ZX2

Gas-insulated medium voltage switchgear

Instruction manual BA 435/03 E

PowerIT
Power IT
 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.
• Ensure that installation, operation and maintenance are carried out by
specialist electricians only.
• Comply in full with the legally recognized standards (DIN VDE / IEC), the
connection conditions of the local electrical utility and the applicable safety
at work regulations.
• Observe the relevant information in the instruction manual for all actions
involving switchgear and switchboards.

• Danger!

Pay special attention to the hazard notes in the instruction manual marked with
this warning symbol.
• Make sure that under operation condition of the switchgear or switchboard
the specified data are not exceeded.
• Keep the instruction manual accessible to all persons concerned with
installation, operation and maintenance.
• The user’s personnel are to act responsibly in all matters affecting safety at
work and the correct handling of the switchgear.

WARNUNG
Anerkannte Regeln der Technik und Betriebsanleitungen
beachten !

Gefährliche Spannung
kann elektrischen Schock und Verbrennungen verursachen.
Vor Aufnahme von Arbeiten jeder Art dieses Gerät unbedingt freischalten,
erden und kurzschließen.

WARNING
Always observe the instruction manual and follow the rules
of good engineering practice !

Hazardous voltage
can cause electrical shock and burns.
Disconnect power, then earth and short-circuit before proceeding
with any work on this equipment.

If you have any further questions on this instruction manual, the members of our
field organization will be pleased to provide the required information.
Contents Page Contents Page

1 Summary 3.12.3.3 Interlocking of the mechanical ON

1.1 General 6 pushbutton for the circuit-breaker
(optional) 23
1.2 Standards and specifications 6
3.13 Earthing a tee-off in a single
1.2.1 Switchgear manufacture 6 busbar system 23
1.2.2 Installation and operation 6 3.13.1 Electrical operation using the
1.3 Operating conditions 6 multifunctional protection and control
unit REF542 plus 23
1.3.1 Normal operating conditions 6
3.13.2 Manual earthing 24
1.3.2 Special operating conditions 7
3.13.3 Automatic earthing (optional) 24
2 Technical Data 8
3.14 Earthing the busbar in a single
2.1 Panel type ZX2 8 busbar system 24
2.2 Disconnector/earthing switch UX2TE 3.14.1 Electrical earthing of a busbar
and disconnector UX2T 10 section using the sectionaliser 24
2.3 Dimensions and weights 11 3.14.2 Manual earthing 25
2.4 Resistance to internal arc faults 12 3.14.3 Maintenance earthing 25

3 Structure and function of the 3.15 Earthing a tee-off in a double

switchgear system and its equipment 13 busbar system 25
3.1 Structure and equipment 3.15.1 Electrical operation using
of the panels 18 the multifunctional protection
and control unit REF542 plus 25
3.2 Gas system in the panels/switchgear 18
3.15.2 Manual earthing 26
3.2.1 Monitoring of operating pressure 19
3.2.2 Limiting the effects of an arc fault 19 3.15.3 Automatic earthing (optional) 26

3.3 Vacuum circuit-breaker, type VD4 X 19 3.16 Earthing the busbar in a double
busbar system 26
3.4 Disconnector/earthing switch,
type UX2TE 19 3.16.1 Electrical earthing of a busbar
section using the bus coupler 26
3.5 Disconnector, type UX2T 19
3.16.2 Manual earthing 27
3.6 Shutdown system for voltage
transformers in metering panels 20 3.17 Test facilities 27
3.7 Measured value acquisition 20 3.18 Circuit diagrams 28
3.8 High voltage connections 20 3.18.1 Circuit diagram for current sensor 28
3.9 Multifunctional protection and 3.18.2 Circuit diagram for panel with
control unit REF542 plus 20 sensor metrology 29
3.10 Conventional secondary systems in 3.18.3 Circuit diagram for panel with
combination with a protection device 21 conventional metrology 30
3.11 Bay control unit CC (optional) 21
3.12 Protection against maloperation / 4 Despatch and storage 31
interlock dependencies 21 4.1 Condition on delivery 31
3.12.1 Interlocks in general 21 4.2 Packaging 31
3.12.2 Function of the interlock between 4.3 Transport 31
the circuit-breaker and
three position switch / disconnector 22 4.4 Delivery 32
3.12.3 Function of the interlock between 4.5 Intermediate storage 32
the three position switch and
disconnector 22 5 Installation of the switchgear at site 34
3.12.3.1 Electrical interlock 22 5.1 General site requirements 34
3.12.3.2 Mechanical interlock (optional) 23 5.2 Construction data 34

4
Contents Page Contents Page
5.3 Fundamental notes on installation work 35
5.3.1 Tightening torques
Your safety first – always!
5.3.2 Treatment of plug connections with
35
6.3.1 Gas monitoring
6.3.2 Electrical / mechanical
55

display / monitoring 55
silicone insulating parts 35
6.4 Test procedures 55
5.3.3 Notes on cleaning 35
5.3.4 Handling SF6 35 6.4.1 Testing for the off-circuit condtion 55

5.4 Foundation frame 35 6.4.2 Testing for the in-phase condition 55

5.5 Assembly of the foundation frame 36 6.4.3 High voltage tests 56

5.6 Raised false floor 38 6.4.4 Current tests 56
5.7 Erection and connection of the panels 43 6.4.5 Maintenance earthing 57
5.7.1 Preparatory work 43 6.5 Safety note on operation of the
5.7.2 Assembly of the switchgear 43 voltage transformers 57

5.8 Insertion and withdrawal of the voltage 6.6 Application of the X-ray regulations 57
transformer truck 51
7 Maintenance 62
5.8.1 Withdrawal of the voltage transformer truck 51
7.1 General 62
5.8.2 Insertion of the voltage transformer truck 51
7.2 Inspection/servicing 62
5.9 Connection of cables and wiring 51
5.9.1 High voltage plastic-insulated cable 7.2.1 Vacuum circuit-breaker 63
with plug connections 51 7.2.2 Three position switch and disconnector 63
5.9.2 Control cables and wiring 52 7.2.3 Gas system and gas servicing 63
5.10 Preparing the insulating gas system 7.2.4 Emission filter 63
for operation 52
7.3 Repairs 63
5.11 Concluding installation work 52
7.3.1 Vacuum circuit-breaker 63
6 Commissioning/operation 53 7.3.2 Three position switch and disconnector 63
6.1 Commissioning 53
7.3.3 Gas system and gas service 63
6.1.1 Preparatory work 53
7.4 Working and auxiliary materials 64
6.1.2 Initial start up 53
7.4.1 Working materials 64
6.2 Switching operations 53
7.4.2 Auxiliary materials 64
6.2.1 Circuit-breaker 53
7.5 Waste disposal 65
6.2.2 Three position switch and disconnector 54
6.2.3 Undervoltage release 55 8 Table of the equipment
designations used
6.3 Observation of the display and (comparison of VDE and IEC designations) 66
monitoring facilities 55

We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual - or
extracts – to third parties is prohibited. The information supplied is without liability. Subject to alteration.
© ABB Calor Emag Mittelspannung GmbH, 2003

5
1 Summary Details on the technical design and equipment of a
switchgear, such as
• technical data,
1.1 General
• detailed list of equipment fitted,
Fundamental features of the ZX2 panels:
• detailed circuit diagrams, etc.
• Rated voltage up to 36 kV (40.5 kV)
can be found in the order documents.
• Three-phase metalclad
• Gas-insulated 1.2 Standards and specifications
• Busbar compartment as hermetically sealed
1.2.1 Switchgear manufacture
pressure system
The panels comply with the relevant IEC standards
• Circuit-breaker compartment as hermetically
valid at the time of type testing. On the basis of an
sealed pressure system
EU harmonisation ruling, these are equivalent to the
• Microprocessor-based (integrated) protection national standards (e.g. DIN / VDE).
and system technology
• Sensor technology and conventional instrument 1.2.2 Installation and operation
transformers for adapted measured value
acquisition The relevant standards are to be observed during
installation and operation, in particular:
• Indoor installation
• DIN VDE 0101, Power installations exceeding
• Factory assembled AC 1 kV,
• Type tested • DIN VDE 0105, Operation of electrical
installations
Basic panel variants:
• DIN VDE 0141, Earthing systems for special power
• Incoming/outgoing feeder installations with rated voltages above 1 kV,
• Bus sectionaliser in single and double busbar • the accident prevention regulations issued by
systems the appropriate professional bodies,
• Bus coupler in double busbar systems • the safety guidelines for production materials,
• Cable connection panel in single busbar • the order-related details provided by the
systems switchgear manufacturer.
• Metering panel in single and double busbar
systems 1.3 Operating conditions

• Bus sectionaliser without circuit-breaker in sin- 1.3.1 Normal operating conditions

gle and double busbar systems Designed in accordance with DIN VDE 0370
Panel equipment, variants: Part 1000, ”Common specifications for high-
voltage and controlgear standards” and IEC
• vacuum circuit-breaker Publication 60694, with the following limit values:
• single or double busbar systems: • Ambient temperature:

– busbar system 1 with disconnector/earthing – Maximum +40 °C

switch (three-position switch) with functions of: – Maximum 24 hour average +35 °C
• busbar connection, – Minimum (corresponding to
”minus 5 indoor” class) –5 °C
• disconnection,
• Site altitude:
• earthing.
≤ 1000 m above sea level
– busbar system 2 with disconnector with
• Ambient air:
functions of:
The ambient air is not to be significantly
• busbar connection, contaminated by dust, smoke, corrosive or
• disconnection. flammable gases, or salt.

6
1.3.2 Special operating conditions
Special operating conditions are to be agreed by
the manufacturer and operator. The manufacturer
is to be consulted in advance about each special
operating condition:
• Site altitude above 1000 m:
– Observe the manufacturer’s instructions.
• Increased ambient temperature:
– The current carrying capacity is reduced,
– Additional cooling facilities for heat dissipation
are to be provided.
• Climate:
– The risk of corrosion or other impairment, e.g.
in the control cabinets, is to be avoided in
areas:
• with high humidity and/or
• with major, rapid temperature fluctuations.
– Take countermeasures to prevent con-
densation phenomena (e.g. provide electric
heaters).
• Seismic withstand capability:
– Tested to IEEE Std. 693 Draft, 1997.

7
2 Technical data

2.1 Panel type ZX2

Electrical data IEC standard series Special series

Rated voltage kV 12 24 36 –
Maximum operating voltage kV 12 24 36 40.5
Rated power frequency withstand voltage kV 281) 501) 701) 85
Rated lightning impulse withstand voltage kV 75 125 170 185
All voltages apply to a minimum
operating pressure for insulation,
absolute, at 20 °C, of kPa2) 100 100 100 120
Rated frequency Hz 50/60
Rated current of busbars A 1250/2500A
Rated current of tee-offs3) A 1250/2000/2500A4)
Rated peak withstand current 3) kA …100 …100 …100 …100
Rated short time current 3 s3) kA …40 …40 …40 ...40
Rated short-circuit breaking current of
the circuit-breaker 3 s kA …40 …40 …40 ...40
Rated short-circuit making current of
the circuit-breaker kA …100 …100 …100 ...100
Rated operating sequence O-0,3 s–CO-3 min–CO 5)
Insulating gas system2) 6)
Insulating gas SF67) SF67) SF67) SF67)
Design pressure, absolute kPa 160 160 160 160
Rated filling pressure for insulation,
absolute, 20 °C (filling pressure) kPa 130 130 130 130
Level for insulation pressure
warning, absolute, 20 °C
(minimum operating pressure) kPa 120 120 120 120
Motor and release data
Chargin motor W < 200 < 200 < 200 <200
Closing coil W 250 250 250 250
Opening coil W 250 250 250 250
Rated supply voltage
DC voltage V 60,110,2208)
Degree of protection (IEC 60529, DIN EN 60529)
Gas-tight enclosure IP65 IP65 IP65 IP65
Control cabinet IP4X9) IP4X9) IP4X9) IP4X9)

1)
Higher values in accordance with international standards on request
2)
100 kPa = 1 bar
3)
For details refer to table: "Panel width-classification" section 2.4
4)
Cooling included
5)
Other operating sequences on request
6)
For further details see BA 427 - insulating gas system for ZX switchgear
7)
Insulating gas: sulphur hexafluoride
8)
Other supply voltages on request
9)
Higher values on request

8
 Assignment of technical data to panel widths

Rated voltage kV 12

Rated short time current Ik, 3s kA 25 25 31,5 31,5 40 40

Rated peak withstand current Ip kA 63 63 80 80 100 100

Rated current of tee-offs Ifeeder A 1250 2000 / 1250 2000 / 1250 / 2000 /
2500 2500 2500

Panel width mm 600 800 600 800 600 800

Rated voltage kV 24 36…40.5

Rated short time current Ik, 3s kA 25 25 31,5 40 25 25 31,5 40

Rated peak withstand current Ip kA 63 63 80 100 63 63 80 100

Rated current of tee-offs Ifeeder A 1250 2000 / 1250 / 1250 / 1250 1250 / 1250 / 1250 /
2500 2000 / 2000 / 2000 / 2000 / 2000 /
2500 2500 2500 2500 2500
Panel width mm 600 800 800 800 6001) 800 800 800
1)
With conventional voltage transformers: panel width 800 mm

9
2.2 Disconnector/earthing switch type UX2TE, and disconnector type UX2T

Test voltages IEC standard series Special series

Rated voltage kV 12 24 36 –
Maximum operating voltage kV 12 24 36 40,5
Rated power frequency withstand
1)
voltage across the isolating distance kV 32 60 80
Rated lightning impulse withstand
1)
voltage across the isolating distance kV 85 145 195
Insulating gas system 3) 4)
Insulating gas SF64) SF64) SF64) SF64)
Rated filling pressure for insulation,
absolute, 20 °C (filling pressure) kPa2) 130 130 130 130
Level for insulation pressure warning,
absolute, 20 °C kPa2) 120 120 120 120
1)
Values on request
2)
100kPa=1bar
3)
For further details see BA 427 -
insulating gas system for ZX switchgear
4)
Insulating gas: sulphur hexafluoride

Rated voltage kV 12/24/36

Test currents
Rated current A 1250 1) 2500 1)
Rated peak withstand current kA …100 ...100
Rated short time current, 3 s kA …40 ...40
Motor data
Motor power, max 2). W 180 180
Motor running times, max 2).:
• Centre position to BB s 18 20
• Centre position to earth s 18 20
Rated supply voltage
DC 3) V 60,110,220
1)
See tables in section 2.1 for panel widths
2)
At rated supply voltage
3)
Other voltages on request

10
2.3 Dimensions and weights
View X

G G G
H E E E
ZX2 ZX2 ZX2 ZX2

X I B B D

26001)
2300 1)
2100
2)
945

1232
F A

4)
n panels 800 600 250 1760 2) 3)

