3.2, rear side. Figure 3/9: Circuit-breaker compartment, door open, withdrawable part removed. 30.1 Rear cover, above 19.1 Earthing rail 30.2 Rear cover, below 35.1 Hinged shutter system, above 35.2...
  • Page 12 10.1 10.2 10.3 Figure 3/12: Circuit-breaker compartment withdrawable part in Figure 3/11: Circuit-breaker compartment, door open, service position. withdrawable part in service position. Control wiring plug connection engaged. Interlocking arm not in blocking position. 10.1 Control wiring socket 10.2 Control wiring plug 10.3 Interlocking, for control wiring plug, disengaged...
  • Page 13 50.2 57.1 57.8 57.2 50.1 50.8 Figure 3/15: Withdrawable part with circuit-breaker, Figure 3/14: Withdrawable part with circuit-breaker, VD4, VD4, operating side. operating mechanism side control wiring plug pluged at 50.1 Earthing contact front partition of the circuit-breaker. 50.2 Front partition plate 50.8 Wheel 57.1...

  • Page 14: Dispatch And Storage

    Dispatch and storage Transport circuit-breaker unit or metering truck with appropriate care: Please refer to instruction Manual Condition on delivery BA 442/E, section 4, transport The factory assembled switchgear panels are • Only handle modules by crane with transport checked at the works for completeness in terms of crossbeam and a suitable harness with lifting ro- the order and simultaneously subjected to routine pes.
  • Page 15 Switchgear panels with simple packaging or no packaging: • A dry and well-ventilated store-room, atmos- phere in accordance with VDE 0670 part 1000 / IEC 60694. • Room temperature which does not fall below -5°C. • No other detrimental environmental influences. •...

  • Page 16: Assembly Of The Switchgear At Site

    When the final construction • The foundation frame must not be subjected to documents are compiled, the binding data sup- plied by ABB Xiamen Switchgear Co., Ltd. must any injurious impacts or pressures, particularly always be taken into account! during the installation phase.
  • Page 17 Structural data Table for figure 5/1 and 5/2: Rated voltage 40.5 System type UniGear ZS3.2 UniGear ZS3.2 Panel equipment Withdrawable Withdrawable Panel width 1200 1200 Aisle width (front side of panel) 2000 2000 Aisle width (rear side of panel) 1500...

  • Page 18: Assembly Of The Switchgear Panels

    Assembly of the switchgear panels Installation of the busbars and bushings (Figures 3/1 to 3/6, 5/4 to 5/17) (Figures 3/2, 5/7 to 5/17) Use DIN screws of tensile class 8.8. The tightening • Install bushings 29. torques for the busbar screw connections with Note: dished washers are as follows: •...

  • Page 19: Connection Of The Power And

    re as a result of the particular design, but which Connection of the power and control cables are no longer required. (Figures 3/2, 3/9, 5/5 and 5/6) • Insert the withdrawable parts into the switchgear • Insert, cut to length and strip the power cable. panels.
  • Page 20 Figure 5/1: Guideline structural data for foundation frame on concrete floor (for information only). Operator aisle Inspection aisle Opening for power cables Opening for control cables(instead of individual openings, continuous openings or drilled holes are possible) Points for fixing the switchgear panel on the floor frame...
  • Page 21 Opening for control cables (instead of individual openings, continuous openings or drilled holes are possible) Openings for power cables Panel type UniGear ZS3.2 ...31.5 kA (40 kA) Power cables Projecting of floor frame: 5-12mm above finished floor level Conductor to main earthing bar...
  • Page 23 Figure 5/8: Bushings with busbar mountings for busbar system with double D-profile, tee-off ...1600 A. Busbar Tee-off conductor, busbar side 25.5 Sealing ring Bushing plate Busbar bushing 29.2 Busbar mounting for double conductor Partitioning 29.2 25.5 Figure 5/9: Bushings with busbar mountings for busbar system with double D-profile, tee-off ...2000 A to 3150 A.
  • Page 24 Detail of a busbar bushing, sectional view. Always check that there is proper contact between the metal tube in the bushing and the busbar via the contact spring. 3.12 Busbar section (length) 29.1 Busbar mounting for single conductor 29.2 Busbar mounting for double conductor 29.3 Contact spring 29.4...
  • Page 25 Figure 5/15: Arrangement and bolting of single and double conductor busbars with single and double tee-off bars. Ensure that screws and accessories of the specified quality are used! Use 2 dished washers per screw. Busbar Tee-off conductor Spacer plate, 15mm Spacer plate, 10mm Busbar bushing Insulation cover...
  • Page 26 D 100 Figure 5/17: Insulating covers for busbars. 58.5 Lid for cover Figure 5/18: Guiding ramp for circuit-breaker insertion, optional. The rail on the guiding ramp must be in line with the guiding rail in the UniGear ZS3.2 panel.

