Professional Documents
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Manual Instalacion Servicio y Mantenimiento Del Switchgear
Manual Instalacion Servicio y Mantenimiento Del Switchgear
UniGear ZS1
Installation, service and maintenance instruction manual
Contents
1 Summary 3
2 Technical data 4
3 Panel design and equipment 7
4 Dispatch and storage 21
5 Assembly of the switchgear on site 27
6 Operation of the switchgear 67
7 Maintenance 84
8 Product quality and environmental protection 102
Your safety first – at all times!
This is why our instruction manual begins with the following recommendations:
• Only install switchgear and/or switchboards in closed rooms suitable for electrical equip-
ment.
• Ensure that installation, operation and maintenance are only carried out by specialist
electricians only.
• Fully comply with the legally recognized standards (IEC or local), the connection condi-
tions 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 the specified data are not exceeded under switchgear or switchboard
operating conditions.
• Keep the instruction manual accessible to all personnel involved in installation, opera-
tion and maintenance.
• The user’s personnel must act responsibly in all matters affecting safety at work and
correct handling of the switchgear.
WARNING
Always follow the instruction manual and respect the rules
of good engineering practice !
Hazardous voltage
can cause electrical shocks and burns.
Disconnect power, then earth and short-circuit before proceeding
with any work on this equipment.
If you have any further questions about this instruction manual, the members of our field
organization will be pleased to provide the required information.
We reserve all rights to this publication. Misuse, and including in particular, duplication
and making this manual - or extracts thereof available to third parties is prohibited. We do
not accept any responsibility for the information provided, which is subject to alternation.
2
Contents
Page Page
1. Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5.6.2 Busbar compartment access . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5.6.3 Busbar installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Standards and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5.7 Installation of the top-mounted boxes. . . . . . . . . . . . . . . . . . . 49
1.3 Operating conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5.7.1 Voltage transformers for busbar metering . . . . . . . . . . . . . . . 49
1.3.1 Normal operating conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5.7.2 Earthing switch for busbar earthing . . . . . . . . . . . . . . . . . . . . 52
1.3.2 Special operating conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5.8 Pressure relief ducts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.8.1 Standard gas duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2. Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5.8.2 Compact gas duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5.8.3 Compact gas duct with top chimneys. . . . . . . . . . . . . . . . . . . 59
2.1.1 Main parameters for panels with circuit-breakers. . . . . . . . . . . 4 5.9 Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.1.2 Main parameters for panels with NALF switch-disconnector . . 4 5.9.1 Power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2 Resistance to internal arc faults. . . . . . . . . . . . . . . . . . . . . . . . 4 5.9.2 Control cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5.10 Earthing the switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3.1 Dimensions and weights of 12/17,5 kV units . . . . . . . . . . . . . . 5 5.11 Laying the ring circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3.2 Dimensions and weights of 24 kV units . . . . . . . . . . . . . . . . . . 6 5.12 Final erection work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3.3 Dimensions and weights of panels with the
NALF 12/17,5 kV switch-disconnectors . . . . . . . . . . . . . . . . . . 6 6. Operation of the switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3.4 Dimensions and weights of panels with the NALF 24 kV 6.1 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
switch-disconnectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1 Preparatory work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3. Panel design and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6.2 Switching operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.1 Basic structure and variants. . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6.2.1 Withdrawable apparatus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.2 Enclosure and partitioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6.2.2 Circuit-breaker – type VD4 and Vmax . . . . . . . . . . . . . . . . . . 73
3.2.1 Ventilation of the panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6.2.3 Circuit-breaker – type VM1. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.3 Compartments in the panels. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2.4 Circuit-breaker – type HD4. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.3.1 Busbar compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2.5 Vacuum contactor – type V-contact . . . . . . . . . . . . . . . . . . . . 76
3.3.2 Circuit-breaker compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2.6 Withdrawable metering parts . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3.3 Withdrawable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.2.7 Earthing switch – type EK6 and ST-VG-01. . . . . . . . . . . . . . . 77
3.3.4 Cable connection compartment . . . . . . . . . . . . . . . . . . . . . . . 12 6.2.8 Busbar earthing switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3.5 Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6.2.9 Earthing and short-circuiting with earthing module. . . . . . . . . 78
