Download as pdf or txt
Download as pdf or txt
You are on page 1of 191

UniGear ZS1 Training

© ABB Group
December 12, 2022 | Slide 1
Personal Information

© ABB Group
December 12, 2022 | Slide 2
Contents
Background theory and standards
Introduction
UniGear ZS1 basic description
Service continuity
Internal arc clasiified
Production portfolio overview
- UniGear ZS1 12-17,5kV and 24kV
- Units produced by other ABB factories

UniGear ZS1 operation


1. Panels overview and structure
2. Low voltage compartment
3. Operation of UniGear ZS1 with circuit breaker
4. Interlocks and locks in UniGear ZS1 with circuit breaker

© ABB Group
December 12, 2022 | Slide 3
Introduction ...

© ABB Group
December 12, 2022 | Slide 4
ABB portfolio – Medium Voltage Products
www.abb.com

UniGear ZS1

Medium Voltage
Air Insulated Switchgear

 12 - 17,5kV and 24kV


 IEC 62271-200

© ABB Group
December 12, 2022 | Slide 5
UniGear ZS1 – the basic description

© ABB Group
December 12, 2022 | Slide 6
UniGear ZS1 – the basic description
The switchgear solution

horizontal communication
integrated station via IEC61850-8-1 withdrawable
automation COM600 apparatus

ready for complete remote control

© ABB Group
December 12, 2022 | Slide 7
UniGear ZS1 – the basic description
Design of a typical functional unit

Low voltage compartment Busbar compartment – tool based


access for maintenance;
ready for future extensions

IEC 62271-200: Metal enclosed


LSC2B-PM
Enclosure IP4X
Internal partitioning IP2X

Cable compartment –
interlock-controlled access
(can be combined also with
Circuit breaker compartment – procedure-based access)
interlock-controlled access
(can be combined also with
procedure-based access)

© ABB Group
December 12, 2022 | Slide 8
UniGear ZS1 – the basic description
Application for indoor switchgear solutions

Operating conditions
 Indoor installation, normal operating conditions
 Authorized person access only switchgear room
 Derating factors shall be considered for installations above
1000m asl, or at average temperatures exceeding 40°C

© ABB Group
December 12, 2022 | Slide 9
UniGear ZS1 – the basic description
Safety first

 System of safety mechanical interlocks preventing


hazardous access to HV compartments and dangerous
operation
 Additional electrical interlocks available via blocking coils
(no-voltage check before the E/S operation, CB movement
blocking coil, CB operation blocking coil, ...)
 Key-locking system available on request

© ABB Group
December 12, 2022 | Slide 10
UniGear ZS1 – the basic description
Designed and type tested as per IEC standards

Type tested as per IEC62271-200:


 Insulation level
 Temperature rise test
 Peak and short time withstand currents
 Making and breaking capacities of the
switching devices
 Functional test
 Protection of persons against access to
hazardous parts and entry of solid
foreign objects
 Internal Arc Classification
 EMC test (on typical layout and wiring)

© ABB Group
December 12, 2022 | Slide 11
Service continuity ...

© ABB Group
December 12, 2022 | Slide 12
UniGear ZS1 – the basic description
Service continuity

Safe only access and flexibility ...


 The service continuity and conditions for accessibility are
key aspects in top-down approach for switchgear selection
 Especially in some industrial and petrochemical applica-
tions, the service continuity belongs to the key features

© ABB Group
December 12, 2022 | Slide 13
UniGear ZS1 – the basic description
The categories for Loss of service continuity

LSC2B - PM
 Segregated switchgear units
(except for the main busbar)
 The unit can be disconnected
from the main busbar (LSC-2A)
 The unit can be also
disconnected from its cable
compartment (LSC-2B)

© ABB Group
December 12, 2022 | Slide 14
Internal arc classified ...

© ABB Group
December 12, 2022 | Slide 15
UniGear ZS1- safety aspects
Internal arc withstand capability

An internal arc can be caused by:


 Wrong sequence of the switchgear operation
 Internal failure of a switchgar component
 Flashover caused by an surface insulation failure
UniGear ZS1 panels provides maximal protection with safety
interlocking system and internal arc withstand capability

© ABB Group
December 12, 2022 | Slide 16
UniGear ZS1- safety aspects
Internal arc classification – IEC62271-200

Five criterions for the IAC classification:


1. Correctly secured doors and covers do
not open
2. No fragmentation of the enclosure
occurs within the test time
3. Arcing do not cause holes in the
accessible sides, up to height of 2m
4. Indicators do not ignite due to effect of
hot gases

Internal arc test in laboratory 5. The enclosure remains connected to


conditions its earthing point

© ABB Group
December 12, 2022 | Slide 17
UniGear ZS1- safety aspects
Arc time duration – influence on the damage level

 Recommended standard values for the


tests are 0.1s, 0.5s or 1s (IEC 62271)
 Internal arc duration has influence on
the level of damage, generally:
 >500ms – severe damage
 <100ms – small damage
 <35ms – subtle damage

 The switchgear withstand duration shall


be stated by the manufacturer
 Unless stated otherwise, UniGear ZS1
panels are type tested for 1s

© ABB Group
December 12, 2022 | Slide 18
UniGear ZS1- safety aspects
Accessibility class IAC AFLR

Pressure relief
flaps

 UniGear ZS1 is designed for accessibility class IAC AFLR


 A – authorized personnel only
 F, L, R – front, lateral and rear side
 Arc proof installation shall always consider all the aspects
from the overall installation point of view (switchgear room)

© ABB Group
December 12, 2022 | Slide 19
UniGear ZS1- safety aspects
Gas exhaust protection covers

 From safety reasons, most of the installations require use


of additional protection covers above the switchgear
 The application of the covers depends on the ceiling
height, rated arcing current and arc time duration
 Alongwith the protection covers, detectors for rapid fault
clearance times are used with UniGear ZS1

© ABB Group
December 12, 2022 | Slide 20
UniGear ZS1- safety aspects
Gas exhaust protection covers - channels

Gas exhaust channels for


full IAC protection

 First type are Gas exhaust channels with outlets, leading


the gasses away from the switchgear room
 The most robust solution, tested up to 50kA/1s
 Requires to be considered in the civil works (wall openings
and its direction, the outlet channels)
 Used also when a higher IP class is required (up to IP53)

© ABB Group
December 12, 2022 | Slide 21
UniGear ZS1- safety aspects
Gas exhaust protection covers – top chimneys

 Second type are protection covers with top chimneys,


without need for outlets from the room
 The solution is tested up to 50kA/0,5s
 In smaller rooms, pressure calculation is recommended
 Used also when a higher IP class is required (up to IP43)

© ABB Group
December 12, 2022 | Slide 22
UniGear ZS1- safety aspects
Detectors for rapid fault clearance – pressure switches

Basic level:
auxiliary switches on the
Option: pressure release flaps
Application of
overpressure sensors Arc detection within 15ms plus
inside the panels direct CB trip (40-60ms)

© ABB Group
December 12, 2022 | Slide 23
UniGear ZS1- safety aspects
Detectors for rapid fault clearance – optic sensors

Advanced level:
arc-protection set REA with
optic sensors and relay unit

Arc detection within 2.5ms plus


direct CB trip (40-60ms)

© ABB Group
December 12, 2022 | Slide 24
UniGear ZS1- safety aspects
Detectors for rapid fault clearance – UFES

QRU

Advanced level:
arc-protection set UFES with
optic sensors and relay unit
PSE
Extendability by TVOC2

Arc detection and


transformation to 3 phase
metalic short circuit within 4ms
plus direct CB trip (40-60ms)
© ABB Group
December 12, 2022 | Slide 25
UniGear ZS1- safety aspects
Internal arc caused by wrong operation sequences

Mechanical interlocks:

