ABB UniGear ZS2 Installation, Operation And Maintainance Instructions
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Industrial Equipment
  5. UniGear ZS2 UniSafe 36
  6. Installation, operation and maintainance instructions
ABB UniGear ZS2 Installation, Operation And Maintainance Instructions

ABB UniGear ZS2 Installation, Operation And Maintainance Instructions

Hide thumbs Also See for UniGear ZS2:
Table of Contents

Advertisement

Quick Links

Download this manual
—
M E D I U M VO LTAG E P R O D U C T S
UniGear ZS2
Installation, operation and
maintainance instruction manual

Advertisement

Table of Contents
loading

Related Manuals for ABB UniGear ZS2

Summary of Contents for ABB UniGear ZS2

  • Page 1 — M E D I U M VO LTAG E P R O D U C T S UniGear ZS2 Installation, operation and maintainance instruction manual...
  • Page 2 — ABB’s UniGear ZS2 is a three-phase, metal enclosed, air- insulated switchgear and all units are factory-assembled, type tested and suitable for indoor applications up to 36 kV. The switchgear is designed with a withdrawable type vacuum / SF6 circuit breaker and fitted with a...

  • Page 3: Table Of Contents

    3.2 Resistance to internal arc fault 3.3 Dimensions and weights Switchgear design and equipment Basic structure and variants 4.2 Compartments in UniGear ZS2 4.3 Interlocks and protection against erroneous operations 4.4 Control wiring plug connector coding 4.5 Instructions for floor-rolling version circuit breaker 4.6 ICOG- Incoming and Outgoing type Switchgear...

  • Page 4: Your Safety First - At All Times

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L —...
  • Page 5 WARNING If you have any further questions about this instruction manual, ABB’s field service team will be pleased to provide the required information. We reserve all rights to this publication. Misuse, including in particular, duplication and making this manual –...

  • Page 6: Summary

    Above and beyond this, customized order specific Details like number of heaters, location and data furnished by ABB must also be taken into temperature settings depend on the project, and account. those details must be taken from customer order document.

  • Page 7: Technical Data

    — 3. Technical data 3.1 Electrical data Table 3 : Dimensions of 36kV units; including withdrawable circuit breaker parts Table 1 : Main parameters for switchgear with Rated Current in A Mass in kg Approximate) circuit breaker upto 1250 1300 Rated voltage (Ur) 1600 1500...

  • Page 8: Switchgear Design And Equipment

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L — 4. Switchgear design and equipment 4.1 Basic structure and variants The basis for UniGear ZS2 switchgear is an incoming or outgoing feeder panel with circuit breaker. It is divided into circuit breaker compartment 1, busbar...
  • Page 9 — — Figure 8 - Cross section of BusPT with measurement Figure 5 - Cross section of feeder unit 36kV, 3150A, 31.5kA with Forced Cooling, 2400 mm depth* 1030 — C/S of 2600mm depth panel (3150A FC) — Figure 6 - Cross section of feeder unit 36kV, 3150A, 31.5kA with Forced Figure 9 - Cross section of Coupler Unit 36kV, 630A - 1250A, 31.5kA cooling , 2600 mm depth* 1038...
  • Page 10 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L —...

  • Page 11: Compartments In Unigearzs2

    End covers at lateral sides ensure good The enclosure and internal partitions of appearance and are arc fault proof both UniGear ZS2 are made of 2 mm thick high quality mechanically and thermally, in the event of an Aluminium Zinc coated steel sheets. Three high internal arc fault at end switchgears.
  • Page 12 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L M16X45 Hex M12X80 Bolt...
  • Page 13 4.2.2 Circuit breaker compartment from service to test position is thereby The circuit breaker compartment contains all the established in the main current circuit. Auxiliary necessary arrangements for the rack-in and rack- plug and socket with control wiring are to be out operation of the withdraw-able part inside connected, when circuit breaker in the test/ the switchgear.
  • Page 14 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L 4.2.3 Withdrawable parts 4.2.3.1 Withdrawable circuit breaker parts The withdrawable assembly with the circuit...
  • Page 15 Earthing truck without making capacity (for main busbar system and power cables) These earthing trucks are intended for fail-safe temporary earthing in cubicles for UniGear ZS2 type indoor switchgear. This earthing truck is suitable to earth a circuit which is in OFF condition.