Figure 2/1: Dimensions, double busbar system

Figure shows panels with rated currents ≤ 2000 A.
A Circuit-breaker compartment D Low voltage compartment G Pressure relief duct with absorber
B Busbar compartment E Pressure relief duct, top H End cover
C Cable termination compartment F Pressure relief duct for circuit-breaker compartment I Pressure relief duct, side
1)
Panels with rated currents greater than 2000 A are additionally equipped with a cooling fan or a static heat sink on the panel.
With a cooling fan, the panel height increases by 200 mm to 2500 mm (panel without absorber) or 2800 mm (panel with
absorber). The panel height with a static heat sink is 2865 mm (panel without absorber). The combination of an absorber with a
static heat sink is not possible.
2)
Depending on the switchgear configuration, panels with rated currents greater than 2000 A are equipped with a static heat sink
on the circuit-breaker compartment. The panel depth then increases by 330 mm to 2090 mm.
3)
With a low voltage compartment depth of 500 mm, the panel depth is increased by 100 mm.
4)
n≥1
View X

G G
H E E
ZX2 ZX2 ZX2 ZX2

X I B D

2600 1)
2300 1)
2100

2)
825
1105

F A

4)
n panels 800 600 250 1760 2) 3)

Figure 2/2: Dimensions, single busbar system

Figure shows panels with rated currents ≤ 2000 A.
A Circuit-breaker compartment D Low voltage compartment G Pressure relief duct with absorber
B Busbar compartment E Pressure relief duct, top H End cover
C Cable termination compartment F Pressure relief duct for circuit-breaker compartment I Pressure relief duct, side
1)
Panels with rated currents greater than 2000 A are additionally equipped with a cooling fan or a static heat sink on the panel.
With a cooling fan, the panel height increases by 200 mm to 2500 mm (panel without absorber) or 2800 mm (panel with
absorber). The panel height with a static heat sink is 2865 mm (panel without absorber). The combination of an absorber with a
static heat sink is not possible.
2)
Depending on the switchgear configuration, panels with rated currents greater than 2000 A are equipped with a static heat sink
on the circuit-breaker compartment. The panel depth then increases by 330 mm to 2090 mm.
3)
With a low voltage compartment depth of 500 mm, the panel depth is increased by 100 mm.
4)
n≥1

11
 Weights:
• Weight of a standard panel, double busbar,
panel width 600 mm, rated current ≤ 1250 A: approx. 1250 kg
• Weight of a standard panel, double busbar
panel width 800 mm, rated current ≤ 2000 A: approx. 1800 kg
• Weight of a standard panel, double busbar,
panel width 800 mm, rated current ≤ 2500 A approx. 1900 kg

See section 5.2 for the dimensions of the switchroom (construction data).

2.4 Resistance to internal arc faults

Panel width
600 mm 800 mm

Core modul/BB-compartment 40 kA, 1s 40 kA, 1s

Cable compartment 25 kA, 1s, three-pole 25 kA, 1s, three-pole

Criteria 1-6 of PEHLA Directive No. 4 (in conjunction with VDE 0670 Part 6 Appendix AA or IEC 60290,
Appendix AA) are fulfilled.
The panels have integrated pressure relief ducts with facilities for:
• channelling via an absorber to the last two panels (when the ceiling height is sufficient), or
• channelling out of the switchroom as suitable for the building.

12
3 Design and function of the switch-
gear system and its equipment
2.3 2.5

4.3

1.2

Figure 3/1: Panel, front view Figure 3/2: Panel type ZX2 with control cabinet open

4.2

4.7

4.6

4.5

4.3

Figure 3/3: Control unit for multifunctional protection and control

unit REF542 plus

13
 1.7

2.9
2.2
2.4

4.0

1.0 3.6

Figure 3/4: Panel for 2000 A with conventional instrument

3.0 transformers, double busbar, with pressure relief ducts at
top and rear.

The side walls of busbar compartments 1 and 2, the

circuit-breaker compartment (1.0) and cable termination
compartment (3.0) are cut away to provide for a clearer
illustration.

2.11

Figure 3/5: Pressure relief disk for a busbar compartment in the Figure 3/6: Vacuum circuit-breaker type VD4 X (before installation in
upper pressure relief duct the works)

14
 -Q5 -Q1 -Q5 -Q1 -Q52 -Q11 -Q51 -Q12

*) *)
-Q0

*) *) *) *) *) *)

Feeder Cable connection Bus sectionaliser Busbar metering

*) Optionally either voltage sensor or voltage transformer for voltage measurement

Figure 3/7a: Examples of panels type ZX2, with single busbars

-Q5 -Q1 -Q2 -Q52 -Q1 -Q51 -Q2 -Q52 -Q21 -Q51 -Q22 -Q52 -Q11 -Q51 -Q12
) )
* *
-Q0 -Q0

*) *)

Feeder Bus coupler Bus sectionaliser

-Q1 -Q2

Bus sectionaliser without c.b. Busbar metering

*) Optionally either voltage sensor or voltage transformer for voltage measurement

Figure 3/7b: Examples of panels type ZX2, with double busbars

15
Figure 3/8: Panel type ZX2, double busbar, 1250 A, Figure 3/9: Panel type ZX2, single busbar, 2000 A,
conventional metrology conventional metrology

Figure 3/10: Panel type ZX2, double busbar, 1250 A, Figure 3/11: Panel type ZX2, double busbar, 2500 A,
sensor metrology sensor metrology, fan cooling