CB rack-in/out allowed with


open CB only

CB rack-in/out allowed only


with closed front doors
Remote control for CB ON/OFF,
Blocked CB closing in the inter-
position Remote control for Rack IN/OUT
(if motorized truck used)

Remote control for E/S ON/OFF


(if motorized E/S used)

© ABB Group
December 12, 2022 | Slide 26
UniGear Family
The production portfolio overview
UniGear
ZS1 ..24kV
Single Busbar
Standard Marine
Double Busbar
Standard Duplex Front to front
Duplex Back to back
Double Level
Standard Marine

550 ..17.5kV
Standard Marine

500R ..12kV
IEC
ENA (for UK)
MCC ..7.2kV
ZVC ..7.2kV
Standard Marine

ZS2 ..36kV

ZS3.2 ..40.5kV

© ABB Group
December 12, 2022 | Slide 27
UniGear

UniGear ZS1 SBB UniGear ZS1 SBB Deep UniGear ZS1 Double Level UniGear MCC

UniGear ZVC UniGear 500R UniGear ZS1 Duplex UniGear ZS1 DBB
Back to Back

© ABB Group
December 12, 2022 | Slide 28
UniGear ZS1
MV AIS 12 - 17,5kV - 24kV

© ABB Group
December 12, 2022 | Slide 29
UniGear ZS1
Basic information

 Switchgear panels suitable for all kinds of applications,


particularly for primary switching stations and industry
 12-17,5kV panels available up to 4000A and STC 50kA
 24kV panels available up to 3150A and STC 31,5kA
 Panels ready for complete remote control and monitoring

© ABB Group
December 12, 2022 | Slide 30
UniGear ZS1
Technical parameters

Rated voltage [kV] 12 17,5 24 4)


Test voltage (50/60 Hz/1 min) [kV] 28 1) 38 1) 50
Impulse withstand voltage [kV] 75 95 125
Rated frequency [Hz] 50/60 50/60 50/60
Rated current of the main busbars [A] Up to 4000 4000 3150
Rated short-time withstand current [kA] Up to 50 50 31,5
Peak withstand current [kA] Up to 125 125 80
Rated circuit-breaker thermal current [A] 630 630 630
1250 1250 1250
1600 1600 1600
2000 2000 2000
2500 2500 2500
2)
3150 3150 3150
4000 2) 4000 2)

Internal arc withstand current [kA] Up to 50 50 31,5

1. 42kV for GOST applications with insulation class B


2. With cooling fan
3. Note: the panels equipped with contactors or disconnector switches are limited by
parameters of these devices
4. 27,6kV available for Canadian market according to CSA standard
© ABB Group
December 12, 2022 | Slide 31
UniGear ZS1
Standard units SBB – Incomer, Outgoing

 Withdrawable circuit breaker


 Dedicated earthing switch with making capacity
 Customizable control cabinet, always fit to the application
 Available also with withdrawable cable VT, optional busbar
CT and many other features ...

© ABB Group
December 12, 2022 | Slide 32
UniGear ZS1
Standard units SBB – Bus tie and metering

 Dedicated busbar metering panel with earthing switch with


full making capacity
 Bus tie consist of two units, bus coupler and riser. The bus
riser can be used as metering panel for the second busbar
 Available with fixed VTs or withdrawable VT truck
 Busbar earthing switch can be interlocked with all the
breakers in the section via system of blocking coils
© ABB Group
December 12, 2022 | Slide 33
UniGear ZS1
Load break switch panel SBB

 UniGear ZS1 NALF - disconnector switch in LSC 2A panel


12-24kV
 At 12-17,5kV: up to Ir = 100A (fuse) and STC 25kA/1s
 At 24kV: up to Ir = 63A (fuse) and STC 20kA/1s
 Suitable typically for station auxiliary transformer feeders

© ABB Group
December 12, 2022 | Slide 34
UniGear ZS1
Deep units SBB – Incomer, Outgoing

 Applications demanding use of 2 sets of CTs/VTs, for


example with a dedicated CT for differential protection
 Applications demanding high number of cables per phase
 Applications demanding connection of the power cables
from top side
 Can be combined with standard units into one switchgar

© ABB Group
December 12, 2022 | Slide 35
UniGear ZS1
Duplex units - double busbar solution with two CBs

 Double busbar applications requesting two CBs for


maximal redundancy and the fastest changeover
 Solution based on two standard UniGear ZS1 units,
arranged back-to-back or front-to-front
 Can be combined with standard units into semi-duplex
switchgear

© ABB Group
December 12, 2022 | Slide 36
UniGear ZS1 DBB
Basic information about DBB units

 Double busbar switchgear, suitable particularly for primary


switching stations and industry
 12-17,5kV panels available up to 4000A and STC 31,5kA
 24kV panels available up to 2500A and STC 25kA
 Panels ready for complete remote control and monitoring

© ABB Group
December 12, 2022 | Slide 37
UniGear ZS1 DBB
Technical parameters

Rated voltage [kV] 12 17,5 24


Test voltage (50/60 Hz/1 min) [kV] 28 38 50
Impulse withstand voltage [kV] 75 95 125
Rated frequency [Hz] 50/60 50/60 50/60
Rated current of the main busbars [A] Up to 4000 4000 2500
Rated short-time withstand current [kA] Up to 31,5 31,5 25
Peak withstand current [kA] Up to 80 80 63
Rated circuit-breaker thermal current [A] 630 630 630
1250 1250 1250
1600 1600 1600
2000 2000 2000
2500 2500 2500 1, 2)
3150 1) 3150 1)
4000 1, 2) 4000 1, 2)

Internal arc withstand current [kA] Up to 31,5 31,5 25

1. The 3150A and 4000A has separate incomers for section A and B (without line
disconnector), the same is for 2500A panel at 24kV
2. With cooling fan
3. Note: against the standard UniGear ZS1 and duplex units, the DBB units are limited in STC
by capabilities of the line disconnectors for 31,5kA (or 25kA at 24kV)

© ABB Group
December 12, 2022 | Slide 38
UniGear ZS1 DBB
Standard units DBB – Incomer, Outgoing

 Alternative to Duplex for double busbar applications up to


STC 31,5kA (12-17,5kA) and 25kA (24kV)
 Arrangement with one CB and two line disconnectors
 Reduced footprint against the Duplex
 The disconnectors are motor operated, typically via ABB‘s
BCPUs as REF630 or REF542 +

© ABB Group
December 12, 2022 | Slide 39
UniGear ZS1 DBB
Standard units DBB – BTT, BTL and metering

 Bus coupler Transversal available


 Longitudinal Bus tie consisting of bus coupler/riser
combinations, completed with busbar metering panel

© ABB Group
December 12, 2022 | Slide 40
UniGear ZS1
The main components used in SBB and DBB units

UniGear ZS1 panels are available complete with the latest


ABB technologies
 Vacuum and SF6 circuit breakers
 Vacuum contactors
 CTs, VTs and sensors
 Protection relays
 Earthing switch
 Surge arresors
 Cable termination kits

© ABB Group
December 12, 2022 | Slide 41
The main components of UniGear ZS1
Apparatus – circuit breakers 12-17,5 and 24kV

 VD4 – unique ABB vacuum technology with embedded


sealed-for-life poles, spring actuator for 30.000 operations
 VM1 – unique ABB vacuum technology with embedded
sealed-for-life poles, magnetic actuator for up to 100.000
operations
 HD4 – SF6 technology, suitable for applications sensitive
to dielectric and dynamic stresses, capacitor banks etc.