3.3.6 Switch-disconnector and cable compartment 6.2.10 NALF type switch-disconnector . . . . . . . . . . . . . . . . . . . . . . . 80
in the panel with switch-disconnector. . . . . . . . . . . . . . . . . . . 13 6.3 Test procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.4 Interlock/protection against erroneous operation. . . . . . . . . . 14 6.3.1 Testing the off-circuit condition. . . . . . . . . . . . . . . . . . . . . . . . 82
3.4.1 Panel internal interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.3.2 Current and voltage tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.4.2 Door interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.4 Service trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.4.3 Interlocks between panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.4.1 Earthing truck without making capacity. . . . . . . . . . . . . . . . . 83
3.4.4 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.4.2 Earthing truck with making capacity. . . . . . . . . . . . . . . . . . . . 83
3.4.5 Internal interlocking of panel with 6.4.3 Power cable test truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
switch-disconnector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.4.4 Isolation truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.5 Circuit-breaker and contactor plug connector
coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 7. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.6 Fast recovery device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.7 Ith Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.1.1 Intervals for inspection, servicing and repairs. . . . . . . . . . . . . 84
7.2 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4. Dispatch and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.3 Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.1 Condition on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.3.1 Maintenance in busbar compartment. . . . . . . . . . . . . . . . . . . 86
4.2 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.3.2 Maintenance in cable compartment . . . . . . . . . . . . . . . . . . . . 87
4.3 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.3.3 Maintenance in circuit-breaker compartment. . . . . . . . . . . . . 91
4.4 Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7.3.4 Maintenance in the low voltage compartment . . . . . . . . . . . . 92
4.5 Intermediate storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7.4 Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.6 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7.4.1 Switchgear in general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.6.1 Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7.4.2 Replacement of complex functional groups . . . . . . . . . . . . . . 95
4.6.2 Apparatus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 7.5 Testing withdrawable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.5.1 Motor-driven withdrawable parts. . . . . . . . . . . . . . . . . . . . . . . 97
5. Assembly of the switchgear on site . . . . . . . . . . . . . . . . . . . 27 7.5.2 Checking correctness of dimensional settings. . . . . . . . . . . . 97
5.1 General site requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.5.3 Checking auxiliary switch setting on withdrawable parts . . . . 97
5.2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.5.4 Checking the direction of rotation of the travel motors
5.2.1 Method of installation A – Installation of the base irons. . . . . 28 on motor-driven withdrawable parts. . . . . . . . . . . . . . . . . . . . 97
5.2.2 Method of installation B – Fixing with anchoring bolts 7.5.5 Testing interlock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
to concrete floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7.6 Tests on the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.2.3 Method of installation C – Fixing to a raised false . . . . . . . . . 31 7.6.1 Auxiliary switch settings on the earthing switch . . . . . . . . . . 100
5.3 Assembly of the switchgear panels. . . . . . . . . . . . . . . . . . . . 36 7.7 Spare parts, auxiliary materials and lubricants. . . . . . . . . . . 100
5.4 Installation of the bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7.7.1 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.4.1 Bushing of 12/17,5 kV panels. . . . . . . . . . . . . . . . . . . . . . . . . 39 7.7.2 Auxiliary materials, lubrificants. . . . . . . . . . . . . . . . . . . . . . . 100
5.4.2 Bushing of 24 kV panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7.8 Operating accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.5 Fixing of the panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6 Installation of the busbars. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 8. Product quality and environmental protection. . . . . . . . . . . . 102
5.6.1 Preparation of the material. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3
1. Summary
1.1 General
UniGear is the new name of the ZS1 switchgear in release 1.2 (ZS1.2). It is three-phase, metal-clad,
air insulated switchgear and all the units are factory-assembled, type-tested and suitable for indoor
applications up to 24 kV.
The units are designed as withdrawable modules and are fitted with a single busbar system. The with-
drawable parts are equipped with circuit-breakers and contactors.
Details of the technical design and configuration of individual switchgear, such as the technical data,
detailed equipment lists for the individual panels and comprehensive circuit documentation etc., can be
found in the relevant order documents.
Note
The UniGear ZS1 switchgear is indicated in the test reports and type test certificates with the abbrevia-
tion ZS1.2
Figure 1: Curve for determination of the altitude factor k in relation to the altitude H.
4
2. Technical data
For individual switching device data, see the instruction manual for the relative switching device, as
listed under 7.1.