16
Figure 3/12: Panel type ZX2, single busbar, 2000 A, with current sensor and
conventional voltage transformers

E Pressure relief duct, top

F Pressure relief duct for the circuit-breaker compartment

17
3.1 Structure and equipment of the panels
(Figures 2/1, 2/2, 3/1 to 3/16)
The enclosures of the metalclad ZX2 switchgear
panels are laser cut and welded from stainless steel
sheet material.
These and the insulating gas permanently protect
all live parts in the high voltage area from soiling,
humidity, foreign bodies and other injurious
influences.
The modular structure provides the conditions
necessary for all panel variants normally required in
a relatively simple manner.
Facilities are provided, for instance, for:
• one or two busbar systems,
• incoming/outgoing feeder panels,
• bus coupler and bus sectionaliser panels,
• metering panels,
• different connection methods, such as multiple
cables.
Relieved pressure is guided into pressure relief
ducts (E), (F), (G) and (I):
• In the unlikely case of an internal arc fault, the
relevant pressure relief disk opens:
– Pressure relief disk (1.3) on circuit-breaker
compartment (1.0) into pressure relief duct
(F). The gases are channelled out via ducts
(I) and (F).
– Pressure relief disk (2.11) on the busbar
3.2
compartment (2.0 and 2.1) into pressure relief
duct (E). The gases are channelled out via
duct (G).
• In the case of an arc fault in the cable
compartment (3.0), a pressure relief flap (3.5) in
pressure relief duct (F) opens. The gases are
channelled out via ducts (I) and (G).
Each panel is a self-contained unit, whose
busbars (2.8) are connected to the bars of the
adjacent panels by plug-in busbar connections
(2.9).
Basic equipment in the panels:
• Circuit-breaker VD4 X (1.1)
• Three position switch UX2TE (2.2)
• Disconnector UX2T (2.4)
18
• Circuit-breaker compartment (1.0)
– with current transformer
– with hybrid of current transformer and current
sensor
– with current sensors
• One or two busbar compartments (2.0 and 2.1)
• Cable termination compartment (3.0)
– with voltage transformers
– with voltage sensors
– with surge arresters
• Low voltage compartment (4.0), optionally fitted
with:
– multifunctional control and protection unit
REF542plus
– mechanical auxiliary switches in conjunction
with protection relays
– bay control unit CC in conjunction with
protection relays
• Cable and test plug sockets
The insulation test criteria of VDE and IEC list 2 are
fulfilled by the ZX2 standard series up to and
including 36 kV even when the gas filling is at
atmospheric pressure.
For the special 40,5 kV series, the insulation test
criteria are fulfilled at a gas pressure of 120 kPa ab-
solute at 20 °C.
Gas system in the panels/switchgear
(Figure 3/12)
Permanently constant ambient conditions for the
entire live primary area are ensured by the
hermetically sealed encapsulation of the panels
and their filling with dry insulating gas.
• The circuit-breaker compartment (1.0) and the
busbar compartments (2.0 and 2.1) in each
panel are separate gas compartments with their
own filling connectors. The gas compartments in
the individual panels set up side by side are not
connected together.
• Full details on the gas system and gas servicing
of ZX2 switchgear can be found in instruction
manual BA 427 – Insulating gas system for ZX
switchgear.
• The gas compartments contain bags of drying
agent (1.8).
Further details on the drying agent material can be
found in instruction manual BA 427.
3.2.1 Monitoring of operating pressure 3.4
• The rated operational pressure for insulation (pe,
= filling pressure) in the individual compartments
is monitored by temperature compensated
pressure sensors:
– Pressure sensor (1.6) for the circuit-breaker
compartment (1.0),
– Pressure sensors (2.6 and 2.7) for busbar
compartments 1 and 2.
• Any pressure drop below the warning signal level
for insulation (minimum operating pressure) in a
gas compartment is detected and displayed
(on LEDs) by the REF542 plus.
• As an alternative, in versions without the
multifunctional protection and control unit
REF542plus, a pressure drop below the warning
signal level for insulation is indicated by signal
lamps.
3.2.2 Limiting the effects of an arc fault (optional)
In the unlikely event of an internal arc fault, a contact
in the gas density sensor opens a loop line which
runs through all the panels in the relevant busbar
section. If overcurrent is simultaneously detected,
the corresponding circuit-breaker (1.1) is switched
off by the REF542 plus.
Observe the details in the order documents.
3.3 Vacuum circuit-breaker, type VD4 X
(Figures 3/2, 3/6 and 3/12, and instruction manual
BA 436)
Functions of the vacuum circuit-breaker (1.1):
• Opening and closing on rated currents
• Short-circuit breaking operations
• Earthing function in conjunction with three
position switch (2.2).
3.5
The earthing function of the three position switch
prepares - under no current - for the connection to
earth. Earthing proper is performed by the circuit-
breaker. This integration of functions is
advantageous, as a circuit-breaker is of higher
quality in the earthing function than any other
earthing switch.
The circuit-breaker poles are installed horizontally
in the circuit-breaker compartment (1.0). The
circuit-breaker operating mechanism (1.2) is
located outside the gas compartment and is
therefore easily accessible. It is connected to the
breaker poles by a gas-tight thrust bushing.
Disconnector/earthing switch, type UX2TE
(Three position switch)
(Figures 3/2, 3/4 and 3/12)
The ZX2 panels are fitted with specially designed
disconnectors and earthing switches -Q1/-Q5 in
the form of a three position switch (2.2). These
switches are motor-operated rod-type switches
whose live switching components are located in
busbar compartment 1 (insulating gas
compartment), while the operating mechanism
block is easily accessible from the low voltage
compartment (4.0).
The operating mechanism block consists of the
following functional groups:
– Drive motor
– Position sensors with integrated LEDs for
position indication or microswitches and
auxiliary switch block
– Mechanical position indicator
– Emergency manual operation system
– Optional: mechanical access interlock for
emergency manual operation
The three position switch performs the functions of:
• connecting,
• disconnecting and
• earthing.
The three switch positions are unequivocally
specified by the operating mechanism. The switch
has its disconnecting position at the centre. In the
limit positions, disconnector ON and earthing
switch ON, the moving contact (sliding part) driven
by an insulating spindle, reaches the isolating
contacts, which are fitted with one or two spiral
contacts (2.35) respectively.
Disconnector, type UX2T
(Figures 3/2, 3/4 and 3/12)
Disconnector -Q2 (2.4) is a motor-operated rod-
type switch. Its live switching components are
located in busbar compartment 2 (insulating gas
compartment). The operating mechanism block is
split and located outside the gas compartment.
The drive motor (2.5) is located at the rear of the
panel behind a removable cover. The switch
position indicators (sensors and mechanical
indicators) and the emergency manual operation
system are accessible from the low voltage
compartment (4.0). Disconnector -Q2 is structured
similarly to the three position switch, but without
the earthing switch assembly.
19
3.6 Shutdown system for voltage transformers in
metering panels
The shutdown system for voltage transformers in
metering panels is accommodated in the busbar
compartment. The actuating shaft for the first bus-
bar compartment is easily accessible from the low
voltage compartment (4.0). The shaft for the se-
cond busbar compartment is located at the rear of
the panel behind a lockable flap.
The shutdown systems for both busbars can be
operated with standard commercial spanners or
ring keys (size 17).
The shutdown system is only to be operated when
the busbar is in the de-energised condition.
3.7 Measured value acquisition
(Figures 3/3, 3/12, 3/13 to 3/16, 6/3 and 6/4)
Sensors or conventional instrument transformers
may be used as options for adapted current and
voltage detection.
Sensors detect actual operating conditions.
This information is passed on by the multifunctional
protection and control unit REF542plus. Further
details on the REF542plus can be found in the
relevant instruction manual (see section 7.1).
The following sensors are used in ZX2 panels:
• Sensors (2.6, 2.7 and 1.6) for insulating gas
density monitoring
• Sensors to detect the switch positions of the
circuit-breaker, disconnector/earthing switch
and disconnector (2.28 – 2.33)
• Sensor to detect the charging condition of the
circuit-breaker stored energy spring
Arrangement of the current and voltage detection
devices:
The current sensors or transformers are located in
the rear part of the circuit-breaker compartment.
The external connections lead through the cable
termination compartment to the REF542plus or
protection relays.
The voltage sensors or transformers are plug-in
units located in the rear part of the cable
termination compartment.
Arrangement of the sensors:
• Sensors for pressure monitoring:
– (B0G) for the circuit-breaker compartment (1.0):
on the circuit-breaker base plate in the low
voltage compartment (4-0).
– (B1G) for busbar compartment 1:
beside the operating mechanism for the
disconnector/earthing switch -Q1/-Q5 in the
low voltage compartment (4.0).
– (B2G) for busbar compartment 2:
beside the base plate for the drive motor of
disconnector -Q2 at the rear of the panel.
20
• Sensors for detection of the switch positions:
– ((B0E and B0A) for the circuit-breaker:
on its operating shaft.
– (B1E, B1A, B5E and B5A) for the disconnec-
tor/earthing switch:
on its operating mechanism in the low voltage
compartment.
– (B2E and B2A) for the disconnector:
beside its emergency manual operation unit in
the low voltage compartment.
• Sensor (B0S) for detection of the charging
condition of the stored energy spring:
above the spring drum in the circuit-breaker
operating mechanism.
3.8 High voltage connections
(Figures 3/4, 3/8 to 3/12, 5/15 and 5/16)
Cable plug connector systems:
• High voltage plastic insulated cable with internal
cone cable plug connector system and sockets
to DIN 47637.
Plug systems: Size 2 or 3.
Plug-in cable sockets (1.5) mounted in a gas-tight
manner in the floor plate of the circuit-breaker
compartment maintain the partitioning between the
insulating gas compartment and the cable
termination compartment.
The termination height is approx. 600 mm.
• Test socket: plug system size 2.
• Solid-insulated bar system: Connection of a
solid-insulated bar by sockets to DIN 47637 size
3 (max. 1250 A) or by special sockets (max.
2500 A).
The details in the order documentation must be
observed.
3.9 Multifunctional protection and control unit
REF542plus
(Figures 3/3, 3/15 and 3/16)
The following functions are integrated in the panel
control and protection unit REF542plus:
• Protection
• Control
• Measurement
• Switch position indication
• Hazard and fault signalling
• Connection to automation systems
Panel interlocks and the sequence of switching
operations are controlled by the panel unit.
The single line diagram providing information on
switching device positions is made visible on the
LC display (4.7) of the multifunctional protection
and control unit REF542plus.
 Measured values such as conductor currents,
conductor voltages, energy metering and active
and reactive power, number of operating cycles
and number of operating hours appear numerically
and/or as a bar diagram on the display. Further
information, such as alarm and fault signals, is
displayed with text by LEDs (4.6).
The multifunctional protection and control unit
REF542plus can be connected to an automation
system via optical fibre cables. Electromagnetic
interference is avoided by the use of optical
waveguides.
Please consult the REF542plus instruction manual
BA 453 for details on handling of the multifunctional
protection and control unit and a detailed technical
description.
3.10 Conventional secondary systems in
combination with a protection device
(Figure 6/4)
The conventional version of the ZX2 has
microswitches on the operating mechanism base
plate for detection of the position of the three
position switch and disconnector, and 5-pole
auxiliary switches on a separately mounted plate.
These are used to start and stop the relevant drive
motor (disconnector or earthing switch). These
microswitches are positioned in such a way as to
detect the limit positions of the three position
switch and the disconnector.
5-pole sets of positively guided auxiliary switches
(1.32) are available for each of the positions
• of the earthing switch:
– Earthing switch ON
– Earthing switch OFF and disconnector OFF
– Disconnector ON
• of the disconnector:
– Disconnector OFF
– Disconnector ON.
At least four of the ten contacts of the auxiliary
switch on the disconnector and three of the five
contacts of the auxiliary switch on the earthing
switch are pre-assigned for internal purposes
within the panel, such as circuit-breaker inter-
locking or local position indication. The order docu-
ments show the actual assignment of the contacts.
3.11 Bay control unit CC (optional)
• The following functions are integrated in the bay
control unit CC:
– Control
– Switch position indication via mechanical
contacts
– Fault signalling
• Protection against maloperation and the
sequence of switching operations are controlled
by the bay control unit CC.
• Information on switching device positions can be
made visible on display units..
• Floating contacts are available for further signals.
• Please consult the CC instruction manual BA
456 for details on handling and a detailed
technical description of the bay control unit CC.
3.12 Protection against maloperation / interlock
dependencies / earthing of a tee-off
3.12.1 Interlocks in general
(Figures 3/3, 3/12, 6/5 and 6/6)
In order to prevent hazardous situations and
maloperation, a series of interlocks are provided to
protect the operators and the switchgear itself.
Protection against maloperation can be implemen-
ted by
• the multifunctional protection and control unit
REF542plus
or
• bay control unit CC.
The circuit-breaker, three position switch and
disconnector can be controlled directly at the panel
or, by means of a local/remote lock switch, from
the control room. Operation at the panel is by
selection on the REF542 plus or conventionally with
push buttons and bar-type annunciators.
• Three position switch UX2TE or disconnector
UX2T and the corresponding circuit-breaker
type VD4 X are electrically interlocked.
– In the case of manual operation of the three
position switch or disconnector, a mechanical
interlock can become effective (optional).
• Three position switch UX2TE and disconnector
UX2T are electrically interlocked.
– In the case of manual operation of the three
position switch or disconnector, a mechanical
interlock can become effective (optional).
• Details of further interlocks/dependencies, e.g.
with neighbouring systems, can be found in the
relevant order documents for the system
concerned.
• The interlock polling (electrical only) between
panels, where implemented, is effected by loop
lines from panel to panel.
Operation on failure of power supply:
On failure of the power supply, the devices can be
operated manually.
Emergency manual operation:
Where no mechanical interlock or optional interlock
is fitted, intervention in the interlock concept is
possible by opening the low voltage compartment
door. Emergency manual operation is possible by
means of a hand crank and mechanical push
button.
21
 Note:
Perform all switching operations fully until the
defined limit position is reached!
Prior to emergency manual operation, switch the
relevant mcb off.
The details of the individual system ordered are
also to be observed.
3.12.2 Function of the interlock between the circuit-
breaker and three position switch / disconnector
(Figures 6/3 to 6/6 and 7/1)
a) Electrical interlock
The electrical interlock using the multifunctional
protection and control unit REF542plus is
achieved by polling and logical operations on the
positions of the three position switch/
disconnector and the circuit-breaker.
With conventional control systems, polling is
performed by microswitches.
This interlock is always effective when auxiliary
voltage is applied.
b) Mechanical interlock (optional)
The mechanical interlock only permits access to
the manual operating shaft of the three position
switch/disconnector under certain conditions.
When the circuit-breaker is closed, the access
flaps (2.22) for the actuating shafts of the three
position switch and disconnector are blocked. If
the circuit-breaker is open, the relevant flaps can
be opened and a hand crank fitted for operation
of the disconnector or earthing switch. When the
flap is open, electrical and mechanical operation
of the circuit-breaker is prevented.
The flap can only be closed in one of the limit
positions.
The three position switch can be moved by
approx. 24 turns of the corresponding hand
crank either from the:
• disconnector ON position into the
3.12.3
• disconnector OFF / earthing switch OFF
position, or from the
3.12.3.1 Electrical interlock
• earthing switch ON position into the
• earthing switch OFF / disconnector OFF
position.
The disconnector can be moved from the
• disconnector ON position into the
• disconnector OFF position, and back.
Do not use force.
22
A cam on the hand crank (6.1) acting together
with a pin on the operating mechanism prevents
the mechanism from overrunning the centre
position.
If the hand crank is withdrawn in an intermediate
position, the flap in front of the manual operating
shaft cannot be closed. In this position, the
circuit-breaker remains blocked and cannot be
closed.
This intermediate position can be detected on
the one hand by the lack of a mechanical limit
position indication for the three position switch/
disconnector, and on the other hand electrically
at the indicators on the front door.
The limit positions are only correctly displayed
when they have actually been reached, i.e. when
the contacts have their full current carrying
capacity. The flap can then be closed and the
circuit-breaker switched on.
In reverse, when the circuit-breaker is open, the
flaps can always be opened in any intermediate
position and the hand crank fitted.
Emergency manual operation of the three
position switch mechanism in the riser
panel of a double busbar sectionaliser on
failure of auxiliary voltage:
Caution: Interlocks are cancelled during this
operation. Use the circuit-breaker only to open
and close circuits! The three position switch
must be in its limit position!
The access interlock to the emergency manual
operating shaft in riser panels is effected by
means of a blocking magnet.
Withdrawing the interlock pin in the blocking
magnet (2.54 or 2.55) releases the flap (2.22)
and permits access to the emergency manual
operating shaft (2.26 or 2.36).
The details of the individual system ordered are
also to be observed.
Function of the interlock between the three
position switch and disconnector
The electrical interlock is achieved by polling and
logical operations on the positions of the three
position switch and disconnector and the
circuit-breaker.
This interlock is always effective when auxiliary
voltage is applied.
3.12.3.2 Mechanical interlock (optional)
(Figures 6/8 and 6/9a and b)
The mechanical interlock only permits access to
the manual operating shaft of the three position
switch and disconnector under certain
conditions.
When the circuit-breaker is closed, the access
flaps (2.22) for the actuating shafts of the three
position switch and disconnector are blocked. If
the circuit-breaker is open, the flaps can be
opened alternately and a hand crank fitted for
operation of the disconnector or earthing switch.
When one of the flaps is opened, electrical and
mechanical operation of the circuit-breaker and
opening of the flap for the other switch are
prevented.
When the three position switch is in the
disconnector ON position, earthing switch ON
position or an intermediate position, the flap for
the disconnector is blocked. When the
disconnector is in the disconnector ON position
or an intermediate position, the flap for access to
the manual operating system of the three
position switch cannot be opened.
The flaps can only be closed in one of the limit
positions.
If the hand crank is withdrawn in an intermediate
position, the relevant flap in front of the manual
operating shaft cannot be closed. In this
position, the circuit-breaker remains blocked
and cannot be closed.
This intermediate position can be detected on
the one hand by the lack of a mechanical limit
position indication for the three position switch/
disconnector, and on the other hand electrically
at the indicators on the front door.
The limit positions are only correctly displayed
when they have actually been reached, i.e. when
the contacts have their full current carrying
capacity. Only then the flap (2.22) can be closed
and the circuit-breaker switched on.
In reverse, when the circuit-breaker is open, the
flaps can always be opened in any intermediate
position and the hand crank fitted. The flaps can
only be closed when the three position switch or
disconnector has been moved into one of the
limit positions using the hand crank.
Note:
The bus coupler in a double busbar system and
the bus sectionaliser in a single busbar system
are equipped with two three position switches.
Mechanical interlocking of these two switching
devices in these panels is not available.
The details of the individual system ordered are
also to be observed.
3.12.3.3 Interlocking of the mechanical ON pushbutton
for the circuit-breaker (optional)
A blocking magnet prevents closing of the
circuit-breaker on failure of auxiliary voltage
and when the three position switch is in an inter-
mediate position.
Emergency operation of the mechanical ON
pushbutton for the circuit-breaker on
failure of auxiliary voltage.
(Figure 6/10)
Caution: Interlocks are cancelled during this
operation. Use the circuit-breaker only to open
and close circuits! The three position switch
must be in its limit position!
Release the fastening screws on the circuit-
breaker cover. Remove the circuit-breaker
cover. Use a suitable tool to draw the pin in the
blocking magnet (1.33) to the right, and at the
same time move the slide (1.34) to close the
circuit-breaker.
Note:
If the disconnector operating mechanism should
fail during a switching operation with the
disconnector in an intermediate position, the
electrical interlock between the circuit-breaker
type VD4 X and the three position switch type
UX2TE or disconnector type UX2T established
by the REF542 plus is effective. The VD4 X
circuit-breaker could however be closed
mechanically (without blocking magnet) if the
low voltage compartment door is open. Even the
optional mechanical interlock does not prevent
this possibility.
3.13 Earthing a tee-off in a single busbar system
(Figures 3/7a, 6/3 to 6/7 and table in section 8)
3.13.1 Electrical operation using the multifunctional
protection and control unit REF542plus
Operating sequence for tee-off earthing:
• Circuit-breaker (-Q0) OFF.
• Disconnector (-Q1) OFF.
• Earthing switch (-Q5) ON.
• Test for off-circuit condition (using the
REF542plus or capacitive voltage indicator
system).
• Circuit-breaker (-Q0) ON.
• Secure panel to prevent switching operations.
– Mcbs (F101) and (F106) OFF.
– Lock the low voltage compartment door or
secure the mechanical OFF pushbutton for
the circuit-breaker if necessary.
• Label the panel to indicate that earthing has
been effected.
23
 Cancelling the earthing:
• Open the low voltage compartment door and
switch on the mcbs. Release the OFF
pushbutton for the circuit-breaker if necessary.
• Circuit-breaker (-Q0) OFF.
• Earthing switch (-Q5) OFF.
3.13.2 Manual earthing
The sequence is identical to that for electrical
operation, but performed using the mechanical
pushbuttons for the circuit-breaker and the hand
crank for the three position switch.
When an additional mechanical interlock between
the circuit-breaker and earthing switch has been
implemented, the following actions are required:
• Open the low voltage compartment door.
• Switch off the circuit-breaker (-Q0) by operating
the mechanical pushbutton.
• Open the flap on the three position switch
operating mechanism.
Note:
The flap can only be opened when the circuit-
breaker is OFF.
Do not use force!
• Switch off the disconnector (-Q1) with the hand
crank.
• Switch on the earthing switch (-Q5) manually
using the hand crank. (Note: Observe
“Emergency manual operation” in section 6.2.2).
Approx. 24 turns clockwise.
• Close the flap again.
Note: When the flap is open, the circuit-breaker is
blocked in the OFF position.
• Test for the off-circuit condition (capacitive
voltage indicator system).
• Switch the circuit-breaker (-Q0) on using the
mechanical ON pushbutton.
• Secure the panel to prevent switching
operations (mcbs (F101 and F106) OFF).
• Lock the low voltage compartment door or
secure the mechanical OFF button for the
circuit-breaker if necessary.
• Label the panel to indicate that earthing has
been effected.
Cancelling the earthing manually:
• Open the low voltage compartment door and
switch on the mcbs. Release the OFF button for
the circuit-breaker if necessary.
• Switch circuit-breaker (-Q0) OFF with the
mechanical pushbutton.
• Open the flap.
• Switch earthing switch (-Q5) OFF manually.
• Close the flap.
24
3.13.3 Automatic earthing (optional)
Automatic earthing by selecting the earthing
sequence on the display of the multifunctional
protection and control unit REF542plus (this facility
depends on the order placed and requires a
voltage signal from the cable).
• Condition: Circuit-breaker (-Q0) OFF.
Select and start the automatic earthing sequence:
• Disconnector (-Q1) OFF.
• Earthing switch (-Q5) ON.
• Test for off-circuit condition using the
REF542plus,
• Circuit-breaker (-Q0) ON.
• Secure panel to prevent switching operations.
– Mcbs (F101) and (F106) OFF.
– Lock the low voltage compartment door or
secure the mechanical OFF pushbutton for
the circuit-breaker if necessary.
• Label the panel to indicate that earthing has
been effected.
Cancelling the earthing:
• Open the low voltage compartment door and
switch on the mcbs. Release the OFF
pushbutton for the circuit-breaker if necessary.
• Circuit-breaker (-Q0) OFF.
• Earthing switch (-Q5) OFF.
3.14 Earthing the busbar in a single busbar system
(Figures 3/7a, 6/3 to 6/7 and table in section 8)
The procedure for earthing the busbar or a busbar
section is dependent on the configuration of the
system. Systems with sectionalisers permit
earthing of a busbar section.
3.14.1 Electrical earthing of a busbar section using the
sectionaliser
Operating sequence:
• Circuit-breaker (-Q0) in the sectionaliser OFF.
• All disconnectors (-Q1) in the busbar section to
be earthed OFF, apart from the disconnector
between the busbar section to be earthed and
the sectionaliser breaker.
• Switch earthing switch (-Q52 or –Q51) on the
opposite side of the sectionaliser breaker ON
(condition for release for the following step).
 • Sectionaliser breaker (-Q0) ON (testing for the • Label the busbar to indicate that earthing has
off-circuit condition is replaced by closing the been effected.
circuit-breaker).
The busbar is then earthed. All the disconnectors in
• Secure the panel to prevent switching the earthed busbar section are blocked. All the
operations. panels affected are to be secured to prevent
switching operations, e.g. by tripping the mcbs.
– Mcbs (F101) and (F106) OFF.
Cancelling the busbar earthing:
– Lock the low voltage compartment door or
secure the mechanical OFF button for the • Open the low voltage compartment door for the
circuit-breaker if necessary. outgoing feeder and switch the mcbs on, if
necessary releasing the OFF switch for the
• Label the busbar section to indicate that circuit-breaker.
earthing has been effected.
• Circuit-breaker (-Q0) OFF.
The busbar section is then earthed. All the
disconnectors in the earthed busbar section are • Disconnector OFF.
earthed. All the panels in the section concerned are Cancelling the tee-off earthing:
to be secured to prevent switching operations, e.g.
• Earthing switch ON.
by tripping the mcbs.
• Circuit-breaker ON.
Cancelling the busbar earthing:
• Remove the short-circuiting bridge from the test
• Open the low voltage compartment door in
sockets and close the sockets off with blanking
the sectionaliser and switch on the mcbs.
plugs.
Release the OFF button for the circuit-breaker if
necessary. • Circuit-breaker OFF.
• Circuit-breaker (-Q0) OFF. • Earthing switch OFF.
• Earthing switch (-Q51 or –Q52) OFF.
3.15 Earthing a tee-off in a double busbar system
3.14.2 Manual earthing (Figures 3/7b, 6/3 to 6/7 and table in section 8)
Perform the switching operations as described in
3.15.1 Electrical operation using the multifunctional
sections 3.13.1 and 3.14.1 accordingly.
protection and control unit REF542plus
3.14.3 Maintenance earthing of a busbar using the free Operating sequence for tee-off earthing:
test sockets in an outgoing feeder
• Circuit-breaker (-Q0) OFF.
Condition: • Disconnectors (-Q1) and (-Q2) OFF.
• The tee-off is earthed. • Earthing switch (-Q5) ON.
• All disconnectors in the busbar to be earthed are • Test for off-circuit condition.
OFF.
• Circuit-breaker (-Q0) ON (only possible when
There are no electrical interlocks! the REF542plus has detected the off-circuit
Operating sequence: condition and enabled a switching operation).
This requires a voltage signal from a voltage
• Fit a short-circuiting bridge to the test sockets sensor or transformer.
for the earthed tee-off and connect to main
• Secure the panel to prevent switching
earthing bar 3.1.
operations:
• Circuit-breaker OFF.
– Mcbs (F101), (F102) and (F106) OFF.
• Earthing switch OFF.
– Lock the low voltage compartment door or
• Disconnector ON. secure the mechanical OFF pushbutton for
• Circuit-breaker ON. the circuit-breaker if necessary.