  • Page 16: Interlocks And Protection Against Erroneous Operations

    4.3 Interlocks and protection against erroneous 1 set of current sensors (Figure-current sensor). operations 4.3.1 Standard safety Interlocks UniGear ZS2 has series of interlocks provided as described below to prevent hazardous situations, erroneous operation to protect both personnel and equipment: —...
  • Page 17 4.3.2 Door interlocking UniGear ZS2 is equipped with the following door interlocks: • The circuit breaker can be racked in from Test to Service position only when door is closed. (Fig. 25.1) • The circuit breaker compartment door cannot be opened if the circuit breaker is in Service or in any undefined positions (Fig 25.2)
  • Page 18 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L —...

  • Page 19: Control Wiring Plug Connector Coding

    — Types of interlocks Standard safety interlocks (mandatory) Condition to be fulfilled Type Description Apparatus racking-in/out Apparatus in OFF position Apparatus closing Defined truck position Apparatus racking-in Apparatus multi-contact plug plugged Apparatus multi-contact plug unplugging Truck in test position Earthing switch closing Truck in test position Earthing switch in OFF position, Earthing sw.

  • Page 20: Instructions For Floor-Rolling Version Circuit Breaker

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L 27.1 Swiveling push rod...

  • Page 21: Icog- Incoming And Outgoing Type Switchgear

    • Ensure that the circuit breaker is in OFF condition (in case of VCB) Upon request, UniGear ZS2 switchgear can also • Fit hand crank on square spigot of the spindle be equipped with Ith limiters on the top of each...
  • Page 22 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L —...

  • Page 23: Dispatch And Storage

    30 mm. • Ensure angles above 60 degree from UniGear ZS2 switchgears are checked at ABB horizontal plane for the rope leading to crane works for, hook. • Completeness with reference to the terms on •...

  • Page 24: Unpacking

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L •...
  • Page 25 — Figure 33 - Lifting arrangement assembly 1VYN402901-BG (554685-801) Ordering number for the lifting hook assly For each switchgear unit, instructive labels or sketch is fixed on the wooden crate — Figure 34 - Transportation Advices...
  • Page 26 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L Holes for lifting the circuit breaker Lifting hook arrangement...

  • Page 27: General Site Requirements & Floor Layout

    5.7 General site requirements & floor layout Lift the CB manually or using a suitable hoist, and place it on the trolley. Ensure Removal of CB On commencement of installation on site: lifting hook arrangement before inserting • The switchgear-room must be completely in the panel.

  • Page 28: Foundations

    Designer, a general precedent is min. 3500 mm for 25kA level and min 4000mm for 31,5kA level. Ceiling height The building designer may take more detailed drawings and advices from related ABB Office during order correspondence. In case of installation with arc pressure relief...
  • Page 29 The switchgear is attached to the base irons by frame is installed. A frame produced using special bolt blocks, which can be supplied on suitable steel profiles are used. ABB does not request. supply this frame. •...
  • Page 30 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L •...
  • Page 31 — Figure 39 - Details of Foundation...

  • Page 32: Assembly Of The Switchgear Panels

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L —...
  • Page 33 2. The tightening torques are recommended for screws ISO 4014-4018 and ISO 4762 (tensile class 8.8). If using other types of screws please contact ABB for clarification. Any tightening torques that deviate from those in the general tables (e.g. for contact systems or device terminals) must be taken into account as stated in the detailed technical documentation.

  • Page 34: Installation Of Busbars

    Accesses for the main busbars installation are from sides and from top of the UniGear ZS2 switchgear. It is recommended to carry out busbar assembly along with erection of individual switchgear;...
  • Page 35 630A/1250A Dropper-630A/1250A Busbar (Copper) Busbar Assembly 2500A/3150A(FC) (Copper) 2000A Dropper-2500A Busbar (Copper) 2000A Dropper-2000A Busbar(Aluminum) 1250A Dropper-1250A Busbar(Aluminum) Busbar Assembly 2500A/3150A(FC) (Aluminum) 1250A Dropper-2500A Busbar(Copper)
  • Page 36 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L Busbar Tee-boot or Shroud Busbar shrouds are provided for all main busbar- dropper connections.

  • Page 37: Cable Connection

    The standard method for terminating power period of operating time and therefore it is not cables in UniGear ZS2 switchgear is shown in necessary to inspect tightness of busbar Fig.47. Power cables are conveyed below through...
  • Page 38 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L Mounting procedures for power cables •...
  • Page 39 — — Figure 51 Figure 53 — — Figure 52 Figure 54 - Sample switchboard — Figure 55 - End covers...