The switchgear units have been tested according to IEC 62271-200 standard (appendix AA, class A,
criteria 1 to 5) and also to PEHLA recommendation no. 4.
In individual cases, depending on the configuration of the switchgear panels and/or the switchgear room
conditions (e.g. low ceiling height), additional measures may be necessary to ensure compliance with
criterion 5.
5
2.3 Dimensions and weights
Dimension mm
Height A 2200/2595 1)
Width B
- Feeder panels up to 1250 A (31.5 kA) 5)
550
- Feeder panels up to 1250 A (up to 31.5 kA) 4)
650
- Feeder panels up to 1250 A (above 31.5 kA) 800
- Feeder panels 1600 - 2000 A 800 2)
- Feeder panels above 2000 A 1000
Depth C 1340/13903)
E 1495
1)
Height of the control cabinet is 705/1100mm (dimensions without gas-duct);
2)
1000mm available on request;
3)
12/17,5 kV-3150A and 4000A are always 1390 depth;
4)
Feeders equipped with vacuum contactor are 650mm wide up to the 50kA short-time current;
5)
UniGear ZS1 550 series only.
The dimension must be verified according to the documentation of the relevant order.
6
2.3.2 Dimensions and weights of 24 kV units
Dimension mm
Height A 2325/2720 1)
Width B
- Feeder panels up to 1250 A 800 2)
- Feeder panels above 1250 A 1000
Depth C 1700
Height of the basic part of panel D 2200
E 1620
1)
Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).
2)
1000mm available on request.
The dimension must be verified according to the documentation of the relevant order.
2.3.3 Dimensions and weights of panels with the NALF 12/17.5 kV switch-disconnectors
Dimension mm
Height A 2200/2595 1)
Width
- Outgoing and incoming panels with B 800
switch-disconnector 630 A
Depth C 1300/1340 2)
Height of basic part of panel D 2100
E 1495
1) Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).
2) The depth of panel with the switch-disconnector in combination with HD4 circuit-breaker panels is recommended at 1340 mm, in
other cases 1300 mm – always take into account the note 3).
3) The dimensions must be verified according to the documentation of relevant order.
Dimension mm
Height A 2325/2720 1)
Width
- Outgoing and incoming panels with B 1000
switch-disconnector 630 A
Depth C 1700 2)
Height of basic part of panel D 2100
E 1495
1) Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).
7
3. Panel design and equipment
8
The finishing coat is in the standard RAL 7035 colour (special colours by agreement). Stoving completes
the procedure and provides considerable insensitivity to impact and corrosion.
The circuit-breaker compartment and cable connection compartment doors are pressure resistant and
can either be fitted with screws or manual closing systems (central handle).
1.7
1.1
A D
1 12.1
2
15.1
3
10
84
1.2
12.2
12 B
5 13
18
18.1 6 18
18.2
7
20.2 20.2
14 20
14.1
14.2 14
8 1.2
C 16
21
17
19
9
3.3 Compartments in the panels
25 kA No 1)
24 kV
31.5 kA Every third panel 2)
1)
In these panels, busbar bushing and bushing plates don’t need to be mounted. The dynamic strength of the busbar system is
sufficient.
2)
In these panels, busbar bushing and bushing plates must be mounted in every third panel only when you have the sequence of
800 and 1000mm wide. If these panels are positioned between 650mm wide panel they don’t need bushings because the dynamic
strength of the busbar system is sufficient.
3)
In these panels, busbar bushing and bushing plates must be mounted in every panel.
According to customer requirements, this separation into individual panels by means of busbar bush-
ings 29 and bushing plates 28 (figures 61, 62) can also be provided in switchgear panels where it is
not technically necessary.
Top-mounted boxes with busbar earthing switches, or busbar voltage transformers can be placed above
the units.
58.5
58
10
In the test/disconnected position, the withdrawable part is still completely inside the panel with the door
closed. The ON/OFF pushbutton located on the circuit-breaker, and the mechanical indicators for ON/
OFF and CHARGED/DISCHARGED can be observed through an inspection window if the circuit breaker
is in service position.
The switching operations are carried out with the doors closed. Installation of an additional mechanical
switching device for manual operation of the circuit-breaker in the service position is also possible (see
fig. 7, 8).