• Secure the panel to prevent switching • Label the panel to indicate that earthing has
operations: been effected.

– Mcbs (F101) and (F106) OFF Cancelling the earthing of a tee-off:

– Lock the low voltage compartment door or
secure the OFF button for the circuit-breaker
if necessary.
• Open the low voltage compartment door and
switch on the mcbs. Release the OFF
pushbutton for the circuit-breaker if necessary.
• Circuit-breaker (-Q0) OFF.
• Earthing switch (-Q5) OFF.

25
3.15.2 Manual earthing
The sequence is identical to that for electrical
operation, but performed using the mechanical
pushbuttons for the circuit-breaker and the hand
crank for the disconnectors.
When an additional mechanical interlock between
the circuit-breaker and earthing switch has been
implemented, the following actions are required:
• Open the low voltage compartment door.
• Switch off the circuit-breaker (-Q0) by operating
the mechanical pushbutton.
• Open the flap on the closed device.
Note:
The flap can only be opened when the circuit-
breaker is OFF.
Do not use force!
• Switch off the disconnector (-Q1) or (-Q2) with
the hand crank.
• Close the flap on the disconnector.
• Open the flap on the earthing switch.
• Switch on the earthing switch (-Q5) manually
using the hand crank. (Note: Observe
“Emergency manual operation” in section 6.2.2).
Approx. 24 turns clockwise.
• Close the flap again.
Note: When the flap is open, the circuit-breaker
is blocked in the OFF position.
• Test for the off-circuit condition (capacitive
voltage indicator system).
• Switch the circuit-breaker (-Q0) on using the
mechanical ON pushbutton.
• Secure the panel to prevent switching
operations (mcbs (F101, F102 and F106) OFF).
• Lock the low voltage compartment door or
secure the mechanical OFF button for the
circuit-breaker if necessary.
• Label the panel to indicate that earthing has
been effected.
Cancelling the earthing manually:
• Open the low voltage compartment door and
switch on the mcbs. Release the OFF button for
the circuit-breaker if necessary.
• Switch circuit-breaker (-Q0) OFF with the
mechanical pushbutton.
• Open the flap on the three position switch
operating mechanism.
• Switch earthing switch (-Q5) OFF manually.
• Close the flap.
26
3.15.3 Automatic earthing (optional)
Automatic earthing by selecting the earthing
sequence on the display of the multifunctional
protection and control unit REF542 plus (this facility
depends on the order placed and requires a
voltage signal from the cable).
• Condition: Circuit-breaker (-Q0) OFF.
• Select and start the automatic earthing
sequence:
– Disconnectors (-Q1 and –Q2) OFF.
– Earthing switch (-Q5) ON.
– Test for off-circuit condition using the
REF542plus,
– sCircuit-breaker (-Q0) ON.
– Secure panel to prevent switching operations.
• Mcbs (F101, F102 and F106) OFF.
• ock the low voltage compartment door or
secure the mechanical OFF pushbutton for
the circuit-breaker if necessary.
• Label the panel to indicate that earthing has
been effected.
Cancelling the earthing of a tee-off:
• Open the low voltage compartment door and
switch on the mcbs. Release the OFF
pushbutton for the circuit-breaker if necessary.
• Circuit-breaker (-Q0) OFF.
• Earthing switch (-Q5) OFF.
3.16 Earthing the busbar in a double busbar system
Figures 3/7b, 6/3 to 6/7 and table in section 8)
The procedure for earthing the busbar or a busbar
section is dependent on the configuration of the
system. Systems with bus couplers permit earthing
of a busbar section.
3.16.1 Electrical earthing of a busbar section using the
bus coupler
Operating sequence:
a) Earthing of busbar 1:
• Circuit-breaker in the bus coupler OFF.
• Disconnector (-Q2) in the bus coupler OFF.
• All disconnectors (-Q1) in the busbar
section to be earthed OFF, except for the
disconnector between the busbar section
to be earthed and the coupler breaker.
• Disconnector (-Q1) in the bus coupler ON.
• Earthing switch (-Q51) in the bus coupler
ON.
 • Circuit-breaker in the bus coupler ON
(testing for the off-circuit condition is
replaced by closing the circuit-breaker).
• Secure the panel to prevent switching
operations:
– Mcbs (F101), (F102) and (F106) OFF.
– Lock the low voltage compartment door or
secure the mechanical OFF pushbutton for
the circuit-breaker if necessary.
• Label the busbar section to indicate that
earthing has been effected.
The busbar section of busbar 1 is then
earthed. All disconnectors in the earthed bus-
bar section are blocked.
b) Earthing of busbar 2:
• Circuit-breaker in the bus coupler OFF.
• Disconnector (-Q1) in the bus coupler OFF.
• All disconnectors (-Q2) in the busbar
section to be earthed OFF, except for the
disconnector between the busbar section
to be earthed and the coupler breaker.
• Disconnector (-Q2) in the bus coupler ON.
• Earthing switch (-Q52) in the bus coupler
ON.
• Circuit-breaker in the bus coupler ON
(testing for the off-circuit condition is
replaced by closing the circuit-breaker).
• Secure the panel to prevent switching
operations:
– Mcbs (F101), (F102) and (F106) OFF.
– Lock the low voltage compartment door or
secure the mechanical OFF pushbutton for
the circuit-breaker if necessary.
• Label the busbar section to indicate that
earthing has been effected.
The busbar section of busbar 2 is then
earthed. All disconnectors in the earthed bus-
bar section are blocked.
3.16.2 Manual earthing
Perform the switching operations as described in
section 3.16.1 accordingly.
3.17 Test facilities
(Figures 6/12 and 6/13)
The panels are properly filled with insulating gas at
the works and tested to the VDE or IEC standards.
Should there be any need to perform tests, the
tests are to be performed as follows:
• For voltage and current tests, direct access to
the conductors in the termination area is
possible without releasing the cable connection
or draining off insulating gas. Access is effected
via free cable connecting sockets or via the
cable sockets for the surge arresters.
The surge arresters must be removed during
voltage tests. The exposed sockets must be
closed off with insulating blanking plugs for the
duration of the tests.
• Voltage tests:
– Free cable sockets are to be closed off and
insulated with blanking plugs. See section 6.4
for details of the test procedure and test
voltages.
– Cable tests with DC voltage, or with a very low
frequency (VLF) cosine or square wave
voltage.
– Cable fault location measurements with
impulse voltage, and
– system tests (without cables) with an AC
voltage can be performed with a test plug as
shown in figure 6/12.
• A test plug for current tests as shown in figure
6/13 can be used to test the protection devices
by primary current injection (see also the note
in section 6.4.4).
The possible testing processes are described in the
following sections:
– testing for the off-circuit
condition: Section 6.4.1
– testing for the in-phase
condition: Section 6.4.2
– high voltage tests: Section 6.4.3
– current tests: Section 6.4.4.
27
3.18 Circuit diagrams

3.18.1 Circuit diagram for current sensor

-XI... P1

S1
1
2

640A/150mV S2 Primary conductor

I N = 1250 A
I x = 100 kA
I x = 40 kA
240A/150mV S3

Capacitance C1 = 30 - 40 pF

80A/150mV S4

Ck
Leakage
P2
Capacitance ≤ 25 pF
Pick-off
12/24kV: 10.000:1
-XU... 36kV: 20.000:1 Socket size 2 Socket size 2 or 3

a
1
n
2
Working area
S 1 - S 2 : 320....1280 A
S 1 - S 3 : 120......480 A
S - S : 40......160 A

Figure 3/13: Current sensor for rated voltages up to 36 kV and panel widths 600 mm and 800 mm
with plug-in voltage sensor

-XI... P1
Primary conductor
S1 I N = 2000 A
1 I p = 100 kA
2 I th 3s = 40 kA
Capacitance C1 = 30 - 40
S2

1600 A / 150 mV

Ck
Leakage
P2
Capacitance ≤ 25 pF
Pick-off
12/24kV: 10.000:1
-XU... 36kV: 20.000:1 Socket size 2 Socket size 3

a
1
n
2
Working area
S 1 - S 2 : 800....3200 A

Figure 3/14: Current sensor for rated voltages up to 36 kV and panel width 800 mm
with plug-in voltage sensor

28
3.18.2 Circuit diagram for panel with sensor metrology

L1 L2 L3
-A 200 T1L1 P1 P1 P1
1 S1

Channel X81
1
2 S2
T1L2
1 S1

Channel X82
2
2 S2
I T1L3
II 1 S1

Channel X83
-Q1/Q5 -Q2 3

Tee-off protection; measurment, metering

2 S2

-Q0 X1L1 X1L2 X1L3

P1 P2 P2 P2
3

150 mV -T1L1....L3 T5L1

-X1L1...L3 1 a
Channel X84
P2 4 n
2
-T5L1....L3 T5L2

10.000 : 1 3 1 a
Channel X85
5 n
3 single core cables
2
T5L3

1 a
Channel X86
6 n
2

1
Channel X87
7
2

1
Channel X88
8
2

Figure 3/15: Current and voltage sensors in an outgoing cable feeder panel, up to 36 kV, double busbar

The circuit diagram is identical for single busbar systems, except that tee-off
disconnector -Q2 is missing.

-Q0 Circuit-breaker
-Q1 Busbar tee-off disconnector
-Q2 Busbar tee-off disconnector
-Q5 Tee-off earthing switch
-T1... Current sensors
-T5... Voltage sensor
-X1... Capacitive voltage divider

Inputs and interfaces on the multifunctional

protection and control unit REF542plus:

X81-X83 Measuring inputs for current

X84-X86 Measuring inputs for voltage
-XI... Interfaces for the current sensors
-XU... Interfaces for the voltage sensors
-A 200 Multifunctional protection and control unit REF542plus

29
3.18.3 Circuit diagram for panel with conventional metrology

L1 L2 L3

-A 200
X 80 T1L1 P1 P1 P1
11 S1

Channel
1
3 S2
T1L2
22 S1

Channel
2
14 S2
I T1L3
II 10 S1

Channel
-Q1/Q5 -Q2 3
2 S2

-Q0 X1L1 X1L2 X1L3

3 P1 P2 P2 P2
*) -T1L1....L3
P2
-X1L1...L3
21 a A
Channel
3
4
*) 3 single core cables
17 n N

-T5L1....L3 5 a A
Channel
*) Transformation
Übersetzung fehlt!!!!
ratio according 5
to order documentation 1 n N

23 a A
Channel
6
19 n N

24
Channel
7
20

12

Channel
8
8

Figure 3/16: Conventional current and voltage transformers in an outgoing cable

feeder panel, up to 24 kV, double busbar

The circuit diagram is identical for single busbar systems,

except that tee-off disconnector -Q2 is missing.

-Q0 Circuit-breaker
-Q1 Busbar tee-off disconnector
-Q2 Busbar tee-off disconnector
-Q5 Tee-off earthing switch
-T1... Current transformer
-T5... Voltage transformer
-X1... Capacitive voltage divider
-X80... Interface to the multifunctional protection and
control unit REF542plus
-A200 Multifunctional protection and control unit REF542plus

30
4 Despatch and storage
4.1 Condition on delivery
The factory assembled switchgear panels are
checked for proper assembly and function.
Condition on delivery:
• Compliance of the equipment with the order
checked.
• Routine testing to VDE 0670 Part 6 or IEC 60298
performed.
• Installation material and accessories packaged
separately.
• Bushings for the busbars closed off with non-
insulating transport covers.
• Condition of the gas compartments:
– Circuit-breaker compartments filled with
insulating gas at rated filling pressure for
insulation and fitted with drying agent bags.
– Busbar compartments with heat sinks for
rated currents of 2500 A filled with N2 for
transport.
– Busbar compartments in all other panel
variants filled with insulating gas at rated filling
pressure for insulation and fitted with drying
agent bags.
Note:
• Air freight is to be discussed and agreed in
individual cases.
• The busbar compartments filled on delivery with
the transport filling of N2 (nitrogen) and the
corresponding heat sinks for rated currents of
2500 A must be filled with SF6 prior to
commissioning:
– Release the transport filling (N2) of the heat
sinks into the atmosphere.
– Release the transport filling (N2) of the busbar
compartments into the atmosphere.
– Assemble the panels (mount the heat sinks on
the busbar compartments).
– Insert drying agent bags into the busbar
compartments.
– Evacuate the units (busbar compartment with
heat sink).
– Fill the busbar compartments and heat sinks
with SF6 insulating gas at the rated filling
pressure for insulation.
4.2 Packaging
• Panels with basic packaging or without
packaging.
• Panels with seaworthy or similar packaging (also
containerised for overseas transport):
– sealed in polythene sheeting,
– transport drying agent bags inserted,
– moisture indicators inserted,
– sight window fitted for checking of the indicator
when AL composite sheeting is used.
• Observe the directions for the drying agent bags
to DIN 55473. The following applies:
– Coloured indicator blue: contents dry.
– Coloured indicator pink: contents moist (e.g.
relative humidity over 40%).
4.3 Transport
(Figures 4/1 to 4/2)
Note:
Do not walk on the tops of the panels (pressure
relief system!).
• The transport units are normally individual panels
on pallets.
• Take account of the weights of the transport
units.
• Take account of the high centre of gravity.
• Handle the panels in the upright position.
• Perform loading operations taking account of all
safety precautions to protect personnel and the
material transported.
Safety note:
• Handling by crane:
– Attach suspension ropes.
– Fasten these to the four lifting lugs.
– Use the bolt-on rope guides at the top edge
of the panels.
• Handling in the switchroom can be effected by a
trolley with steerable wheels. Take account of
the high centre of gravity of the panels.
31
4.4 Delivery 2. Panels with seaworthy or similar packaging with
The responsibilities of the consignee include but internal protective sheeting:
are not limited to: • Store the transport units:
• Checking the delivery for completeness and – protected from the weather,
freedom from damage (e.g. also for moisture – in a dry place,
and its injurious effects).
– protected from damage.
• Any deficiencies/transport damage noted
• Check the packaging for damage.
– are to be documented on the waybill,
• Check the drying agent (see section 4.2):
– reported to the shipper/carrier in accordance
– on delivery,
with the ADSP or KVO liability conditions for
German insurance. – later at appropriate intervals.
Note: • When the service life from the date of
packaging has been exceeded (project-
Always document major damage with photographs. related):
4.5 Intermediate storage – the protective effect of the packaging is no
longer ensured,
Conditions for optimum intermediate storage:
– take action for further intermediate storage.
1. Panels with basic packaging or without packaging.
• Dry and well ventilated storage room. Climate
in accordance with VDE 0670 Part 1000/
IEC 60694.
• Room temperature not falling below -5°C.
• No other injurious environmental influences.
• Store the panels upright.
• Do not stack panels.
• Panels with basic packaging:
– open the packaging at least partially.
• Panels without packaging:
– loosely cover with protective sheeting.
– sufficient air circulation must be preserved.
• Check regularly for any condensation.