  • Page 27: Operation Of The Switchgear

    Operation of the switchgear • Instruct the local operators in the fundamen- tal details of regular handling of the switchgear. Note on safety at work • Check the readiness for operation and switch- The relevant work and operating procedures are ing status of electrical systems upstream and to be carried out carefully by trained specialists down stream from the switchgear.

  • Page 28: Circuit-Breaker

    • Turn the crank clockwise through approx. 45 444/E, EK6 earthing switch. turns until the stop is reached and the withdraw- The earthing switch type EK6 has a snap-action able part is in the service position. closing mechanism which is independent of the •...

  • Page 29: Testing For In-Phase Condition

    different ratings, and the measuring point sock- out with a suitable phase comparator coupled to ets and indicator units are of different types. the measuring point sockets of the capacitive volt- age indication system (if fitted). Note: Test procedure: The only permissible indicators are those which satisfy the requirements of the IEC and VDE stan- •...
  • Page 30 51.1 51.2 51 54.1 50.7 55.7 55.4 55.5 50.6 50.4 Figure 6/1: Withdrawable part with circuit-breaker, VD4, operating mechanism side. 50.4 Guide cam 50.6 Front cover plate, right hand side 50.7 Front coverplate, left hand side nterlock yoke 51.1 Catch pin spring loaded 51.2 Sliding handle Spindle...
  • Page 31 146 52.1 52 Figure 6/3: Fitting the hand cranck (against spring-loaded Figure 6/4: Manual operation of the circuit-breaker, by turning the intermediate plate) to move the truck inside the panel double bit key approx. 15 clockwise (ON), or approx. 15 °...
  • Page 32 Figure 6/7: Operating accessories. 122 Operating lever (for earthing switch) 128 Charging lever (for circuit-breaker) 145 Three bit key (ON-OFF) operation 146 Hand cranck (for moving the withdrawable part) 14.3 14.1 14.4 14.2 14.5 Figure 6/8: Earthing switch operation mechanism. Figure 6/9: Earthing switch operation mechanism (panel front side).
  • Page 33 14.1 6.10 Figure 6/10: Active part of the earthing switch, EK6 mounted in the cable connection compartment shown in open position. Insulated separating plate Bearing bracket Short circuit bridge Pair of earthing blades Bevel gear mechanism (not belonging to the earthing switch) Operating shaft 6.10...
  • Page 34 14.1 Figure 6/12: Bevel gear mechanism and earthing switch, EK6 in open position. Bearing bracket Earthing conductor Bevel gear mechanism (not belonging to the earthing switch) Operating shaft Driver lever 14.1 Hexagonal shaft...

  • Page 35: Maintenance

    • Check the surface condition of the isolating con IEC and of other technical authorities, and with other tact system (for visual examination of the contact overriding instructions. It is recommended that ABB pins with the withdrawable part removed). When service personnel be called in to perform servicing...

  • Page 36: Repair

    Observe the manufacturer’s instructions and the parts with a wire brush or Scotch Sprite, and clean special ABB instruction manuals BA 1002E and with a dry cloth. Then evenly grease the parts BA 1006E respectively on safety at work.

  • Page 37: Testing Of Interlock Conditions

    • With the circuit-breaker closed, withdrawal In the inspection and test operation, the withdraw- movement of the withdrawable part must be able part is to be moved with the crank fitted. blocked after only half a turn of the crank in 1.

  • Page 38: Tests On The Switchgear Panel

    (for general cleaning) of the slide 14.2 must be blocked after only one and a half clockwise turns on the crank. ABB directions for use BA 1002/E GCEA901002P0102 Tests on the switchgear panel • Cold cleanser 716 GCE0007706P0100 7.5.1...
  • Page 39 127.1 57.3 Figure 7/1: Contact system sample for 2000 A to 3150 A. Figure 7/2: Sliding the contact system onto the auxiliary arbour with 1> left: front view the rear end first, schematic representation here for 1600 A. 2> right: rear view 57.3 Contact system, ...1600 A Auxiliary arbour, ...1600 A...

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