© ABB Group
December 12, 2022 | Slide 42
The main components of UniGear ZS1
Apparatus – vacuum contactors 7,2 and 12kV

 VSC – fused contactor with permanent-magnet actuator,


single or double command version, suitable for high
number of hourly operation
 V-contact (abandoned) – contactor with electro-magnetic
actuator, single command version (electrical latching) or
double command version (mechanical latching)

© ABB Group
December 12, 2022 | Slide 43
The main components of UniGear ZS1
Measurement – Current transformers

 Cast epoxy resin, supporting type TPU 4, 5, 6 – used for


currents ≤ 2500A, with optional capacitive sensor for CPI
 Cast epoxy resin, ring type KOKS – used for high currents
in panels >2500A ≤ 4000A
 Optional use of types KORI and BD – LV ring CTs installed
on insulated primary conductor for MV (12-17,5kV)
 Alternative installation also as busbar CT (TPU type)
© ABB Group
December 12, 2022 | Slide 44
The main components of UniGear ZS1
Measurement – Core balance Current transformers

 Ring types KOLMA/KOLA, window type KOKM


 Reconnectable or split-types available
 Methods of the CBCT installation:
 Separately, bellow the switchgear panel
 Inside the cable compartment (if allowed by distances)
 Inside in a special bottom-mounted cable box
© ABB Group
December 12, 2022 | Slide 45
The main components of UniGear ZS1
Measurement – Voltage transformers (cable side)

 Cast epoxy resin type TJC 4, 5, 6 – single pole, fixed


without fuse (standard)
 Cast epoxy resin type TJP 4, 5, 6 – single pole with HV
fuse, mounted on VT truck
 Double pole VTs can be mounted in some special cases
 Auxiliary VT for aux. power supply can be used, if needed
(for Self-powered substations without DC systems)
© ABB Group
December 12, 2022 | Slide 46
The main components of UniGear ZS1
Measurement – Voltage transformers (busbar side)

 Cast epoxy resin type TJC 4, 5, 6 – single pole, fixed


without fuse in separate top-mounted box
 Cast epoxy resin type TJP 4, 5, 6 – single pole with HV
fuse, VT truck in Apparatus compartment

© ABB Group
December 12, 2022 | Slide 47
The main components of UniGear ZS1
Measurement – Electronic transformers (sensors)

 Replacement for conventinal inductive CTs and VTs with


one current sensor (Rogowski coil) and voltage detector
 KEVCD – light weight current and voltage combisensor
with optional capacitive sensor for CPI
 Linear response, designed for use with ABB relays REF
 Low energy output – reduced cost of ownership!

© ABB Group
December 12, 2022 | Slide 48
The main components of UniGear ZS1
Measurement – Electronic transformers (sensors)

Transformer Sensor
180 462 154
Customers
benefit
18 308
33 283 3 4 33%
15
234 Cost
Connection Connection saving

Adaptation Adaptation
to REF to REF

Purchase Energy TCO Purchase Energy TCO


(NPV) (NPV)

 Conventional inductive Instrument Transformers consume


significant amount of energy, and thus contribute to power
losses in substation in significant way
 Sensor technology dramatically reduces energy
consumption of Switchgear and its total cost of ownership

© ABB Group
December 12, 2022 | Slide 49
The main components of UniGear ZS1
Protection relays and IEDs

REF630
Suitable for switchgear with
single busbar, double busbar
and duplex systems
REM630
Machine protection terminal
RET630
Transformer protection
 Terminals (IEDs) for protection, control, measurement and
supervision
 Full implementation of IEC 61850 can be perfectly used for
making of fast switchgear horizontal communication
 Interactive mimic diagram
 PLC functions for automation and sequence logic functions

© ABB Group
December 12, 2022 | Slide 50
The main components of UniGear ZS1
Protection relays and IEDs

REF615
Suitable for single busbar
switchgear, incoming/out-
going feeders

 Terminals (IEDs) for protection, control, measurement and


supervision
 Full implementation of IEC 61850 can be perfectly used for
making of fast switchgear horizontal communication
 Interactive mimic diagram
 PLC functions for automation and sequence logic functions

© ABB Group
December 12, 2022 | Slide 51
The main components of UniGear ZS1
Protection relays and IEDs

REF 610
Suitable for single busbar
switchgear, incoming/out-
going feeders
REM 610
Motor protection relay

 REF 610 simple and reliable feeder relays for protection


and supervision
 Perfectly suits to basic feeder applications, optional arc-
protection optical sensors
 Variety of communication standards IEC 61850, Modbus,
DNP ...
 Plug-in design
© ABB Group
December 12, 2022 | Slide 52
The main components of UniGear ZS1
Protection relays and IEDs

REF 542+
Suitable for switchgear with
single busbar, double busbar
and duplex systems;
feeder, transformer and
motor protection

 REF 542+ feeder terminals (IEDs) for protection, control,


measurement and supervision, including power quality
 Interactive mimic diagram
 PLC functions for automation and sequence logic functions
 Excellent for use with ABB combisensors KEVCD
 Variety of communication standards, including IEC 61850;
available as Webserver
© ABB Group
December 12, 2022 | Slide 53
The main components of UniGear ZS1
Protection relays and IEDs

REF 541, 543, 545


Suitable for switchgear with
single busbar, double busbar
and duplex systems
REM 543, 545
Machine protection terminal
RET 541, 3, 5
Transformer protection
 REF 541/3/5 feeder terminals (IEDs) for protection, control,
measurement and supervision
 Interactive mimic diagram
 PLC functions for automation and sequence logic functions
 Excellent for use with ABB combisensors KEVCD
 Variety of communication standards, including IEC 61850
via SPA-ZC 400
© ABB Group
December 12, 2022 | Slide 54
The main components of UniGear ZS1
Protection relays and IEDs

REX 521
Suitable for single busbar
switchgear, incoming/out-
going or motor feeder

 REX 521 feeder relay for protection, measurement and


supervision
 Excellent for use with ABB combisensors KEVCD
 Variety of communication standards, including IEC 61850
via SPA-ZC 400

© ABB Group
December 12, 2022 | Slide 55
The main components of UniGear ZS1
Protection relays and IEDs

RED 615
Differential protection
for overhead lines and
cable feeders in
distribution networks

 RED 615 line differential protection relay, measurement


and control
 Selective protection
 Full implementation of IEC 61850 can be perfectly used for
making of fast switchgear horizontal communication
 Plug-in design

© ABB Group
December 12, 2022 | Slide 56
The main components of UniGear ZS1
Protection relays and IEDs

COM 600
Station automation device,
all-in-one communication
gateway and user interface
for utility and industrial
distribution substations

 IEC 61850 gateway connectivity between substation IEDs


and network-level control and management systems
 Flexible platform for substation-level automation tasks
 Web technology, access via a web browser as the human
machine interface (HMI)

© ABB Group
December 12, 2022 | Slide 57
The main components of UniGear ZS1
Earthing switch – cable and busbar side

 Integrated earthing switch with making capacity, type EK6*,


used for cable earthing in Feeder panels and for busbar
earthing in Metering or Bus Tie panel
 Busbar earthing switch EK6 can be placed also in separate
top-mounted box (alternative solution)
 EK6 is available with motor-drive or manual operation
*Note: Maximal making capacity of EK6 is 120kA, from the reason in 50kA
panels, there can be optionally used ST-E type with making capacity 125kA
© ABB Group
December 12, 2022 | Slide 58
The main components of UniGear ZS1
Surge arrestors

 Additional protection against overvoltages in the network


 The surge arrestors are placed in cable compartment,
instead of one position of the cable connections
 There are used ABB surge arrestors of type MWD in
UniGear ZS1 panels

© ABB Group
December 12, 2022 | Slide 59
The main components of UniGear ZS1
Cable termination kits

Recommended cable terminations kits for UniGear ZS1:


 ABB type SOT 12-36kV indoor for 1-core or 3-core XLPE
cables, for standard applications
 ABB type APIT 12-36kV indoor for 1-core or 3-core XLPE
cables, for extremely high demands (polluted areas etc.)