The socket 10.1 (figure 4) for the control wiring is mounted fixed in the circuit-breaker compartment.
10.1
10.2
12.1
43.3
13.1
12.2
42
18.1
14/14.1
14
Figure 4: View into the circuit-breaker compartment Figure 5: Circuit-breaker compartment open
10.1 Control wiring socket Withdrawable part in disconnected position,
12.1 Top shutter control wiring plug connector open
12.2 Lower shutter 10.2 Control wiring plug
14 Earthing switch operating mechanism 13.1 Withdrawable part
14.1 Drive shaft 14 Earthing switch operating mechanism
42 Right-hand travel rail 18.1 Square spigot
43.1 Duct cover, top left
43.3 Duct cover, top right
13.16
11
45.2
45.3
45.1
Figure 7: Push button for mechanical ON/OFF breaker Figure 8: View of the push rod extension swung out by
operation with the door closed (on request). the knob at the front, with the withdrawable
If the withdrawable part is in the service circuit-breaker part in service position and the
position, operation is carried out using the door open
knob which swings a push rod extension out. 45.3 Swivelling push rod
45.1 Mechanical pushbutton
45.2 Turning knob
12
13.15 18.2 18.1 S9 S8 10.3
91.15
91.13
91.14
Figure 11: V-Contact VSC type vacuum contactor – front Figure 12: V-Contact type vacuum contactor – pole side
view 91.15 MV fuses
91.13 Signalling device ON/OFF 91.13 Signalling device ON/OFF
91.14 Operating cycle counter 91.14 Operating cycle counter
13
The voltage transformers mounted fixed are connected on the primary side with flexible, fully- insulated
cables which are inserted in the transformers.
The removable voltage transformers are fitted with HRC fuses. The EK6 type earthing switch can be
used with either a manual or motor-operated mechanism.
Its switching position will be indicated both mechanically by indication on the shaft and electrically by
means of the auxiliary switch. Earthing switch in 550 series cannot be equipped with a motor-operated
mechanism.
Three surge arrestors can be mounted fixed, instead of one position of single-core cables.
For detailed information about cable connections, please make reference to the figures
102...106.
The cable connections are supplied without screws, washer and nuts; the supply of this mate-
rial, according to the cable termination, is at Customer charge.
Important note
In the case of any atypical cable connections an agreement must already be reached between customer
and manufacturer in the technical preparation stage of order.
14
3.4 Interlock/protection against erroneous operation
Warning
It is important that when the front doors (circuit-breaker and cable) are supplied with screws,
these screws are all fixed properly in order to guarantee the interlocks and the safety of the
personnel in case of internal arc.
1) In the case of a motor operator, the mechanical interlock or the locking magnet is replaced by an electrical interlock of the
earthing switch. The manual emergency switch is not locked!
2) The locking magnet is not installed in the case of a motor operator; busbar earthing switches or the withdrawable parts
are electrically locked. The manual emergency switch is not locked!
3) This interlock is not available for motor-operated withdrawable apparatus as a mechanical device.
15
A
16
C
C1
Figure 18: Cable compartment door enabling slot (C1) and earthing switch enabling pin (C2)
17
3.4.5 Internal interlocking of panel with switch-disconnector
To prevent hazardous situations and erroneous operation, there is a series of interlocks to protect both
personnel and equipment:
• The switch-disconnector can only be switched on if the earthing switch is off. The earthing switch can
only be switched on if the switch-disconnector is off. The switch-disconnector and earthing switch are
mutually mechanically interlocked;
• The door of the lower cable HV part on the panel can only be opened if the earthing switch is on.
During closing of the earthing switch the insulating plate 205.1 (figure 21) is automatically inserted in
the isolating distance of the switch-disconnector, which increases safety. This plate is automatically
removed again during opening of the earthing switch;
• The earthing switch can only be operated if the cable compartment door is closed;
• If the control voltage is not connected, the switch-disconnector can only be opened and closed manu-
ally. Manual operation of switch-disconnector and earthing switch can be prevented if the slides 201.2
and 208.1 of the operating openings are locked up;
• In the panels with digital control techniques the protection against erroneous operation is basically car-
ried out by means of panel software. But the earthing switch is operated locally by means of operating
lever 215 (figure 22). The mechanical interlock between the switch-disconnector and earthing switch
is still in operation;
• Details of other possible interlocks, e.g. in connection with a locking magnet on the switch-disconnector,
can be obtained from the relevant order documents.