32
 o
4 5
i n.
m
1.12

ZX2

1.11

725 580 1.16

945
1232

Figure 4/1: Preparation for handling by crane, double busbar system

565 580
825
1105

Figure 4/2: Preparation for handling by crane, single busbar system

33
5 Erection of the switchgear at site 5.1 General site requirements

In the interests of the best possible erection se-
quence, and in order to ensure a high quality stand-
ard of the panels, local installation of the switchgear
should only be carried out, or at least responsibly
managed and supervised, by specially trained
skilled personnel.
At the start of erection, the switchgear room at site
must be complete, fitted with lighting and power for
the erection work, lockable, dry, and with good ven-
tilation facilities. All necessary provisions for laying of
the power and control cables such as openings,
ducts, etc. must already be in place.
Compliance with the conditions for indoor switchgear
to DIN VDE 0670 Part 1000 etc., including those
for the ”minus 5 indoor” temperature class, must
be ensured.

5.2 Construction data

(Figures 5/4 to 5/7)

Panel width mm 600 800 800

Rated current A ≤1250 ≤ 2000 > 2000
Ceiling height1)2):
• without additional absorber mm 2500 2500 –
• with additional absorber mm 2800 2800 –
• with additional cooling fan,
without absorber mm – – 2800
• with additional cooling fan,
with absorber mm – – 3100
Assembly opening1):
• in ceilings: width mm 700 900 900
length mm 1860 4)5) 1860 4)5) 1860 4)5)
• in doors: width mm 1100 1300 1300
height mm 2300 2300 2300
Aisle width3):
• Inspection aisle mm 700 700 700
• Operator aisle mm 1300 1500 1500
Panel weight kg ca. 1250 ca. 1800 ca. 1900
(outgoing feeder, double busbar)
Floor load kg/m2 ca. 1200 ca. 1300 ca. 1400

1)
Minimum dimensions
2)
Panel including top pressure relief duct
3)
Governed by DIN VDE 0101 and the data on maximum panel width.
4)
With a low voltage compartment depth of 500 mm, the panel depth is increased by 100 mm.
5)
With a static heat sink on the circuit-breaker compartment, this measurement is increased by 330 mm.

• The ZX2 switchgear installations are mounted on Note:

a foundation frame set into the screed, or on a
raised false floor.
Floor openings can take the form of large break-
throughs or drill holes, depending on the number
of high voltage cables.
• Openings (drill holes) for power cables in the
station floor are to be constructed so as to be
eddy-current free.
The following is to be taken into account in
determining the foundation data:
• Single busbar systems:
Any additional frame available for the voltage
sensors in the busbar metering system.
The distance from the additional frame including
end coffer to the side wall of the room should be
≥ 500 mm to ensure sufficient room for
movement (see also section 2.3).

34
5.3 Fundamental notes on installation work • Evenly grease the silicone parts with assembly
paste GCE0009098P0101.
5.3.1 Tightening torques
• Use the quantities set out in the table.
DIN-bolts of tensile class 8.8 are to be used.
Component Quantity of assembly
Recommended paste to be used
tightening torque1)
Nm Insulating
part in busbar 2/3 packet (=20 g)
Lubricant2) connection

Thread Without Oil or Sealing

grease plug in busbar 1/3 packet (=10 g)
bushing
M 6 10 ,5 4 ,5
Silicone part on
M 8 26 10 voltage transformers,
voltage sensors, 1/3 packet (=10 g)
M 83) 12 4 ,5
surge arresters,
M 10 50 20 test bushings and
blanking plugs
M 12 86 40
M 16 200 80 • Clean the mating piece for the silicone part – the
cable socket or busbar socket – with cable
1)
• The rated tightening torques for fasteners without cleaner MAB as required and allow it to dry. A
lubrication are based on a coefficient of friction for the light, clean film of grease is permissible.
thread of 0.14 (the actual values are subject to an
unavoidable, partly not inconsiderable, spread). • Assemble the components immediately.
• Rated tightening torques for fasteners with lubrication in
accordance with DIN 43 673. 5.3.3 Notes on cleaning
2)
Thread and head contact surface lubricated.
3)
• Remove any dirt from the surfaces in general
These values apply to welded on studbolts only.
and from insulating material surfaces. Observe
Any tightening torques which deviate from those in the
general table (e.g. for contact systems or device terminals)
the cleaning instructions in section 7.2.
are to be taken into account as stated in the detailed
technical documentation.
5.3.4 Handling SF6
It is recommended that the threads and head contact • As a rule, no gas work is necessary during
surfaces of bolts should be lightly oiled or greased, so as to installation.
achieve a precise rated tightening torque.
• The instructions in gas manual BA 427 are to be
observed when handling SF6.
5.3.2 Treatment of plug connections with silicone
insulating parts • Should gas work be required during installation,
it is to be performed by persons trained in the
• Check the silicone part for damage. If any damage
handling of SF6.
is found on the silicone part, the component may
only be used with the manufacturer’s express
approval. 5.4 Foundation frame
The insulating silicone surface must be free of: (Figures 5/1 to 5/3)

– gas bubbles Switchgear on a foundation frame:

– scoring The relevant data for the order in hand can be

found in the ABB documentation.
– damage
The single or multiple panel foundation frame can
– foreign bodies be supplied with the switchgear. It is as a rule laid
by site personnel and should be aligned and in-
– abrasions
spected under the supervision of a responsible
• Remove surplus grease from the silicone specialist.
part with a soft, clean, non-fraying cloth. To
The specifications of DIN 43 661 are also to be
remove dirt, use only cable cleaner MAB
maintained when laying the foundation frame,
GCE0009100P0100. After cleaning, wipe off
in particular the evenness and straightness
any surplus cleaner with a dry cloth. As the
tolerances as a condition for perfect switchgear
cleaner causes the silicone to swell slightly, it
assembly.
then has to dry for approx. 15 minutes in the air.

35
 Tolerance conditions for laying of the frame to DIN
43 661, version A:
• Evenness tolerance: +/- 1 mm per metre.
• Straightness tolerance: max. 1 mm per metre,
but max. 2 mm for the
entire length of the
frame.

5.5 Assembly of the foundation frame

(Figures 5/1 to 5/3)
• Bolt the individual parts of foundation frame
sections (7.1 and 7.2) together.
• Bolt the resulting individual foundation frame
sections (where the system has several panels)
together using connecting links (7.4).
• Set up the complete foundation frame on the
concrete floor precisely at the specified position.
• Fasten the foundation frame to the concrete
floor sufficiently firmly with the screws (7.7) and
dished washers (7.10), continuously checking
the correct dimensional position.
• Release compensation screws (7.6) and care-
fully align the entire surface of the foundation
frame in the horizontal plane and at the correct
height, using a levelling instrument. The top
edge of the foundation frame must be 1 to 3 mm
above the floor topping (take account
additionally of the material thickness of any
additional floor covering).
• Tighten the compensation screws (7.6), per-
forming a final check on the dimensions and ho-
rizontal position of the frame.
• Perform the necessary work for proper earthing
of the foundation frame with 30 x 4 mm galva-
nised steel strip. Two connections are necessary
in systems with more than 6 panels.
• Carefully backfill the foundation frame when ap-
plying the floor topping.
Note:
Before applying the floor topping, insert auxiliary
screws (7.8). These prevent the floor topping
from penetrating into the nuts. Remove auxiliary
screws (7.8) when the floor topping has hard-
ened.
• The foundation frame must not be subjected to
any undue impacts or pressures, particularly
during the installation phase.

36
 Figure 5/1: Individual parts of a foundation frame section,
2 panel example version

n x FT = a

Panel width FT

7.2
1593
1653

7.1 Panel Foundation frame width a

width Number of panels n
FT 1 2 3 4

600 600 1200 1800 2400

800 800 1600 2400 _

Figure 5/2: Foundation frame

37
 8

9 7.8, 7.9

A 7.4

A
7.0

Section A-A
(without item 1)

1653

1593
7.6, 7.9 7.8, 7.9

7.6, 7.9

7.3
h

7.7, 7.10
7.11

Figure 5/3: Foundation frame on concrete floor

(showing the switchgear panel)

8 Panel
9 Panel fastening screw

5.6 Raised false floor

(Figures 5/6 and 5/7)
When a raised false floor is used, the manu-
facturer’s installation instructions are to be ob-
served. The false floor must satisfy all requirements
specific to the switchgear installation.

38
 A B C

3
1 190 2x210 190 3x150 85 430 1) 580 1) 110

5
8

110 580
1)
400 250 600
800 800 600 800 600 600 800 800 800 1)
50
7 2

A B C 2000

Figure 5/4: Guideline construction data for a foundation frame on a Panel width Low voltage a b c d e
concrete floor in switchboard compartment depth mm mm mm mm mm
See figure 5/5 for sections
600 mm 1377 1465 1300 1100 1760
1)
Minimum 400 mm
800 mm or
1 Inspection aisle 600 mixed 1577 1665 1500 1300 1760
2 Operator aisle with 800 mm
3 Basement entrance
600 mm 1477 1565 1300 1100 1860
4 Platform, approx. 25 kN 500 mm
800 mm or
5 Pressure relief duct at side, including end cover
600 mixed 1677 1765 1500 1300 1860
6 Instead of individual openings, continuous with 800 mm
openings or drilled holes are possible
7 Earthing bar
8 Panel without cable connection, e.g. bus coupler
panel Room height 20 :
9 Door
10 Waste air opening Rated Absorber Room height
11 Intake air opening current
A mm
12 Intake air opening, if required
13 Waste air opening ≤ 2000 with 2800
14 Waste air channel ≤ 2000 without 2500
15 Height of cable basement as required
> 2000 with 3100
16 To earthing bar
17 Opening for control cable > 2000 without 2800

18 Opening for power cable

19 Floor topping, see also figure 5/3

39
 Section A - A Section B - B
1) 1) 1) 2) 1)
700 1760 2) 1500 700 1760 1500

1 2 11 1 2 11

200

200
ZX2 ZX2

1)

1)
20

20
9 9

2600

2600
2100

2100
2300 1)

2300 1)
3x155 565 1300 1) 2x185 600 1300 1)
10 16 165 10 16 165

19 19

625 1665 1) 2) 13 500 1665 1) 2) 13

15

15
130 190 180 190
12 18 17 14 12 18 17 14

1653 1577 1) 2) 1653 1577 1) 2)

a) Panel width 600 mm b) Panel width: 800 mm <= 2000 A

Section C - C
1) 2) 1)
500 330 1760 1500

11
200

1 2
200

1)

ZX2
20

9
2600
2100

2300 1)

3x155 565 1300 1)

10 165

19

16 13
625 1665 1) 2)
15

130 190
12 18 17 14

1653 1577 1) 2)

c) Panel width: 800 mm > 2000 A

Figure 5/5: Sections for figure 5/4

See figure 5/4 for legend and dimensional table
1)
Minimum
2)
With a low voltage compartment depth of 500 mm, this
dimension is increased by 100 mm.