© ABB Group
December 12, 2022 | Slide 60
Switchgear units produced by other ABB factories
UniGear ZVC - slim panel up to 7,2kV

 Compact 325mm motor control unit with fused vacuum


contactor, produced by ABB Australia
 Suitable as motor feeders for power plants, industry, ...
 Directly connectable with UniGear ZS1, 550 and 500R
 Up to Ir=400A and STC 50kA
 Electrical life of the contactor 100,000 operations
(closing-opening)
© ABB Group
December 12, 2022 | Slide 61
Switchgear units produced by other ABB factories
Is Limiter panel 12-24kV

 Solution for switchgear applications with high STC ratings


– protection by Is Limiter panel produced by ABB Germany
 Directly connectable with UniGear ZS1
 The device consists of main conductor (Ir ≤ 4000A) with
fast switch and high rupturing capacity fuse in parallel
 Short-circuit current limited at the first rise, in less than
1ms
© ABB Group
December 12, 2022 | Slide 62
1. Panels overview and structure

© ABB Group
December 12, 2022 | Slide 63
1. Panels overview and structure
a) Compartments and components

1. LV compartment
2. Gas duct
3. Busbar compartment
4. Cable compartment /
feeder compartment
5. Switching apparatus
(usually circuit breaker)
6. CB compartment /
apparatus compartment
7. Withdrawable VTs

© ABB Group
December 12, 2022 | Slide 64
1. Panels overview and structure
b) Standard Feeder layout
1

2 1
1

3
2 4 4 3
4 2
3
5
6 5
6
5
6

© ABB Group
December 12, 2022 | Slide 65
1. Panels overview and structure
b) Standard Feeder layout
1

2 1
1

3
2 4 4 4
5 2 3
4
5 3

6
6 5
6

© ABB Group
December 12, 2022 | Slide 66
1. Panels overview and structure
c) Bus Voltage Metering and Bus Riser panel layout
1

1
2

© ABB Group
December 12, 2022 | Slide 67
1. Panels overview and structure
c) Bus Coupler panel layout
1

1
1
2

2 3 2
3
4
3 4

4 5
5 5

© ABB Group
December 12, 2022 | Slide 68
2. Low voltage compartment

© ABB Group
December 12, 2022 | Slide 69
2. Low voltage compartment
a) Low voltage compartment exterior and interior
 LV compartment exterior:
 Key device is usually protection relay
display (HMI)
 Additional devices, like voltage
indicators, measurement
visualization, position signalization,
switches and lamps are on the door
as well
 The tag (identification) plate of the
panel is on the top, designation plates
are under each device

 LV compartment interior:
 The LV compartment contains
secondary circuits including MCBs,
terminals, wiring
 The protection relay main unit is
usually in top left corner on the
backplane, other auxiliary relays next
to it, MCBs in a row below
 Terminals are on the bottom plate,
that can be lifted for access to wiring

© ABB Group
December 12, 2022 | Slide 70
2. Low voltage compartment
b) Terminals in low voltage compartment

 Terminals in low voltage compartment:


 -X10,11,12 ... Inter panel wiring (aux. supply, interlocks, ...)
 -X9 ... Secondary circuits of current transformers
-X5 ... Secondary circuits of voltage transformers
-X7 ... Spare contact
-X2 ... For panel internal wiring – AC Lighting&Heater
-X3 ... For panel internal wiring – CB Control
-X4 ... For panel internal wiring – Relay & Indication

© ABB Group
 -X8 ... Terminals for EXTERNAL control circuits and signals
December 12, 2022 | Slide 71
2. Low voltage compartment
c) Interconnection wiring

 Interconnection wiring is there to distrubute auxiliary voltage,


measuring and control signals from one panel to others
 Plug and socket system, plugs have yellow fixing holders
preventing disconnecting
 Openings in sidewalls serves for pulling the interconnection
bundles to the neighbouring panels

© ABB Group
December 12, 2022 | Slide 72
2. Low voltage compartment
d) Connection of external LV cables

External control and


auxiliary cables continue
via the channel to LV
comartment, -XC terminals

Removable channel
duct cover

External control and


auxiliary cables entry
from the bottom through
opening with bushings

© ABB Group
December 12, 2022 | Slide 73
3. Operation of UniGear ZS1 with
circuit breaker

© ABB Group
December 12, 2022 | Slide 74
3. Operation of UniGear ZS1 with circuit breaker
a) Glossary

 Interlock is a device preventing access or operation untill certain


condition(s) are fulfilled.
 Lock is an apparatus preventing access to the panel or a panel
compartment independently on status of the panel. Access is
possible with a key.
 Racking in/out is moving the CB to/from service position
 Service position of the CB is the position when CB is connected
to the main circuit
 Test position of the CB is the position when CB is disconnected
from the main circuit but still inside the panel behind the closed
door.
 Withdrawn position of the CB is the position when CB is on
service trolley outside the panel.
 Interposition is a situation when CB is between service and test
position (during the process of racking in or out).

© ABB Group
December 12, 2022 | Slide 75
3. Operation of UniGear ZS1 with circuit breaker
b) Operating accessories
Hand crank for Ramp for withdrawable
racking in and out cable VT truck
the withdrawable
part inside the
panel

Operating lever for


earthing switch

Service trolley for


witdrawable part

Double bit key for


locking the
compartment
doors (3mm for
LV doors, 5mm
for MV doors)
© ABB Group
December 12, 2022 | Slide 76
3. Operation of UniGear ZS1 with circuit breaker
b) Operating accessories

Shutters lifting truck


(optional)

Test and earthing truck


(optional)

 These two accessories are optional and project related

© ABB Group
December 12, 2022 | Slide 77
3. Operation of UniGear ZS1 with circuit breaker
c) CB racking operation
1 - Open the slot
2 - Insert the crank
3 - Turn approx. 20x
clockwise to rack-in or
counterclockwise to rack-out

Rack in and out smoothly


pushing the crank towards the
slot and turning untill you hear
limit switch click and see the
signalization of the desired
position

© ABB Group
December 12, 2022 | Slide 78
3. Operation of UniGear ZS1 with circuit breaker
d) CB mechanical ON/OFF
1 - Turn knob counterclockwise
until stop (only if CB in service
position)
2 - Press desired button (ON or
OFF)
1

2 With truck in test position simply


press the desired button

© ABB Group
December 12, 2022 | Slide 79
3. Operation of UniGear ZS1 with circuit breaker
e) CB manual spring charging
 CB spring is charged
automatically by charging
motor, manual charging is
needed in case of auxiliary
voltage or charging motor failure

 Lever for manual charging is on


the front plate of the circuit
breaker

 Spring is charged after approx.


20 strokes, see the indicator of
spring status

© ABB Group
December 12, 2022 | Slide 80
3. Operation of UniGear ZS1 with circuit breaker
f) Withdrawing on service trolley

Slot for apparatus


Latch Latch lever fixing Setscrew

 Service trolley enables safe removal of withdrawable truck with


circuit breaker – be aware of latches and fixing slots
 It must be levelled and latched to the panel prior CB truck
withdrawal
© ABB Group
December 12, 2022 | Slide 81
3. Operation of UniGear ZS1 with circuit breaker
f) Withdrawing on service trolley
1 – Remove the
plug
2 – Fix the
service
trolley
3 – Release the
latches and
1 pull out the
CB

© ABB Group
December 12, 2022 | Slide 82
3. Operation of UniGear ZS1 with circuit breaker
f) Withdrawing on service trolley

 Withdrawal from the test/isolated position onto the service


truck step by step description:
 Open the door of the circuit-breaker compartment. Release CB
control plug and place it in the storage position on the
withdrawable part.
 Level service trolley to the correct height facing the panel front,
and allow latch to engage – check the trolley is firmly held by
the latch
 Move sliding handles inwards against the springs to release
withdrawable part, draw the withdrawable part out onto the
service truck and secure it in the slots on the truck.
 By moving the latch lever release the service truck from the
switchgear panel.