Warning
• The door of the upper HV part on the panel can only be opened if the off-circuit condition of the switch
disconnector is verified. This means that the off-circuit condition must be unconditionally verified both
on the upper and lower contacts of switch disconnector.
200.1
200
215
205.1
205
Figure 21: Switch-disconnector compartment – open posi- Figure 22: Preparation for the operation of earthing switch
tion. Insulating plate in the isolating distance of in panel with the switch-disconnector.
switch-disconnector Operating lever prepared for the operation
200 Switch-disconnector OFF.
200.1 Position indicator of switch- 215 Operating lever
disconnector
205 Insulation partition wall
205.1 Movable insulation plate
18
Coding
The corresponding coding designation for the control
wiring plug is given in brackets (10.2)
The coding pins can be fitted in the control wiring
socket (10.1) and/or in the control wiring plug (10.2).
Basic design
The number of sockets is optional, but the basic as-
signment is 1, 8, 10, 20, 21, 31, 33 and 40.
Sockets and pins can be mixed as required in the
control wiring socket (10.1) and control wiring plug
(10.2).
Circuit-breakers and contactors Plug pin coding (apparatus) Socket hole coding (panel)
12-17.5 kV 650 mm 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6
400 A V • • • •
630 A VD4 VM1 HD4 • • • •
1250 A VD4 VM1 HD4 VD4 VM1 HD4 • •
1600 A VD4 VM1 HD4 VD4 VM1 • • • •
2000 A VD4 VM1 • •
2500 A VD4 VM1 HD4 • • • •
3150 A VD4 VM1 HD4 • • • •
3600 A VD4 VM1 HD4 • • • •
4000 A VD4 VM1 HD4 • • • •
Isolating trucks Plug pin coding (apparatus) Socket hole coding (panel)
12-17.5 kV 650 mm 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6
400 A
630 A 17.12.32
1250 A • • • •
1600 A 17.20.50
2000 A • • • •
2500 A 17.25.50 • • • •
3150 A • • • •
3600 A 17.32.50 • • • •
4000 A • • • •
Isolating trucks Plug pin coding (apparatus) Socket hole coding (panel)
24 kV 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6
630 A
24.12.25
1250 A • • • •
1600 A
2000 A 24.25.25
2500 A • • • •
Figure 23: Control wiring plug connector coding, shown for a 58 pole connector
10.1 Control wiring socket
10.4 Centring strinking tabs
10.5 Bore for actuating pin of the control wiring plug for controlling the auxiliary switch
19
3.6 Fast recovery device
UniGear ZS1 switchgear can optionally be equipped with “Fast Recovery Device”, a specific protection
system.
This system is based on pressure sensors (figure 24), suitably located in the switchgear and directly
connected to the shunt opening release installed in the circuit-breaker operating mechanism (figure 25).
The sensors detect the pressure rise front at the moment of an internal arc and promptly open the
circuit-breaker.
Thanks to the “Fast recovery” system, only the part involved in the fault is selectively excluded in under
100ms (including the circuit-breaker opening time). Rapid elimination of the fault along with the metal
segregation between compartments and the use of self-extinguishing materials drastically reduces any
possible damage.
1 Pressure reducer
2 Lever for opening the air valve
3 Manometer
20
3.7 Ith Limiters
UniGear ZS1 switchgear can optionally be equipped with microswitches on the top of each unit. The
microswitch generates a fault signal immediately when the overpressure flap is being opened. Reaction
time is less then 15ms. The signal from microswitch can be sent directly to circuit-breaker OFF trigger.
Rapid elimination of the fault along with the metal segregation between compartments and the use of
self-extinguishing materials drastically reduces any possible damage.
11.5
49.2
49.5
49.4
Figure 28: Auxiliary Ith limiter switch. It may be necessary to move the auxiliary switches into their service position when the
lifting eyebolts have been removed.
It is necessary to adjust the centre of the switch knob of the auxiliary switch to the centre of the pressure relief
flap’s hole. Correct value of the adjustment of the auxiliary switches’ height in pressed position according to the
particular type of the switch is on the figure A) or B).