40
 A B
19

500 1)
1)
1 2x210 190

700
190 3x150

330
5
8

3x155
2x185
1593

d
6

565
4

600
1)
400 250 600
800 800 600 800 600 600 800 800 800 1)
50

1)

1)
b
a 1)

c
7 2

A B 2000

M 10 M 10 M 10

100 600 400 100

100 100

Figure 5/6: Guideline construction data for a foundation frame on a

Panel width Low voltage a b c d
concrete floor in switchgear compartment depth mm mm mm mm
See figure 5/7 for sections
1)
600 mm 1377 1300 1100 1760
Minimum 400 mm
800 mm or
1 Inspection aisle 600 mixed 1577 1500 1300 1760
2 Operator aisle with 800 mm
3 Basement entrance
600 mm 1477 1300 1100 1860
4 Platform, approx. 25 kN 500 mm
5 Pressure relief duct at side, 800 mm or
including end cover 600 mixed 1677 1500 1300 1860
with 800 mm
6 Instead of individual openings, continuous
openings or drilled holes are possible
7 Earthing bar
8 Panel without cable connection, e.g. bus coupler panel
9 Door
10 Waste air opening Room height 20 :
11 Intake air opening
12 Intake air opening, if required Rated Absorber Room height
13 Waste air opening current
A mm
14 Waste air channel
15 Height of cable basement as required ≤ 2000 mit 2800
16 To earthing bar ≤ 2000 ohne 2500
17 Opening for control cable
> 2000 mit 3100
18 Power cable
19 Addtional frame in case of feeder > 2000 ohne 2800
with voltage transformer

41
 Section A - A Section B - B
1) 1) 1) 1)
700 1760 b 700 1760 b

13 1 2 11 13 1 2 11

200
200
ZX2 9 ZX2 9

1)
1)
14 14

20
2600
20
2600

2100
2100

2300
2300
3x155 565 c 1) 2x185 600 c 1)
16 16
10 10

A A

12 17 18 112 12 17 18 112

15
15
1293 a 1) 1293 a 1)
300 300

A A

> 0 < 3mm

> 0 < 3mm

77 77

a) Panel width 600 mm b) Panel width 800 mm

Figure 5/7: Sections for figure 5/6

See figure 5/6 for legend and dimensional table
1)
Minimum

42
5.7 Erection and connection of the panels
(Figures 5/3 and 5/8 to 5/14)
Note:
Do not walk on the top of the panels (pressure relief
system!).
5.7.1 Preparatory work
• Grease the upper surfaces of the foundation
frame (this facilitates erection and alignment of
the individual panels).
• Enter the two or four guide pins (2.17) at the
sides of the panels into the relevant bores (see
figure 5/10, section A-A).
5.7.2 Erection of the switchgear
• Erect the end panel of the switchgear at the pre-
cise position specified on the foundation frame.
• Lightly enter panel fastening bolts (7.8) into the
relevant threaded bores in the foundation frame.
• Align the panel.
• Perform a final check on the aligned position of
the panel and fasten it to the foundation frame by
tightening the panel fastening bolts (7.8).
• Remove the protective caps from the busbar
sockets (2.13).
• Carefully check insulating parts (2.14) and
contact tubes (2.21) for any dirt, and clean if
necessary (see also section 7.2 and 5.3.2).
Note:
Only prepare insulating parts and contact tubes
for the panel currently being erected. Protect
them from further contamination!
• Evenly apply a thin coating of assembly paste
AP to the conical surfaces A of insulating parts
(2.14).
Note:
Leave no ungreased areas on conical surface A.
• Carefully insert first contact tubes (2.21) and
then insulating parts (2.14) into the busbar
bushings (2.13).
• Slide the adjacent panel carefully and evenly
(without tipping) against the erected panel in
such a way that the contact tubes, insulating
parts and guide pins slide into the correspond-
ing bores without the use of force.
If necessary, align the panel appropriately.
• As soon as the distance between the two panels
is so small that bolts (2.16 and 2.17) can be
entered in the bores in the erected panel, insert
these, each with nuts and dished washers
respectively. Spacer (2.39) is also to be fitted
on socket head bolt (2.38) (see figure 5/9,
section B-B).
• Then join the two panels together by tightening
bolts (2.15 and 2.16) step by step.
• Completely bolt the panels together with bolts
(1.13), each with dished washers (1.15) (see
figure 5/8).
• When the panels have been completely joined,
check the second panel again for correct align-
ment and fasten it to the foundation frame with
the panel fastening bolts (7.8).
• Dismantle connecting link (3.2) for the main
earthing bar (3.1) in the cable compartment and
lead it through to the adjacent panel. Bolt the
connecting link to the main earthing bar with
bolts (2.15) and one dished washer at each of
the bolt head and nut ends.
• Check the bolted connection between main
earthing bar (3.1) and the connecting link (3.2)
in the previously erected panel and tighten bolt
(2.15) if necessary.
• Erect the further panels by following the same
procedure.
• Assembly of the top pressure relief duct, the ab-
sorber and the cooler if fitted can be effected
during installation of the individual panels or
when all panels have been joined together.
43
 View X
1.13
1.15 1.13 2.17
A 1.15
2.13 2.14
1.13 2.9
1.14
1.15
A B 2.21

1.13
1.13 1.15
1.14
1.15
X

C
1.13
1.15

C 1.13
1.15
1.13
1.14
1.15
a) Double busbar

1.13 1.13
1.15 A 1.15

1.13
1.14
1.15
B A

B 1.13
1.15

1.13
1.14 1.13
1.15 1.15

C
1.13
1.15

C 1.13
1.15
1.13
1.14
1.15

b) Single busbar

Figure 5/8: Installation of the switchgear

(See figure 5/9 for sections and details)

44
 Section A-A
2.15 2.13 2.14

2.9

1)
ca. 50
A
10

Panel division

Section B-B Schnitt C-C Panel division

10 Panel division

3.1
2.16
2.19
3.2
2.19
2.18

2.45 2.40 2.38 2.40 2.39

Figure 5/9: Switchgear erection

(section for figure 5/8)
1)
Evenly greased with assembly paste AP

45
 Section A-A
2.17 2.16
A 2.19 2.17
A
B B 2.18

Section B-B
2.19 2.19

2.18 2.16

a) Panel joined up from the right

2.16 2.17

b) Panel joined up from the left

Figure 5/10: Switchgear erection

panel/panel connection, view from top
(without pressure relief duct)

46
 Detail X
35.2 35.2

43 35.1
X

42
Detail Y
37.2
41
40

Evenly greased,
assembly paste AP

42

Figure 5/11: Busbar end in an end panel

1330 250
665
6.5
6.6 G

J I
2600

Figure 5/12: Pressure relief duct, side, double busbar,

right-hand side mounting shown

G Pressure relief duct with absorber

E Pressure relief duct, top
I Pressure relief duct, side
J Panel

47
 2.13 2.14 2.21 L3 L2 L1

Figure 5/13: Busbar connection Figure 5/14: Assembly of the busbar connection,
Check the fit of the spiral contacts prior to assembly shown for 1250 A

≤ 1250 A, 1 spiral contact • L1: Protective cap removed

≥ 1250 A, 2 spiral contacts • L2: Contact tube (2.21) fitted
• L3: Insulating part (2.14) and contact tube (2.21) fitted

1.5

3.4

K
3.8 3.11 3.3 3.9

Figure 5/15: Plug connector for single core plastic insulated cable Figure 5/16: Cable compartment

K Cable earthing conductor to be connected to station

earth. Observe the manufacturer’s directions for
installation.

48
3.0 3.12 3.15

Figure 5/17: Cable termination compartment with rail for voltage Figure 5/18: Voltage transformer truck
transformer truck, insertion area, shown without shutter

3.13 3.14

Figure 5/19: Locking screw Figure 5/20: Crank

49
 3.16

Figure 5/21: Interlock

50
5.8 Insertion and withdrawal of the voltage trans-
former truck
The following operations should always be
performed by appropriately trained personnel, so
as to ensure correct operation at all times.
5.8.1 Withdrawal of the voltage transformer truck
(Figures 5/17 to 5/21)
Procedure for withdrawal of the voltage trans-
former truck:
• Earth the tee-off (sections 3.12 and 3.14) and
secure it to prevent reconnection.
• Remove the crossbar (3.12) from the lower area
of the cable termination compartment.
• Ensure that the secondary wiring moves freely,
releasing plug connections where necessary.
• Release the locking screw (3.13) on the spindle.
• When the lower stop has been reached, remove
the crank (3.14).
• Draw the voltage transformer truck (3.15) out of
the panel by its handles.
• Fit the protective caps supplied to protect the
silicone parts from soiling.
5.9
• Fit insulating covers to the sockets before
re-energising the feeder.
5.8.2 Insertion of the voltage transformer truck:
(Figures 5/17 to 5/21)
• Fit the hand crank (3.14) and crank the truck
upwards with 4 to 5 clockwise turns until the
interlock engages.
• Check the position of the silicone parts relative
to the sockets and correct if necessary.
• Carefully crank the truck upwards until the
silicone parts are cleanly inserted in the sockets.
• Continue cranking until the mechanical stop
(lock nut on the spindle) is reached.
When raising the voltage transformer truck,
forces are exerted on the floor of the cable
termination compartment.
• Remove the hand crank (3.14) and tighten the
locking screw (3.13).
• Connect the secondary wiring and check that
the connections are firm.
• Refit the crossbar (3.12) in the lower area of the
cable termination compartment.
• Stow the secondary wiring at the side, and fit the
shutter on the cable termination compartment.
• Store the protective caps for the silicone parts
for later use.
Connection of cables and wiring
The cable compartments in the panels are fitted
with cable connection fittings in accordance with
the cable types and sizes specified in the project
planning for the switchgear as a whole.

• Remove the protective caps from the silicone
parts.
• Position the truck in front of the panel and check
it for damage. If any damage is found on the
transformer or silicone part, the transformer may
only be used with the manufacturer’s express
approval.
• Remove surplus grease from the silicone part and
the mounting flange with a soft, non-fraying cloth.
To remove dirt, use only cable cleaner MAB
(GCE0009100P0100). Then allow the parts to dry
for approx. 15 minutes in the air. (See also “Notes
on handling of high voltage plug connections in
silicone rubber for the ZX series of panels”.)
• Evenly grease the silicone parts with assembly
paste GCE0009098P0101. One bag is sufficient
for three silicone parts.
• Check whether the transformer truck (3.15) has
been fully lowered (interlock is raised).
• Clear the insertion area, removing any
secondary wiring from the area as necessary.
• Carefully insert the voltage transformer truck
(3.15) until the rear stop is reached.
5.9.1 High voltage plastic-insulated cable with plug
connectors
(Figures 3/4, 3/11, 5/15 and 5/16)
• Lay the single-core plastic-insulated cables as
specified in the project planning to the individual
panels.
• Remove the transport covers fitted to protect
the sockets.
• Expose the cable cores, check the correct
phase assignment, and secure.
• Fit cable plug (3.4) in accordance with the
manufacturer’s instructions.
• Fit the plugs to the sockets (1.5) mounted in the
circuit-breaker compartment floor (without open-
ing the insulating gas compartment) and secure
them with bolts.
• Align the cables and fasten them at mountings
(3.3)
• Fasten the voltage sensors or transformers
where necessary.
• Close off any unused sockets, e.g. in spare
panels, with suitable cable blanking plugs to
ensure the necessary insulation.

51
5.9.2 Control cables and wiring
(Figures 3/2)
• Establish the necessary connections for incom-
ing and outgoing cables and wiring, and cross
connections.
• The control cables and wiring are to be led into
the low voltage compartment from below and
connected there.
• The connections from panel to panel are to be
made by plug connectors in the control cabinets.

5.10 Preparing the insulating gas system for operation

Observe the relevant data in instruction manual
BA 427/E – Insulating gas system for ZX switch-
gear.

5.11 Final erection work

• Clean the external surfaces of the enclosure and
control cabinets in the switchgear where neces-
sary and check for any damage to the paintwork,
touching up with a suitable paint if necessary
(see Section 7.3).
• Properly refit any cladding and covers of operat-
ing mechanisms, cable ducts, etc. removed dur-
ing the erection work.
• Remove all tools and other foreign bodies from
the switchgear.
• Check the general condition of the switchgear.
• Check that the areas adjacent to the switchgear
are in the proper condition.