© ABB Group
December 12, 2022 | Slide 83
3. Operation of UniGear ZS1 with circuit breaker
g) Earthing switch operation
1 – Open the
earth switch
operating slot
2 – Engage the
lever and
turn
clockwise to
switch ON,
conterclockwi
se to switch
OFF

2
1

© ABB Group
December 12, 2022 | Slide 84
3. Operation of UniGear ZS1 with circuit breaker
g) Earthing switch operation

 Manual earth switch operation step by step description:


 Earthing switch is ready for operation when the related CB
truck(s) is in test position or withdrawn from the panel – ensure
the interlocks are allowing operation you are going to perform
 Press slider on the earthing switch operating slot downwards.
Caution! If the operation is prevented, do not force the interlock
and check there are no interlocks prohibiting the earthing switch
closing.
 Engage the operating lever with the hexagonal shaft. Note: The
operating lever can be inserted in vertical position only. Turn the
lever clockwise by 180° to close the E/S, or counterclockwise to
open the E/S.
 Check the mechanical/electrical earth switch position indicator.
 Remove operating lever. Slider remains opened when the E/S is
closed.

© ABB Group
December 12, 2022 | Slide 85
3. Operation of UniGear ZS1 with circuit breaker
h) VT truck withdrawal

4
1
2
3

 VT truck for cable voltage measurement is behind the cable


compartment door:

1 – Disconnect the secondary wiring plug and fix it on the holder


2 – Disengage the truck locking on both sides
3 – Use the ramp for truck witdrawal to extend the truck guiderails
4 – Pull the truck out of the panel

© ABB Group
December 12, 2022 | Slide 86
3. Operation of UniGear ZS1 with circuit breaker
i) Shutter lifting truck operation

1 2
3

 You can use shutter lifting truck (optional accessories) for access to
spouts after removing the CB from CB compartment:

1 – Place the shutter lifitng truck into the rails for the CB truck in CB
compartment
2 – Push the shutter lifting truck in by means of isolated operation rod and open
the shutters for access to spouts
3 – Rotate the operatio rod to lock the truck and pull the truck out when you are
finished

© ABB Group
December 12, 2022 | Slide 87
4. Interlocks and locks in UniGear
ZS1 with circuit breaker

© ABB Group
December 12, 2022 | Slide 88
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch

 Internal circuit breaker mechanical interlocks prevent:


 CB racking in or out when CB is closed
 CB closing if truck is in the interposition
 Mechanical interlocks in the panel prevent:
 Disconnecting CB control plug if CB is not in test position
 Closing the earthing switch if CB is not in test position
 CB racking in if earthing switch is closed
 Connecting the control plug of CB with wrong rating
 Electrical interlocks (when CB truck blocking coil is applied) prevent:
 CB racking in if control plug is disconnected
 CB racking in or out if auxiliary voltage is not present
 Electrical interlocks (when earthing switch blocking coil is applied)
prevent:
 Closing the earthing switch if auxiliary voltage is not present

© ABB Group
December 12, 2022 | Slide 89
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch

 Internal circuit breaker mechanical


interlocks prevent:
 CB racking in or out when CB is closed
 CB closing if truck is in the interposition

© ABB Group
December 12, 2022 | Slide 90
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch

 Mechanical interlocks in the panel prevent:


 Closing the earthing switch if CB is not in test position
 CB racking in if earthing switch is closed

© ABB Group
December 12, 2022 | Slide 91
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch

 Mechanical interlocks in the panel prevent:


 Disconnecting CB control plug if CB is not in test position
 Connecting the control plug of CB with wrong rating

© ABB Group
December 12, 2022 | Slide 92
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch

 Electrical interlocks (when CB truck blocking coil is applied) prevent:


 CB racking in if control plug is disconnected
 CB racking in or out if auxiliary voltage is not present

© ABB Group
December 12, 2022 | Slide 93
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch

 Electrical interlocks (when earthing switch blocking coil is applied)


prevent:
 Closing the earthing switch if auxiliary voltage is not present

Earthing switch
blocking magnet
positioning

© ABB Group
December 12, 2022 | Slide 94
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters

 Circuit breaker compartment door mechanical interlocks prevent:


 CB compartment door opening if CB truck is not in test position
 CB truck racking in if CB compartment door are opened
 Cable compartment door mechanical interlocks prevent:
 Cable compartment door opening if earthing switch is not closed
 Earthing switch opening if the cable compartment door are opened
 Shutters interlocks (optional) prevent:
 Shutter opening by hands

© ABB Group
December 12, 2022 | Slide 95
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters for 24 kV

 Circuit breaker compartment door mechanical


interlocks prevent:
 CB compartment door opening if CB truck is not in test
position

© ABB Group
December 12, 2022 | Slide 96
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters for 12 kV

 Circuit breaker compartment door mechanical interlocks prevent:


 CB compartment door opening if CB truck is not in test position

© ABB Group
December 12, 2022 | Slide 97
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters

 Circuit breaker compartment door mechanical


interlocks prevent:
 CB truck racking in if CB compartment door are opened

© ABB Group
December 12, 2022 | Slide 98
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters for 24 kV

 Cable compartment door mechanical


interlocks prevent:
 Cable compartment door opening if
earthing switch is not closed

© ABB Group
December 12, 2022 | Slide 99
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters for 12 kV

 Cable compartment door mechanical interlocks prevent:


 Cable compartment door opening if earthing switch is not closed

© ABB Group
December 12, 2022 | Slide 100
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters

 Cable compartment door mechanical interlocks prevent:


 Earthing switch closing if the cable compartment door are opened

© ABB Group
December 12, 2022 | Slide 101
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters

 Shutters interlocks (optional) prevent:


 Shutter opening by hands

© ABB Group
December 12, 2022 | Slide 102
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities

Options
 CB racking slot Double bit, padlock, key lock, no
lock

© ABB Group
December 12, 2022 | Slide 103
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities

Options
 ES operating slot Padlock, key lock, no lock

© ABB Group
December 12, 2022 | Slide 104
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities

Options
 Buttons on the CB Padlock, key lock, no lock

© ABB Group
December 12, 2022 | Slide 105
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities

Options
 Buttons on the CB door Padlock, no lock

© ABB Group
December 12, 2022 | Slide 106
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities

Options
 Shutters Padlock

© ABB Group
December 12, 2022 | Slide 107
UniGear ZS1 installation and
maintenance
© ABB Group
December 12, 2022 | Slide 108
Contents
1. Installation pre-requisites
a) Outline dimensions and MV, LV floor openings in documentation
b) Positioning of switchgear inside the switchroom
c) Foundation frames readiness
2. Installation of the panels
a) Unpacking
b) Tools, equipment, resources and time scale
c) Panels erection & assembly
d) Bus bars assembly
e) Panels LV interconnection
f) Earthing bar installation
g) Top mounted box with earthing switch or VT installation
h) Busbar bridge installation
i) Panel flaps and Ith limitors setup
j) Gas duct installation
k) Fixing the panels to the floor frame
3. Power and control cables installation
a) Control cables installation
b) Preparation for power cable pulling in
c) Power cable entry
4. Maintenance of UniGear ZS1 switchgear
a) Maintenance recommendation
b) Maintenance tasks and intervals
c) Inspection
d) Servicing
e) Repair
f) Practical repairs and troubleshooting

© ABB Group
December 12, 2022 | Slide 109
1. Installation pre-requisites

© ABB Group
December 12, 2022 | Slide 110
1. Installation pre-requisites

a) Outline dimensions and MV, LV floor openings in documentation

© ABB Group
December 12, 2022 | Slide 111
1. Installation pre-requisites
a) Outline dimensions and MV, LV floor openings in documentation