  • Page 40: End Covers

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L 6.3 End covers End covers are provided to be assembled on the switchgear at extreme lateral ends of...

  • Page 41: Unigear Zs2 Digital

    Rated feeder current from 1 250 A up to 2500 A • Busbars up to 2500 A * compared to a conventional UniGear ZS2 • 31.5 kA 3 sec short-circuit current ** compared to typical substation with 14 switchgear panels of •...
  • Page 42 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L —...

  • Page 43: Operation Of The Switchgear

    Set protective devices in the switchgear for the carried out carefully by trained specialists familiar required values and check their functioning with with the operation of UniGear ZS2 switchgear, test equipment. taking into account all required safety regulations according to the IEC and other relevant 8.2 Preparatory work...
  • Page 44 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L 8.3.1 Withdrawable apparatus CAUTION Manual insertion from the Test/Disconnected...
  • Page 45 8.3.3 Earthing switch - type EK6 An additional mechanical switching device for manual operation of the circuit breaker in the The earthing switch EK6 has a snap closing Service position is also installed (see Fig. 26, 27). mechanism which is independent of the rotation If the withdrawable part is in the Service position, of the drive shaft.
  • Page 46 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L —...
  • Page 47 Opening the earthing switch Ensure that the circuit breaker is in test or withdrawn position. The crank entrance is open. Insert the operating lever. This is not possible if the Earth switch is key locked at closed position. Turn the lever anti-clockwise 180º to open the earthing switch.

  • Page 48: Service Trucks

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L Fixed voltage transformer in cable compartment CAUTION! Before accessing potential...
  • Page 49 1. The earthing truck with pre-sensing contacts These trucks consist of circuit breakers fitted is inserted into the switchgear till it reaches either with top terminals (for main busbar its test position. earthing) or with bottom terminals 2. For ensuring safety, the door is closed before (for power cable earthing) racking earthing truck into service position.
  • Page 50 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L 4.
  • Page 51 79.1 - Control wiring socket 79.2 - Interlock 79.3 - Control wiring plug — Figure 79 - Control wiring socket Fig number 80 below represents arrangement involved in Forced cooling fan placement in CB compartment. Radial fan Radial fan — Figure 81 - Forced cooling arrangement...

  • Page 52: Maintenance

    This method is based on scheduled instructions. It is recommended that ABB service activities performed on the out-of-service personnel be called in to perform the servicing and repair work detailed below. The inspection...

  • Page 53: Inspection

    9.3 Inspection cloth. For more strongly adherent grime, use a • Wherever necessary, the working area must be mild alkaline household cleanser or with ETHANOL F 25M isolated and secured against reconnection in accordance with the Safety Regulations • Clean insulating surfaces and conductive specified by IEC and appropriate national components with ETHANOL F 25 M standards before inspection.
  • Page 54 U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L Bus side Voltage transformer in removable version: •...

  • Page 55: Repair

    (do not use woollen cloths). and service positions are signaled by limit switches located on the withdrawable assembly 9.5 Repair and are configured at ABB. These electrical 9.5.1 Switchgear in General indications are mounted on low voltage •...

  • Page 56: Testing Interlock Conditions

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L 2) The withdrawable part must be movable from rack-in of withdrawable part towards the the test/ disconnected position into the...
  • Page 57 9.8.1 Spare parts: The list of spare parts, including moving parts and parts subject to wear, in UniGear ZS2 switchgear and VD4 circuit breaker is available on request. When parts are required, the serial number of the relative device shall always be quoted.

  • Page 58: Product Quality And Environmental Protection

    U N I G E A R Z S 2 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N TA I N A N C E I N S T R U C T I O N M A N U A L — 10. Product quality and environmental protection UniGear ZS2 switchgears are produced in • The duty of the company is to facilitate compliance with the requirements of...
  • Page 60 abb.com...
  • Page 61 abb.com...
  • Page 62 MIDC Estate, Satpur, Nashik - 422 007 Maharashtra, India Customer support Contact: 1-800-420-0707 Customer support: ppmvsupport@in.abb.com ABB Limited operates a process of continuous product development. We therefore reserve the right to change designs, dimensions and data without prior notice. © Copyright 2021 ABB. All rights reserved.

Table of Contents