52
6 Commissioning/operation
Note on safety at work
• Operation by trained specialists familiar with the
particular switchgear only.
6.1 Commissioning
6.1.1 Preparatory work
In preparation for commissioning, the following
work is to be performed prior to connection with
the high voltage power supply:
• Connect the auxiliary and control voltage and
check the correct polarity.
• Check mechanical and electrical interlocks for
compliance with the specified conditions.
• Perform a functional test on the protective de-
vices (observe DIN VDE 0141).
• Check the overall condition of the system.
• Display the instructions for handling SF6 in the
switchroom.
• Display the ABB instruction manual on the han-
dling of insulating gas and behaviour during
faults in the switchroom.
• Instruct the local operators on the fundamental
details of operating the switchgear in normal
service.
• Check the readiness for operation and the
switching condition of the upstream and down-
stream electrical equipment.
• Perform further checks where necessary on the
following equipment from the areas adjacent to
the switchgear:
– power cables
– control wiring
– auxiliary voltage and its polarity
– remote controls
– external earth with connection to main
earthing bar (3.1)
– switchroom equipment
– switchroom condition.
6.1.2 Initial start-up
• Comply with all relevant safety regulations
• Ensure that the switchgear circuit-breakers are
in the OFF position.
• Close the disconnector for the relevant busbar
system.
• Cancel any existing short-circuiting and earthing
connections in the critical switching area.
• Check that corresponding conductor sections
are in phase where relevant with several incom-
ing feeders and switchgear sections.
• Energise the system step by step, observing the
displays on the REF542plus.
• Check measurements and functions dependent
on high voltage.
• Look out for irregularities of any kind.
6.2 Switching operations
6.2.1 Circuit-breaker
(Figures 3/2, 6/7 and 6/11)
The circuit-breaker is fitted with a charging motor.
Charging of the spring energy storage mechanism
takes place automatically.
Opening and closing the circuit-breaker:
• Opening and closing are effected by operation of
the devices fitted.
• Normal ON-OFF switching operations may only
be performed with the low voltage compartment
door closed.
• Opening the low voltage compartment door may
constitute intervention in the interlock system.
• Observe the position indicator (1.28).
Emergency manual operation:
1. On failure of the charging motor, the charging
process can be performed or completed by
hand:
• Open control cabinet door (4.3).
• Insert charging lever (6.2) into recess (1.31)
and pump for approx. 25 strokes until the
charged condition is displayed.
When the charged condition is reached, the
charging mechanism automatically disengages
and further strokes of the charging lever have no
effect.
Key to the charging condition displays:
Discharged Charged
53
 2. If the control voltage fails with the circuit-breaker
closed, it is possible to open it using the
mechanical OFF push-button (1.26).
Note:
On failure of the control voltage, there is no
maloperation protection for the circuit-breaker,
three-position switch and disconnector during
emergency manual operation.
6.2.2 Three-position switch and disconnector
(Figures 3/2, 3/12, 6/3 to 6/7)
• The three position switch (2.2) and the
disconnector (2.4) are fitted with motor-oper-
ated mechanisms. Opening and closing are ef-
fected by selection on the multifunctional pro-
tection and control unit REF542plus.
• Normal ON-OFF switching operations may only
be performed with the low voltage compartment
door closed.
• Opening the low voltage compartment door may
constitute intervention in the interlock system.
• Observe the position indicator on LCD display
(4.7) or on the control unit (2.27).
• Sensors (2.28 to 2.31) on the three-position
switch operating mechanism (2.3) detect the
following switch positions:
Disconnector -Q1 ON and OFF, and earthing
switch -Q5 ON and OFF.
• Sensors (2.50 to 2.51) on disconnector operat-
ing mechanism (2.4) detect the following switch
positions:
Disconnector -Q2 ON and OFF.
Emergency manual operation:
In place of motorised operation, the switching
process can also be initiated and completed manu-
ally.
Caution!
Opening the low voltage compartment door may
constitute intervention in the interlock system.
• The following operations are to be performed to
open or close the three position switch manually:
– Open the low voltage compartment door
(4.3).
– Switch the circuit-breaker off.
– With the ”mechanical interlock between
circuit-breaker and three position switch“
option, opening the flap on the three position
switch operating mechanism activates a
mechanical interlock between the two devices.
54
Note:
A flap can only be opened when the circuit-breaker
is in the OFF position.
• Prior to emergency manual operation, switch the
relevant mcb (F101 or F102) off.
• Insert the crank in the hollow shaft.
• Three position switch -Q1/-Q5:
– If the three position switch is in the central
position (i.e. disconnector and earthing switch
OFF), the disconnector can be closed with
approx. 24 clockwise turns, and the earthing
switch with approx. 24 anti-clock-wise turns.
If the ”earthing switch ON“ position is to be
reached from the „disconnector ON” position,
or vice versa, the crank is to be removed in
the self-inhibiting central position (disconnec-
tor and earthing switch OFF) and refitted.
When the crank is refitted, the further
switching operation is automatically enabled.
– With the ”mechanical interlock between the
switching devices“
option, the flap can only be opened when the
disconnector (-Q2) is in the disconnector OFF
position.
• Disconnector -Q2:
– Close the disconnector with approx. 24
clockwise turns and open it with approx. 24
anti-clockwise turns.
– With the ”mechanical interlock between the
switching devices“ option, the flap can only
be opened when the three position switch (-
Q1/-Q5) is in the disconnector OFF / earthing
switch OFF position.
Note:
Always perform every switching operation
right up to the stop in the relevant limit
position.
• Observe the mechanical switch position
indicator (2.27).
• Close the flap again.
Note:
When the flap is open, the circuit-breaker is
blocked in the OFF position and the other
disconnector is also blocked in the OFF position.
 • Close the low voltage compartment door.
6.2.3 Undervoltage release
Undervoltage releases may be fitted as an option. In
order to prevent the circuit-breaker being opened by
the undervoltage release on power failure with tee-
off earthing, an interlock rod or wire is provided.
6.3 Observation of the display and monitoring
facilities
6.3.1 Gas monitoring
(Figures 3/12 and 6/1)
All high voltage compartments in the system must
have a sufficient insulating gas pressure during
operation. The minimum operating gauge pressure
(pe) is listed in section 2.1. This is monitored by the
sensors (1.6, 2.6 and 2.7). If the insulating gas
pressure falls below the level for a warning signal,
an LED on the multifunctional protection and
control unit signals that the gas should be topped
up. With conventional panel control, the issue of
the signal is optional and dependent on the
individual project.
Note:
If a panel is isolated for a relatively long period
(several weeks), the mcb (F116) for the auxiliary
voltage supply to the REF542plus must remain on.
Only in this way is monitoring of the insulating gas
ensured. With conventional panel control, the
details in the order documents are to be observed.
Details on the gas system of the ZX2 switchgear
can be found in instruction manual BA 427 E.
6.3.2 Electrical/mechanical display/monitoring
During operation of the switchgear, observe all vis-
ible operating data and condition displays in the
secondary system and watch out for irregularities
of any kind, including the external conditions of the
switchgear.
6.4 Test procedures
6.4.1 Testing for the off-circuit condition
(Figure 6/1)
The panels are fitted with the low impedance,
capacitive voltage indicator system LRM or KVDS
for testing of the off-circuit condition.
For details, see draft DIN VDE 0682 Part 415, or
IEC 61243 Part 5.
Note:
Only display units which comply with the IEC or
VDE standards and the technical design of the
indicator system in the relevant switchgear may be
used!
Note:
The measuring sockets must on no account be
short-circuited, except during voltage testing of the
system (e.g. with power frequency withstand
voltage or impulse withstand voltage)!
Testing for the off-circuit condition is performed
with a plug-in display unit at corresponding pairs of
measuring sockets on the rear wall (1.4) or
optionally at the pairs of measuring sockets in the
low voltage compartment door (4.5).
Use of the display unit:
• Perform a functional test on the display unit
immediately before and after use, e.g. with
interface tester KSP. The display must be clearly
visible.
• The presence of operating voltage is indicated
by a signal.
• Observe the individual operating instructions for
the display unit for the relevant switchgear!
Interface testing:
• Perform interface testing as a functional test on
all coupling components, e.g. with interface
tester KSP.
• The interface test is a repeat test to IEC 61243
Part 5 or draft VDE 0682 Part 415.
6.4.2 Testing for the in-phase condition
Testing for the in-phase condition, e.g. when there
is more than one incoming feeder, can be per-
formed with a suitable phase comparator at meas-
uring sockets (1.4 or 4.5) on the capacitive voltage
indication system.
Test procedure:
• Only use phase comparators which comply with
the IEC or VDE specifications and the technical
design of the display system in the relevant
switchgear!
• Perform a functional test on the equipment at the
start of testing.
• Do not exceed the maximum permissible length
of measuring leads per phase.
• Connect the measuring leads precisely assigned
to the corresponding main conductor sections.
• Always follow the details in the operating
instructions for the phase comparator!
55
6.4.3 High voltage tests
(Figures 6/1 and 6/12)
The test plugs available for high voltage tests,
shown in figure 6/12, are suitable for the following
applications up to and including 36 kV rated
voltage.
For high voltage tests over the 36 kV rated voltage
level, separate test facilities (test cables) are
required. Information on these can be obtained
from the switchgear manufacturer.
Taking account of the sensor systems used and
the multifunctional protection and control unit, the
test voltages must not exceed the following:
• Cable tests with DC voltage:
6.4.4 Current tests
– 12 kV switchgear: 48 kV1)
– 24/36 kV switchgear: 70 kV1) up to 1 hour.
• Insulation testing of the switchgear at the rele-
vant power frequency withstand voltage:
– 12 kV switchgear: 28 kV
– 24 kV switchgear: 50 kV
– 36 kV switchgear: 70 kV.
Performance of voltage tests:
• Isolate the switchgear area in accordance with
the safety rules of DIN VDE 0105 and secure it to
prevent reconnection.
• Verify the off-circuit condition with a suitable
hand held display unit at the measuring sockets
(1.4 or 4.5) on the capacitive voltage indicator
system.
• Unscrew surge arresters where fitted, and close
off the exposed sockets with insulating cable
blanking plugs.
• Close off free cable sockets with insulating cable
blanking plugs.
• Check the test plugs to ensure that the surface is
clean and dry, and clean them if necessary.
• Grease the silicone part of the test plugs in
accordance with the directions.
• Unscrew and remove cable blanking plugs, volt-
age sensors or voltage transformers from the
relevant test sockets.
• Connect an earthing lead to the test plug.
• Insert the test plug into the prepared cable
socket and screw it tight.
1)
With plug-in voltage sensors/transformers, the cable test
voltages permissible to DIN standards may be used if the
sensors are withdrawn.
56
Notes:
• Only fit the test plugs for voltage tests for the
duration of those tests.
• Short-circuit the measuring sockets (1.4 or 4.5)
in the panels concerned for the duration of the
testing process at test voltages up to rated
power frequency withstand voltage.
• For performance of cable tests, in the switching
condition ”tee-off disconnected and earthed“,
earthing of the cable has to be cancelled by
opening the circuit-breaker. This is accom-
plished by using the mechanical OFF button to
open the circuit-breaker (see also sections 3.10,
3.12 and 3.14).
(Figures 6/1 and 6/13)
The test plugs available for current test are suitable
for the following applications:
• Testing of the protection functions in the multifunc-
tional protection and control unit REF542plus by
means of primary current injection.
Test instruction:
The following is to be observed when testing the
protection system of the REF542:
In order to prevent damage to the OFF-release coil
during testing, either the OFF-release coil has to be
disconnected or the protection test equipment
must be deactivated by the trip command.
This ensures that the opening release is not
energised in the meantime by the trip command,
which could lead to the coil burning out.
• Establishment of maintenance earthing in con-
junction with an earthing and short-circuiting set.
The short-circuit resistance of the current test
plugs for the switchgear must correspond to the
condition of the individual switchgear.
Handling of the plugs for current tests:
• Isolate the switchgear area in accordance with
the safety rules of DIN VDE 0105 and secure it to
prevent reconnection.
• Verify the off-circuit condition with a suitable
(hand-held) display unit at measuring sockets 6
on the capacitive voltage indicator system.
• Check the test plugs to verify that the surface is
clean and dry, and clean them if necessary.
• Insert the test plugs into the prepared test sock-
ets and screw them tight.
• Only fit the test plugs for the duration of the tests.
6.4.5 Maintenance earthing
a) Double busbar systems:
In the double busbar system, there is an oppor-
tunity to earth the busbar via the bus coupler.
b) Single busbar systems:
• Earthing of the busbar with the bus tie / riser,
as described in section 3.13 and 3.15.
• Earthing with an earthing and short-circuiting
set.
Handling during earthing with an earthing and
short-circuiting set:
(Figures 6/1 and 6/9)
The plugs for current tests described under 6.4.4
are used in conjunction with corresponding cable
sets for short-circuiting and earthing to establish
maintenance earths. The short-circuit resistance of
the cable set must correspond to the conditions of
the switchgear.
Caution!
Observe the notes in Section 3.11 on the interlock
dependencies for all work with earthing and short-
circuiting sets!
• Isolate the switchgear area in accordance with
the safety rules of DIN VDE 0105 and secure it
to prevent reconnection.
• Verify the off-circuit condition with a suitable
(hand held) display unit at the measuring sockets
(1.4 or 4.5) on the capacitive voltage indicator
system.
• Check the test plugs to ensure that the surface
is clean and dry, and clean them if necessary.
• Carefully screw the short-circuiting and earthing
cable set to the test plug.
• Connect the common earthing connector of the
cable set to the earthing terminal of the panel.
• Unscrew and remove the cable blanking plugs
from the relevant test sockets.
• Insert the test plugs into the prepared cable
sockets and screw them tight.
6.5 Safety note on operation of the
voltage transformers
The screws marked in figure 6/14 establish the
earthing connections to the relevant cable
terminals in the terminal box shown (illustration
shows condition as delivered).
The wiring and in particular the earthing of the
secondary terminals is to be implemented in
accordance with the circuit diagrams!
Releasing the earthing screw on the ‚N‘ terminal
leads to potentially lethal high voltage at the
terminal during operation of the voltage
transformers!
Releasing earthing screw ‚N‘ is only permissible
when the voltage transformers are off-circuit on the
primary side (for test purposes)!
Always use original earthing screws!
6.6 Application of the X-ray regulations
One of the physical properties of vacuum insulation
is the possibility of x-ray emissions when the con-
tact gap is open. The specified type test performed
by the Physikalisch-Technische Bundesanstalt
(PTB) in Brunswick demonstrates that the local
dosage output of 1 µSv/h at a distance of 10 cm
from the touchable surface is not exceeded.
The results are as follows:
• The use of the vacuum interrupters at rated volt-
age is completely safe.
• Application of the rated power frequency with-
stand voltage specified for the switching device
by DIN VDE 0670 and IEC 62271-100 or a
DC voltage of 48 kV or 70 kV during cable tests
is also safe.
• Higher voltages than the rated power frequency
withstand voltage specified in DIN VDE or IEC
standards or the DC voltage must not be ap-
plied!
• Fulfilment of the above requirement with the
vacuum interrupter in the open position is de-
pendent on maintenance of the specified dis-
tance between the contacts (which is automati-
cally ensured with correct mechanism function
and force transmission).
57
 4.2
4.3
4.7
4.4
4.6
4.10
4.8
4.5 (4.9)

4.3

Figure 6/1: Display area on the panel Figure 6/2: Handling of the door catch

• Opening the control cabinet door:

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

2.30 2.29 2.28 2.31 2.27 2.22 2.3 2.2

2.33 2.32 2.27 2.22 2.4

Figure 6/3: Operating mechanisms for the three position switch and
disconnector, with switch position detection by sensors

58
 2.24 2.6 2.46 2.47 2.49 2.48 2.22 2.25 2.52 6.1 2.26 2.22 2.25

2.50 2.51 2.22 2.53

Figure 6/4: Operating mechanisms for the three position switch and Figure 6/5: Emergency manual operation, three position switch
disconnector, with switch position detection by UX2TE, with switch position detection by sensors
microswitches

6.1 2.26 2.22

1.2

1.24
1.25
1.26 6.2
1.27
1.31

1.28 1.30

1.29

Figure 6/6: Emergency manual operation, disconnector UX2T, Figure 6/7: Emergency manual operation, circuit-breaker VD4 X
swith switch position detection by sensors

59
 1.33 1.34

▼
Figure 6/8: Mechanical interlock between three position switch and Figure 6/10: Cancellation of the interlock on the mechanical
disconnector, switch position detection by microswitches, ON pushbutton of the circuit-breaker
flap on operating shaft of the disconnector open

2.54 2.22

Figure 6/9a: Cancellation of the access interlock on the three Figure 6/11: View of the stored energy spring mechanism for the
position switch operating mechanism for the first busbar circuit-breaker, front plate removed
in a riser panel of a double busbar sectionaliser

2.22 2.55

Figure 6/9b: Cancellation of the access interlock on the three

position switch operating mechanism for the second
busbar in a riser panel of a double busbar sectionaliser

60
 earthing screws

▼ ▼ ▼

Figure 6/12: Test plug for high voltage tests up to 36 kV Figure 6/14: As-delivered condition of the earthing screws on the
rated voltage voltage transformer terminals

(Voltage transformers with two secondary terminals

shown here)

Figure 6/13: Test plug for current tests

Also usable as maintenance earth in conjunction with an

earthing and short-circuiting set.