© ABB Group
December 12, 2022 | Slide 112
1. Installation pre-requisites
a) Outline dimensions and MV, LV floor openings in documentation

© ABB Group
December 12, 2022 | Slide 113
1. Installation pre-requisites
b) Positioning the switchgear inside the switchroom

© ABB Group
December 12, 2022 | Slide 114
1. Installation pre-requisites
b) Positioning the switchgear inside the switchroom

© ABB Group
December 12, 2022 | Slide 115
1. Installation pre-requisites
c) Foundation frame readiness

 Classic frame – ladder type

© ABB Group
December 12, 2022 | Slide 116
1. Installation pre-requisites
c) Foundation frame readiness

 C-profile type

© ABB Group
December 12, 2022 | Slide 117
2. Installation of the panels

© ABB Group
December 12, 2022 | Slide 118
2. Installation of the panels
a) Unpacking

 Packing list – all material


needed for installation
 Connecting material for
cubicles
 Assembly material for
bus bars
 Switchgear accessories

© ABB Group
December 12, 2022 | Slide 119
2. Installation of the panels
b) Tools and equipment
 Minimum set of tools:
 Spanners M6, M8, M10,
M12
 Allen keys M6, M8,
M10, M12
 Torque wrench up to
70Nm
 Screwdrivers

 Resources and timescale


 4 people per switchgear
station
 6 panels per day

© ABB Group
December 12, 2022 | Slide 120
2. Installation of the panels
c) Panels erection and assembly
 Read and follow the UniGear
type ZS1 – Installation, service
and maintenance manual (UG
ZS1 IOM Man_Rev.H_2013),
chapter 5
 Panels erection
 One by one – from the first
to the last
 Put up Line up
Tighten up
 Do not fix panels to the floor
before end of whole
installation!
 Finish one task before starting
the second one!

© ABB Group
December 12, 2022 | Slide 121
2. Installation of the panels
c) Panels erection and assembly

 Use all four eyebolts when


lifting
 Support both sidewalls
when shifting
 The sidewalls are carrying
the weight of the panel and
inside apparatus

© ABB Group
December 12, 2022 | Slide 122
2. Installation of the panels
c) Panels erection and assembly

© ABB Group
December 12, 2022 | Slide 123
2. Installation of the panels
c) Panels erection and assembly

 Panels assembly
 One by one – from the
first to the last
 3 vertical rows of bolts
– middle, front, rear

© ABB Group
December 12, 2022 | Slide 124
2. Installation of the panels
d) Busbar assembly

 Read and follow the


UniGear type ZS1 –
Installation, service and
maintenance manual,
chapter 5 and UniGear ZS1
assembly manual
 The nominal voltage and
rated current of your
switchboard influence:
 Bushings
 Bus bar joints type
 Bus bars joints covers

© ABB Group
December 12, 2022 | Slide 125
2. Installation of the panels
d) Busbar assembly
 Bushings 12kV and 17,5kV in busbar comartment

© ABB Group
December 12, 2022 | Slide 126
2. Installation of the panels
d) Busbar assembly
 Bushings 12kV and 17,5kV in bus coupler/riser

© ABB Group
December 12, 2022 | Slide 127
2. Installation of the panels
d) Busbar assembly
 Bushings 24kV in busbar compartment

© ABB Group
December 12, 2022 | Slide 128
2. Installation of the panels
d) Busbar assembly
 Bushings 24kV in bus coupler/riser

© ABB Group
December 12, 2022 | Slide 129
2. Installation of the panels
d) Busbar assembly
 Busbar joints

© ABB Group
December 12, 2022 | Slide 130
2. Installation of the panels
d) Busbar assembly

 Busbar joints
 Clean the contact
surfaces and slightly
grease them with
contact grease
 Be careful about correct
positioning of the
conical washers – they
are creating reactive
force (like spring
washers) for the bolts
and nuts not to get
loosened
 Dry bolts torque 44Nm

© ABB Group
December 12, 2022 | Slide 131
2. Installation of the panels
d) Busbar assembly

 Busbar joint covers


 12kV, current >2000A
 17kV, whole current
range
 24kV, whole current
range

© ABB Group
December 12, 2022 | Slide 132
2. Installation of the panels
d) Busbar assembly
 The side caps must be mounted on the busbars prior to
busbar installation

© ABB Group
December 12, 2022 | Slide 133
2. Installation of the panels
d) Busbar assembly
 Busbar end cover

Lid holder

Lid cover
Flat
full
washers
delivered in
the
switchgear
accessories

© ABB Group
December 12, 2022 | Slide 134
2. Installation of the panels
e) Panel LV interconnections

© ABB Group
December 12, 2022 | Slide 135
2. Installation of the panels
f) Earthing bar installation

 Earthing bar
 It creates the least
resistance path for
earth currents
 Must be connected
minimum at one point to
substation main
earthing (recommended
two points)
 Joints should be
torqued

© ABB Group
December 12, 2022 | Slide 136
2. Installation of the panels
f) Earthing bar installation
 Earthing bar – connection to neighbouring panels

© ABB Group
December 12, 2022 | Slide 137
2. Installation of the panels
g) Top mounted box with earthing switch or VT installation
 Installation of top mounted
boxes is described in the
manuals

 Top mounted box with


busbar earthing switch

 Top mounted box with


VTs

© ABB Group
December 12, 2022 | Slide 138
2. Installation of the panels
h) Busbar bridge installation

 For installation of busbar


bridges (if included) reffer
to a busbar duct installation
instruction (document
number 1VLM000021),
annex. to UniGear type
ZS1 – Installation, servicing
and maintenance manual

© ABB Group
December 12, 2022 | Slide 139
2. Installation of the panels
h) Busbar bridge installation
Switchgear A Switchgear B
 Installation of standard Aisle width frame-to
frame
modular busbar bridges
 The bridge is constructed
for aisle width that was
specified before the
manufacturing and is
measured frame to frame

 Basic structure of the


standardized modular bridge:
 Two corner coupling
modules bolted to the swg.
frame
 Two fixed outer modules
bolted to the corner
modules
 One central module, put
over the fixed outer
modules and fixed as per
the exact aisle width

© ABB Group
December 12, 2022 | Slide 140
2. Installation of the panels
h) Busbar bridge installation

 The main busbar system is made of flat copper profiles,


with single (Ir ≤ 1250 A), double (Ir ≤ 2500 A) or triple (Ir ≤
4000 A) profile
© ABB Group
December 12, 2022 | Slide 141
2. Installation of the panels
h) Busbar bridge installation

 Bus duct structure must be fixed to the ceiling by


suspending or supporting structure (see instruction
1VLG100191 for details)
 The busbar duct is equipped with over-pressure flaps and
a sufficient ceiling clearance above the busbar duct shall
be kept, the fixing structure not preventing the flaps to
open
© ABB Group
December 12, 2022 | Slide 142
2. Installation of the panels
i) Panel flaps and Ith limitors setup
A B C
 Flaps purpose:
 Limit the duration of arcing
to a maximum of 100 ms,
minimizing damages
reduced downtime.
 Fault area selective control
 A – cable compartment
 B – busbar compartment
 C – CB compartment
 Internal arc duration has
influence on the level of
damage, generally:
 >500ms – severe damage
 <100ms – small damage
 <35ms – subtle damage

© ABB Group
December 12, 2022 | Slide 143
2. Installation of the panels
i) Panel flaps and Ith limitors setup

 Flaps setup (if no gas duct


is used):
 The front part of the flaps
Plastic
should be fixed by metalic
bolt
bolts, the rear part by
plastic bolts (there are
metalic bolts inserted for Metalic
transport, they must be bolt
removed)
 Ith limitor setup:
 The Ith limitor must be Thrust
correctly positioned, so adjustnig
that the detection pin is thread
touching the panel frame
through opening in the flap
Detection
 The thrust of the Ith limitor pin
can be adjusted by thread correct
position

© ABB Group
December 12, 2022 | Slide 144
2. Installation of the panels
i) Panel flaps and Ith limitors setup

 Flaps setup (if gas duct is used):


 The front part of the cable
compartment flap should be
fixed by plastic bolts, the rear
part by metalic bolts
 Ith limitor setup – newer version: Plastic
 The Ith limitor correct bolt
possitioning is ensured by part
of the holder is fixed to the flap
 The thrust of the Ith limitor can Thrust
be adjusted primarily by thrust adjustnig
adjusting bolt, if further Thrust
thread
adjustment needed by thrust adjusting
adjusting thread bolt
 Testing of the microswitch is
possible by releasing the bolt Metalic bolt

Detection pin
matching the hole in
the pressure relief
© ABB Group
December 12, 2022 | Slide 145
flap
2. Installation of the panels
j) Gas duct installation
 Gas duct purpose:
 Creates an enclosed
compartment above the
switchgear flaps and leads
the gases from internal arc
out of the building or
spread the gas energy to
wide area by top chimneys

 Assembly:
 Gas dusts are delivered as
loose items (separate for
each panel), start
assembly from one side of
the switchgear and finish
on the other side

© ABB Group
December 12, 2022 | Slide 146
2. Installation of the panels
j) Gas duct installation

 Compact gas duct 12kV / 17,5kV up to 31,5kA


and 24kV up to 31,5kA

Top chimneys

© ABB Group
December 12, 2022 | Slide 147
2. Installation of the panels
j) Gas duct installation
 Standard gas duct 12kV / 17,5kV for 40kA with top
chimneys

© ABB Group
December 12, 2022 | Slide 148
2. Installation of the panels
j) Gas duct installation
 Standard gas duct 12kV / 17,5kV for 40kA without top
chimneys

© ABB Group
December 12, 2022 | Slide 149
2. Installation of the panels
j) Gas duct installation
 Standard gas duct 12kV / 17,5kV for 50kA with and without
top chimneys

© ABB Group
December 12, 2022 | Slide 150
2. Installation of the panels
k) Fixing the panels to the floor frame
 C-profile foundation
frame installation
material
 Fixing from the top is
possible with set of fixing
material, that can be
delivered on request
 In non seismic zone it‘s
enough to fix leftmost
and rightmost panel and
every 5th panel in the
row in between
 In seismic zones it‘s
mandatory to fix all and
every panel

© ABB Group
December 12, 2022 | Slide 151
2. Installation of the panels
k) Fixing the panels to the floor frame

 Fixing to the concrete


and to the metal sheet
floor
 In non seismic zone it‘s
enough to fix leftmost
and rightmost panel and
every 5th panel in the
row in between
 In seismic zones it‘s
mandatory to fix all and
every panel

© ABB Group
December 12, 2022 | Slide 152
3. Power and control cables
installation

© ABB Group
December 12, 2022 | Slide 153
3. Power and control cables installation
a) Control cables installation

 External control cables


continue through the channel
to LV comartment

 Removable channel duct cover

 External control and auxiliary


cables enter from the bottom
through opening with bushings

© ABB Group
December 12, 2022 | Slide 154
3. Power and control cables installation
a) Control cables installation

 There are fixation points for


the control cables on their way
to the top
 Parallel in the same channel
secondary circuit of core
balance CT are pulled
 It‘s recommended not to strip
the armour and the shield (if
aplicable) from the cable untill
the LV compartment entry
 Plate with grommets is at the
LV compartment entry point.
Do not remove it, it serves for
separating the LV
compartment from the control
cable channel

© ABB Group
December 12, 2022 | Slide 155
3. Power and control cables installation
b) Preparation for power cable pulling in

 Loosen the four bolts holding the partition from inside and
pull the partition out of the panel

© ABB Group
December 12, 2022 | Slide 156
3. Power and control cables installation
b) Preparation for power cable pulling in

 Bolts on the right hand side hold part of the earth switch interlock,
be careful when removing and replacing the partition

© ABB Group
December 12, 2022 | Slide 157
3. Power and control cables installation
b) Preparation for power cable pulling in

 If the partition includes a cooling fan (panels for 3150A and


above) then unplug the connector before pulling-out the
partition!

© ABB Group
December 12, 2022 | Slide 158
3. Power and control cables installation
c) Power cable entry

 The power cable entry type


depends on power cable
type (1 core, 3 core)
specified at the design
phase

 The standard system of


holders and openings is in
any case modular enabling
flexible positioning of the
openings

© ABB Group
December 12, 2022 | Slide 159
3. Power and control cables installation
c) Power cable entry
 Alternatively, the system of
non drilled stainless steel
plates can be delivered and
it‘s up to installation
company to properly drill
and gland the cable entry
point

 The modular holders can


be fully removed and
replaced by other
supporting and sealing
structure (if needed due to
the limited room for cable
termination)

© ABB Group
December 12, 2022 | Slide 160
3. Power and control cables installation
c) Power cable entry

 On special request, panel


floor can be lowered below
the floor level, giving more
space for cable termination

 The core balance CTs may


be removed for cable
pulling – do not forget to
install them back and
connect them to their
secondary circuits.

© ABB Group
December 12, 2022 | Slide 161
3. Power and control cables installation
c) Power cable entry
 Do not cut the botom
plates, the sharp edges
may damage your cable,
always use at least
grommets to seal the cable
entry

 Do not twist the cable


inside the cable
compartment if the phase
sequence is not correctly
arranged – mechanicaly
stressed cable cores create
a high risk of fault

© ABB Group
December 12, 2022 | Slide 162
4. Maintenance of UniGear ZS1
switchgear

© ABB Group
December 12, 2022 | Slide 163
4. Maintenance of UniGear ZS1 switchgear
a) Maintenance recommendations
 Read and follow the UniGear
type ZS1 – Installation, service
and maintenance manual (UG
ZS1 IOM Man_Rev.H_2013),
chapter 8
 Maintenance comprises
following closely related
activities:
 Inspection: Determination
of the actual condition
 Servicing: Measures to
preserve the specified
condition
 Repair: Measures to
restore the specified
condition

© ABB Group
December 12, 2022 | Slide 164
4. Maintenance of UniGear ZS1 switchgear
b) Maintenance tasks and intervals

 The maintenance tasks and intervals described in the manual


have background in long-term experience of delivering and
servicing the UniGear ZS1 switchgears. Using these guidelines for
your maintenance works should ensure the best possible reliability
and life time of your switchboard.
 Depending on location of your facility, there might be local
standards and rules prescribing more strict maintenance intervals
or wider maintenance scope for the switchboard. The local rules
must be followed as the information in ABB manuals can be used
as manufacturer recommendation for the maintenance only, not as
mandatory or standard requirement.