61
7 Maintenance
Maintenance serves to preserve trouble-free op-
eration and achieve the longest possible working
life of the switchgear. In accordance with DIN 31 051
and IEC 60694, it comprises the following closely
related activities:
Inspection: Determination of the actual condition
Servicing: Measures to maintain the specified
condition
Repairs: Measures to re-establish the speci-
fied condition
7.1 General
It is essential to observe the following during all
maintenance work:
• The relevant regulations in section 1.2.2
• The notes on safety at work in section 6
• Standards and specifications in the country
where the switchgear is erected.
It is recommended that ABB after sales service
personnel be called in to perform servicing and
repair work.
Follow/observe the instructions on SF6 systems
and the ABB instruction manual on the handling of
insulating gases and procedures for fault con-
ditions. The handling regulations for SF6 also apply
accordingly to nitrogen.
• Keep these instructions and manual perma-
nently on display and available in the switch-
room.
The inspection and servicing intervals for the
switching devices are determined by fixed criteria
such as switching frequency and number of short-
circuit breaking operations.
The length of the intervals for inspection and servic-
ing of the control cabinet and its equipment is influ-
enced by ambient conditions (for instance pollution
and aggressive atmosphere).
In addition to this instruction manual, the following
instruction manuals must be observed:
• Insulating gas system BA 427/E
• Multifunctional protection and
control unit REF542plus BA 453/E
• Bay control unit CC BA 456/E
(for single busbar systems only)
• Circuit-breaker VD4 X BA 436/E
Further details can be found in the technical docu-
mentation for the switchgear installation (including,
for example, any agreed special operating condi-
tions).
62
7.2 Inspection/servicing
• Under normal operating conditions (see section
1.3), inspection of the operating mechanisms is
to be carried out by a suitably qualified electri-
cian after 10 years at the latest or after 5,000
operating cycles of the circuit-breaker and 2,000
operating cycles of the three position switch or
disconnector. Attention is also drawn to instruc-
tion manual BA 463/E.
• In exceptional operating conditions (including
adverse climatic conditions) and/or particularly
adverse environments (including heavy contami-
nation and aggressive atmosphere) inspection
at shorter intervals may be required.
• Inspection is first and foremost to be visual ex-
amination for contamination, corrosion and
moisture.
• The inspection should however also include
checking of the mechanical and electrical func-
tions of the following devices:
– Switching devices
– Multifunctional protection and control unit
REF542plus
– or bay control unit CC
– Conventional control units
• If an incorrect condition is found, the corre-
sponding repair work is to be initiated immedi-
ately.
Cleaning
If the necessity of cleaning is established during
inspections, the following procedure is to be
adopted:
• Prior to cleaning, isolate and secure the working
area if necessary in accordance with the safety
rules of DIN VDE and IEC.
• Cleaning of surfaces in general:
– Remove weakly adhering dry dust deposits
with a soft dry cloth.
– Remove more strongly adhering contamina-
tion with slightly alkaline household cleanser,
or with Rivolta BWR 210.
• Cleaning of insulating material surfaces and con-
ductive parts (outside the gas compartments):
– Minor contamination with Rivolta BWR 210.
– Strongly adhering contamination with Cold
cleanser 716
• Cleaning of busbar insulating parts, cable sockets
and busbar sockets with cable cleaner MAB.
• Observe the manufacturer’s instructions and the
special ABB instruction manuals BA 1002/E and
BA 1006/E on safety at work.
• Wipe down after cleaning, using clean water,
and dry properly.
7.2.1 Vacuum circuit-breaker
(Figure 6/7)
• The vacuum circuit-breaker has a long service
life. It has a low maintenance operating mecha-
nism and the breaker poles are maintenance-
free.
Consult the relevant sections of instruction
manual BA 436/E for further information.
7.2.2 Three-position switch and disconnector
• The three-position switch and disconnector are
maintenance-free for 2000 operating cycles.
7.2.3 Gas system and gas servicing
• Consult the relevant sections of instruction
manual BA 427/E for further information.
• Caution when working in gas compartments!
High gas concentrations may result in a danger
of asphyxiation!
• Hermetically sealed pressure system to IEC
60694.
The SF6 gas from this system must be recycled
and not released into the atmosphere.
7.2.4 Outlet filter
The filter mats in the outlet filter are to be changed
as required. Note the information on inspection and
servicing in section 7.2.
Replacement procedure:
• Draw off the grille.
This is done by prising off with the fingertips in
the recesses at the bottom end of the filter.
• Change the filter mat.
• Replace the grille.
Spare filter mats: Part no. (order ref.)
• Filter mat for fan system: GCE0995403P0100
• Filter mat for control cabinet: GCE0995404P0100
7.3 Repair
7.3.1 Replacement of breaker parts and accessories
Only dismantle and assemble breaker parts and
accessories when the breaker has been switched
off, the working area properly isolated and secured
and the stored energy spring discharged.
All sources of auxiliary power must also be
disconnected or secured to prevent switching on
during the dismantling and replacement work.
7.3.2 Checking the dimensional correctness of settings
(Figure 7/1)
The following checks are necessary after any work
on the circuit-breaker or disconnector operating
mechanism when the optional mechanical
interlocks are fitted:
• The distance between the lever (1.21) operated
by a link rod and the plastic cam (1.19) should be
2+1 mm.
• There must be a gap between the lever (1.21)
and the OFF release shaft (1.18).
• When corrective action is necessary, the wire
link is to be adjusted:
– Release the clamping screw (1.23) on the
clamping piece (1.22).
– Align the flap (2.22) in such a way that the two
bores are in line.
– Fasten the wire link with the clamping screw
(1.23) in position so that the above mentioned
distance of 2+1 mm is maintained. The wire
link must not be under tension in that position.
7.3.3 Touching up surfaces
• Sheet steel parts, painted:
– Remove rust, e.g. with a wire brush.
– Grind and degrease the paint coat.
– Apply anti-rust primer and top coat.
– Use a top coat in the standard colour
RAL 7035 or the relevant special colour.
• Sheet steel parts with aluminium-zinc surfaces
and chromated functional parts:
– Remove white rust with a wire brush or
cleaning pad (e.g. Scotch-Brite, white).
– Remove loosely adhering particles with a dry
cloth.
– Apply zinc spray or zinc dust primer.
• Functional parts, phosphated.:
– Remove rust with a wire brush or cleaning
pad (e.g. Scotch-Brite, white).
– Clean with a dry cloth.
– Grease with Isoflex Topas NB 52 lubricant.
Notes:
• It is essential to observe the section on safety at
work in instruction manual BA 427/E for all work
on gas compartments.
• Caution when working in gas compartments!
High gas concentrations may result in a danger
of asphyxiation!
63
7.4 Working and auxiliary materials

7.4.1 Working materials Part no. (Order ref.)

• Insulating gas system:
– Sulphur hexafluoride (SF6 ) GCE0990253P0103
Delivery form: liquid gas in steel cylinders
Observe the quality requirements to IEC 60376/
VDE 0373!
Observe the relevant ABB instruction manual GCEA901004P0102
BA 1004/E, pp. 1 to 3, on safety at work!

Note:
If extreme temperatures ≥ 50°C cannot be ruled
out where gas cylinders are stored, transported or
temporarily stored in the open air in direct sunlight,
a reduced filling factor of 0.75 kg/l cylinder con-
tents is to be required when ordering for safety
reasons!

• Drying agent material:

Drying agent bag to DIN 55 473, GCE0990443P0100
capacity per bag 210 g

7.4.2 Auxiliary materials

• Lubricants:
Isoflex Topas NB 52, GCE0007249P0100
• Assembly paste AP,
for insulating part/cast resin plug connections GCE0009098P0100
• Cleaning agents for general cleaning:
Rivolta BWR 210, GCE0007707P0100
Observe the relevant ABB instruction manual BA 1002/E GCEA901002P0102
• Cleaning agent for conductive parts, parts in insulat-
ing material, and all parts with heavy contamination:
Cold cleaner 716, GCE0007706P0100
Observe the relevant ABB instruction manual BA 1006/E GCEA901006P0102
• Cleaning agent for busbar insulating parts,
busbar sockets and cable sockets:
Cable cleaner MAB GCE0009100P0100
• Paintwork:
Paint in standard colour RAL 7035
– 1 kg-box GCE9014060R0103
– Spray tin GCE0007895P0100

64
7.5 Waste disposal

SF6 from hermetically sealed pressure systems to
IEC 60694 must be recycled and may not be
released into the atmosphere.
Disposal of the client’s systems and components
and the client’s waste, residue materials and used
substances can be performed by ABB. ABB
performs such disposal as a service enterprise
in connection with its servicing and installation
activities. The client’s waste materials are passed
on to authorised disposal specialists close to the
point of origin.
Details can be found in instruction manual
BA 477 E.

+1
2

1.17 1.21

1.19 1.18

1.20

X
1.32
a) Circuit-breaker, side view 1.22 1.23
2.23 2.22

2.37

b) Three position switchgear, front view

Figure 7.1 : Interlocking circuit breaker/three position switch

65
8 Table of equipment designations used
(Comparison of DIN and IEC designations)
The equipment designations listed may deviate if so requested by the customer.
(Figures 3/7a and 3/7b)

Designation Designation
to VDE to IEC

-Q0 -QB0 Circuit-breaker

-Q1/Q5 -QI1/E5 Three position switch in outgoing feeder panel and cable termination panel
-Q11/Q52 -QI11/E52 Three position switch in busbar 1 of a double busbar coupler,
single busbar sectionaliser and riser panel of a double busbar sectionaliser
-Q12/Q51 -QI12/E51 Three position switch in busbar 2 of a double busbar coupler,
single busbar sectionaliser and sectionaliser panel of a double
busbar sectionaliser
-Q2 -QI2 Disconnector in a tee-off panel
-Q21/-Q52 -QI21/-QE52 Three position switch in busbar 2 in the riser panel
of a double busbar sectionaliser
-Q22/-Q51 -QI22/-QE51 Three position switch in busbar 2 in the sectionaliser panel
of a double busbar sectionaliser
-T1 -BC Current transformer
-T5 -BV Voltage transformer
-X1 -BU Capacitive indicator
-C1 -CC1 Capacitive voltage divider
-C2 -CC2 Capacitive voltage divider, optional
-F100 -FB0 Mcb for charging motor of the circuit-breaker
-F101 -FB1 Mcb for the motor of three position switch –Q1
-F102 -FB2 Mcb for the motor of disconnector –Q2
-F106 -FB6 Closing and opening releases of the circuit-breaker
-B0G -BP0 Density sensor for circuit-breaker compartment
-B1G -BP1 Density sensor for busbar compartment 1
-B2G -BP2 Density sensor for busbar compartment 2
-B0A -BB1 Sensor to detect switch position: circuit-breaker OFF
-B0E -BB2 Sensor to detect switch position: circuit-breaker ON
-B0S -BS1 Sensor to detect the charging condition of the stored-energy spring
for the circuit-breaker
-B5A -BE1 Sensor to detect switch position of three position switch: earthing switch OFF
-B5E -BE2 Sensor to detect switch position of three position switch: earthing switch ON
-B1A -BI1 Sensor to detect switch position of three position switch: disconnector OFF
-B1E -BI2 Sensor to detect switch position of three position switch: disconnector ON
-B2A -BI1 Sensor to detect switch position of disconnector: disconnector OFF
-B2E -BI2 Sensor to detect switch position of disconnector: disconnector ON

66
67
 ZX2
Gas-insulated medium voltage switchgear
Instruction manual BA 435/03
Legend

1.0 Circuit-breaker compartment 2.12 Drying agent bag for busbar 3.11 Cable retaining bar
1.1 Circuit-breaker compartment 3.12 Crossbar
1.2 Circuit-breaker operating 2.13 Busbar socket 3.13 Locking screw
mechanism 2.14 Insulating part 3.14 Crank
1.3 Pressure relief disk for circuit- 2.15 O-ring 3.15 Voltage transformer truck
breaker compartment 2.16 Cheese head screw, M10 x 50 3.16 Interlock for voltage
1.4 Measuring socket for capacitive 2.17 Guide pin transformer truck
voltage indicator system 2.18 Hexagon nut, M10
1.5 Cable socket 2.19 Dished washer, 10 4.0 Low voltage compartment
1.6 Density sensor for circuit-breaker 2.20 Cheese head screw, M10 4.1 Central unit of the multifunctional
compartment 2.21 Contact tube protection and control unit
1.7 Pressure relief duct, top 2.22 Access flap REF542 plus
1.8 Drying agent bag for circuit-breaker 2.23 Bore hole for padlock 4.2 Control unit of the multifunctional
compartment 2.24 Filler valve for busbar compartment protection and control unit
1.9 Bushing, circuit-breaker/busbar 2.25 Mechanism motor for three position REF542 plus
compartment switch 4.3 Low voltage compartment door
1.10 Filler valve for circuit-breaker 2.26 Hollow shaft (emergency manual 4.4 Door catch
compartment operation shaft) 4.5 Measuring sockets for capacitive
1.11 Transport bracket 2.27 Mechanical switch position voltage indicator system, front
1.12 Edge guard indicator (optional)
1.13 Cheese head screw, M8 x 25 2.28 Sensor, disconnector –Q1 ON 4.6 LEDs
1.14 Hexagon nut, M8 2.29 Sensor, disconnector –Q1 OFF 4.7 LC display of the multifunctional
1.15 Dished washer, 8 2.30 Sensor, earthing switch ON protection and control unit
1.16 Centre of gravity 2.31 Sensor, earthing switch OFF REF542 plus
1.17 ON release shaft 2.32 Sensor, disconnector –Q2 ON 4.8 Fastener
1.18 OFF release shaft 2.33 Sensor, disconnector –Q2 OFF 4.9 Safety lock
1.19 Cam 2.34 Bore hole for padlock 4.10 Closing lever
1.20 Mechanical interlock, circuit- 2.35 Spiral contact
breaker/three position switch 2.36 Manual mechanism for isolating 5.0 Current sensor
1.21 Lever system 5.1 Current transformer
1.22 Clamping piece 2.37 Wire 5.2 Voltage sensor
1.23 Clamping screw 2.38 Spacer 5.3 Voltage transformer
1.24 Front plate 2.39 Cheese head screw, M8 x 40
1.25 ON pushbutton 2.40 Dished washer, 8 6.0 Accessories
1.26 OFF pushbutton 2.41 Blanking plug 6.1 Hand crank
1.27 Operating cycle counter 2.42 Busbar end insulator 6.2 Charging lever for stored energy
1.28 Mechanical switch position indicator 2.43 Cheese head screw, M10 x 30 spring mechanism
1.29 Rating plate 2.44 Cheese head screw, M8 x 25 6.3 Pressure plate for blanking plug
1.30 Charging condition indicator 2.45 Hexagon nut, M8 6.4 End plate
1.31 Recess for charging lever 2.46 Microswitch, disconnector –Q1 ON 6.5 Screw material, packaged in bag
1.32 Auxiliary switch 2.47 Microswitch, disconnector –Q1 OFF group “Screws for side pressure
1.33 Blocking magnet for circuit-breaker 2.48 Microswitch, earthing switch ON relief duct”
1.34 Slide (mechanical operation, circuit- 2.49 Microswitch, earthing switch OFF 6.6 Plug
breaker ON) 2.50 Microswitch, disconnector –Q2 ON
2.51 Microswitch, disconnector –Q2 OFF 7.0 Foundation frame
2.0 Busbar compartment I 2.52 Auxiliary switch plate for busbar 1 7.1 Longitudinal beam
2.1 Busbar compartment II 2.53 Auxiliary switch plate for busbar 2 7.2 Transverse beam
2.2 Three position switch 2.54 Blocking magnet for busbar 1 7.3 Compensator bracket
2.3 Three position switch operating 2.55 Blocking magnet for busbar 2 7.4 Connecting link
mechanism 7.5 Bolts for base frame
2.4 Disconnector 3.0 Cable termination compartment 7.6 Cheese head screw, M8 x 25
2.5 Disconnector operating mechanism 3.1 Main earthing bar 7.7 Cheese head screw, M10 x 25
2.6 Density sensor for busbar 3.2 Panel to panel connecting link 7.8 Cheese head screw, M8 x 25
compartment I 3.3 Cable fastening 7.9 Dished washer, 8
2.7 Density sensor for busbar 3.4 Cable plug 7.10 Dished washer, 10
compartment II 3.5 Pressure relief flap 7.11 Compact dowel
2.8 Busbar 3.6 Pressure relief duct
2.9 Busbar connection, plug-in type 3.7 High voltage cable
2.10 Tee-off conductor 3.8 Floor plate, split
2.11 Pressure relief disk for busbar 3.9 Reducer ring
compartment 3.10 Cable clamp
 Instruction manual no. GCEA 68 0435 P0102 Printed in Germany (01.04-500-PPI)

ABB Calor Emag Mittelspannung GmbH Note:

We reserve the right to make technical changes or modify the contents of this
Oberhausener Strasse 33 Petzower Strasse 8 document without prior notice. With regard to purchase orders, the agreed
particulars shall prevail.
40472 Ratingen 14542 Werder (Havel) OT Glindow ABB does not accept any responsibility whatsoever for potential errors
DEUTSCHLAND DEUTSCHLAND or possible lack of information in this document.
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Phone: +49(0)21 02/12-12 30, Fax: +49(0)21 02/12-19 16 contained therein. Any reproduction – in whole or in parts – is forbidden without
E-mail: powertech@de.abb.com ABB’s prior written consent.
Copyright© 2003 ABB
Internet: http://www.abb.de/calor All rights reserved.