© ABB Group
December 12, 2022 | Slide 165
4. Maintenance of UniGear ZS1 switchgear
c) Inspection
 Inspection means
primarily a visual check
for grime, corrosion and
moisture:
 Corrosion on the
primary circuits

 Dust and grime on the


switchgear surfaces,
apparatus surfaces

© ABB Group
December 12, 2022 | Slide 166
4. Maintenance of UniGear ZS1 switchgear
c) Inspection
 Inspection means
primarily a visual check
for grime, corrosion and
moisture:
 Effects of high
temperature on the
main circuits

 Traces of partial
discharge on the
insulating material parts

© ABB Group
December 12, 2022 | Slide 167
4. Maintenance of UniGear ZS1 switchgear
c) Inspection
 Inspection means
primarily a visual check
for grime, corrosion and
moisture:
 Traces of leakage
current on the insulating
material parts

 Surfaces of the contact


systems

© ABB Group
December 12, 2022 | Slide 168
4. Maintenance of UniGear ZS1 switchgear
c) Inspection
 Inspection must contain functional tests for correct
mechanical and electrical operation of main functional
goups:
 Switching devices (circuit breakers, contactors and
earthing switches) including actuating and auxiliary
devices
 Instrument transformers including their secondary
circuits up to the measuring and protection devices – by
primary injection
 Primary circuit joints conductivity – especialy busbar
joints conductivity test
 Interlocks between CB, truck and ES, door interlocks
 Functionality of control and protection circuits – by
secondary injection and function testing
 Switchgear insulation – by insulation resistance
measurement
© ABB Group
December 12, 2022 | Slide 169
4. Maintenance of UniGear ZS1 switchgear
d) Servicing
 Servicing covers following tasks
(scope is based on the input gathered
during inspection):
 Cleaning of the surfaces, insulators,
contact system
 Greasing of joints and contact
systems, operating mechanisms of
switching devices
 Reassembly and retightening of
primary circuit joints (busbars, cable
connections)
 Mechanical troubleshooting of
switching devices and their
operating and auxiliary mechanisms,
interlocks, shutter mechanism
 Troubleshooting of the measurement
and protection system including
instrument transformers
 Functional troubleshooting of control
and protection circuits

© ABB Group
December 12, 2022 | Slide 170
4. Maintenance of UniGear ZS1 switchgear
d) Servicing
 Access to busbar compartment for maintenance:
 Access is best from the back side after removing the back
cover and the rear separation plate
 Access is possible from the top after removing the busbar
compartmenr pressure flap, if no gas duct is installed
 Access is possible from the front side after removing cable
and CB compartment partitioning plate and front separation
plate of the busbar compartment

Cable and CB
Separation compartment
plate for partitioning
rear and separation
access plate for front
access

© ABB Group
December 12, 2022 | Slide 171
4. Maintenance of UniGear ZS1 switchgear
e) Repair
 Repair is action to restore specified (usually normal
functionality, operation) condition
 Depending on the type and extent of the failure, the
basic repairs with in-catalogue spare parts for
switchgears outside of warranty period can be done by
third party, the rest of repair should be done by
certified ABB personnel

© ABB Group
December 12, 2022 | Slide 172
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Releasing the locking magnet RL2 on breaker truck
 Remove front plate of circuit breaker, check for access
through a slot to the locking magnet in the truck
 Disengage locking magnet RL2 by pulling the magnet
armature
 While doing so, turn crank about one half turn (either
direction of rotation is permissible

© ABB Group
December 12, 2022 | Slide 173
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of circuit breaker trolleys auxiliary switches

BT2

BT1

© ABB Group
December 12, 2022 | Slide 174
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of circuit breaker truck auxiliary switches
 Rack the CB out to test position
 For adjustment of the auxiliary switches you need to access
the CB truck from bottom side:
 On a de-energized panel, remove the separation plate
between CB and cable compartment and get access to CB
truck from the bottom

© ABB Group
December 12, 2022 | Slide 175
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of circuit breaker truck auxiliary switches
 If you the panel is energized, you can withdraw the breaker
and tilt it to one side on a firm horizontal surface in the same
height with service trolley platform
 Remove plastic sheet covering both swithes BT1 and BT2 (1
screw off)

© ABB Group
December 12, 2022 | Slide 176
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of circuit breaker truck auxiliary switches
 Unscrew two allen-key screws. Push the aux group BT2
according to the arrow indication and lock the screws.
 Be careful that there is 0,5 mm of gap between the shaft and
the aux frame.

0,5mm

© ABB Group
December 12, 2022 | Slide 177
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of circuit breaker truck auxiliary switches
 To adjust the aux. group BT1 (service position) is necessary
simulate the CB in service position
 Push the service position forcing slider with a screwdriver and
unscrew the allen-key screws for BT1, push the aux group
BT1 according to the arrow indication and lock the screws.
Again maintain 0,5mm safety distance between the fixed and
moving part.

© ABB Group
December 12, 2022 | Slide 178
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of circuit breaker truck auxiliary switches
 After adjusting BT1 group, don‘t forget to put the slider into
original position and apply the plastic cover

© ABB Group
December 12, 2022 | Slide 179
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of earthing switch auxiliary switches

Auxiliary switch BE3 – earthing


switch OFF

Slider

Drive shaft (earthing switch)

Cam plate, adjustable

Auxiliary switch BE2 - earthing


switch ON

© ABB Group
December 12, 2022 | Slide 180
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of earthing switch auxiliary switches
 Auxiliary limit switch (BE2) for earthing switch ON must
be operated immediately after the dead centre position of
the toggle spring mechanism is reached in the closing
process and the automatic rapid closing process has
started
 If adjustment of BE2 is required
 Loosen the cam plate
 Set the cam plate into correct position

© ABB Group
December 12, 2022 | Slide 181
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Adjusting of earthing switch auxiliary switches
 Auxiliary limit switch BE3 for earthing switch OFF must
 a) be operated on earthing switches with manual
mechanisms during the opening movement of the
slide before half of the hexagonal shaft has become
visible, or 1 mm before the tab of the slide makes
contact with the armature of the de-energised locking
magnet
 b) be operated on earthing switches with motor
operators immediately after the toggle spring
mechanism has passed the dead centre position
during rotation to the OFF position
 If adjustment of BE3 is required
 Loosen 2 screws fastening switch BE3 to cubicle
 Set the BE3 to requested position

© ABB Group
December 12, 2022 | Slide 182
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting

© ABB Group
December 12, 2022 | Slide 183
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Safety notes for VD4 circuit breaker repair
 Before you start any work on CB auxiliaries, make sure
the CB auxiliary wiring is disconnected from the power
source and the mechanical energy stored in the CB
main and auxiliary springs is discharged – i.e. CB is
opened and main spring is discharged.

© ABB Group
December 12, 2022 | Slide 184
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Replacement of closing (MC), opening (MO) and
undervoltage (MU) coil
 The coil baseplate on right hand side is locked in place
by one bolt only. Remove the bolt and take out the
baseplate with coils by releasing handle.

© ABB Group
December 12, 2022 | Slide 185
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Replacement of closing (MC), opening (MO) and
undervoltage (MU) coil
 Each coil is holding on two bolts and has one electrical
connection with the baseplate itself.
 When returning the baseplate in it‘s position, match the
two holes on the baseplate with the guiding pins in
breaker, which allows proper alignment

© ABB Group
December 12, 2022 | Slide 186
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Replacement of blocking coil (RL1)
 The coil baseplate on right upper side above the
closing pushbutton is mounted in place by two bolts.
Disconnect the control wiring plug, remove the bolts,
and take out the baseplate with coil. Replace the coil
and mount the holder back in place.

© ABB Group
December 12, 2022 | Slide 187
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Replacement of spring charged signalling contact
(BS2)
 The contact is located on right bottom side below the
coils. The baseplate with coils must be removed to
access the contact. Disconnect the contact electrical
connections, two bolts are holding the contact in
position.

© ABB Group
December 12, 2022 | Slide 188
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Replacement of charging motor
 The motor is located left to the operating mechanism.
After disconnecint the electrical connections and
removing one locking screw, the motor can be sliped
from the shaft sideways and replaced.

© ABB Group
December 12, 2022 | Slide 189
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
 Replacement of charging motor
 To align the motor with the shaft, first set the motor
socket to match the position as shown on the picture
and then slip the motor on the shaft. Holding the
charging lever can help you to get more space for the
alignment.

© ABB Group
December 12, 2022 | Slide 190
© ABB Group
December 12, 2022 | Slide 191

You might also like