11.5 Ith limiter
49.2 Pressure relief flap, made of steel sheet
49.4 Rupture bolt (plastic)
49.5 Socket screw
21
4. Dispatch and storage
4.2 Packing
According to the kind of transport and country of destination, the panels remain unpacked or are welded
in foil and packed in seaworthy crates. A drying agent is provided to protect them against moisture:
• Panels with basic packing or without packing;
• Panels with seaworthy or similar packing (including packing for container shipments):
- Sealed in polyethylene sheeting;
- Transport drying agent bags included;
- Moisture indicator included;
• Observe the directions for use of the drying agent bags. The following applies:
- Coloured indicator blue: contents dry;
- Coloured indicator pink: contents moist (relative humidity above 40%).
4.3 Transport
The transport units normally comprise individual panels and, in exceptional cases, small groups of panels.
The panels are each fitted with four lifting eyebolts.
Transport panels upright. Take the high centre of gravity into account. Only ever carry out loading op-
erations when it has been ensured that all precautionary measures to protect personnel and materials
have been taken and use the following:
• Crane;
• Fork-lift truck and/or;
• Manual trolley jack.
Loading by crane:
• Fit lifting ropes of appropriate load capacity with spring catches (eyebolt diameter: 30 mm);
• Keep an angle of at least 60° from the horizontal for the ropes leading to the crane hook;
• Hang the unit using ALL four eyebolts!
1.5
22
4.4 Delivery
The responsibilities of the consignee when the switchgear arrives at site include, but are not limited to,
the following:
• Checking the consignment for completeness and lack of any damage (e.g. also for moisture and its
detrimental effects). In case of doubt, the packing must be opened and then properly resealed, putting
in new drying agent bags, when intermediate storage is necessary;
• If any quantities are short, or defects or transport damage are noted, these must be:
- documented on the respective shipping document;
- notified to the relevant carrier or forwarding agent immediately in accordance with the relative liability
regulations.
Note
Always take photographs to document any major damage.
Optimum intermediate storage, where this is necessary, without any negative consequences depends
on compliance with a number of minimum conditions for the panels and assembly materials.
Warning
Do not walk on the roof of the panels (rupture points in pressure relief devices!).
The pressure relief devices and/or Ith Limiters could by damaged.
4.6 Handling
4.6.1 Switchgear
The switchgear sections are usually fixed to wooden pallets. Handling should be carried out by means
of bridge or mobile cranes. Otherwise, use rollers or fork lift trucks.
Weights and dimensions of each section are listed in the shipping documents and in the plant drawings.
23
Unpacking
• Remove the nails and crate lid and sides;
• Open the compartment door and loosen the bolts fixing the switchgear to the pallet;
• Lift the cubicles by means of the crane following the instructions below;
• Remove the pallet;
• Position the unloading shims;
• Put the switchgear on the loading shims by using the crane.
Switchgear handling
After unpacking, lift the unit groups by means of a crane (figure 29). Use the eyebolts (1.5) and the ropes
fitted with safety.
After installation of the panels, remove the eyebolts used for lifting.
Lift the switchgear section by means of a bridge or mobile crane or using jacks (figure 29); remove the
wooden pallet loosening the screws fixing it to the switchgear section base.
Put a sturdy metal sheet between the rollers and the unit base and place the switchgear on the sliding rollers.
24
Metal sheet
Sliding rollers
To guarantee stability, the switchgear must not be lifted too high. Check the levelness of the forks.
Figure 32: Lifting switchgear packed in a wooden crate Figure 33: Switchgear handling
4.6.2 Apparatus
The apparatus can be handled by means of cranes, fork lift trucks or using the truck provided by ABB.
For each piece of apparatus follow the instructions below.
• While handling do not put any stress on the insulating parts and on the apparatus terminals.
• Before handling the apparatus, make sure that the operating mechanism springs are discharged and
that the apparatus is in the open position.
25
4.6.2.1 Handling by means of crane
Circuit-breakers
Hook the lifting bolts to the relevant supports (figure 34). While handling, pay the utmost attention not to
put any stress on the insulating parts and on the circuit-breaker terminals (figure 35).
Contactor
• Insert the lifting bar (1) centring it with the contactor;
• Hook the bracket (2) to the lifting bar (1);
• Hook the bracket (2) by means of a spring catch and lift the contactor;
To remove the lifting equipment proceed in reverse order.
2 2
Handling by means of fork-lift trucks can be carried out only after the apparatus has been positioned
on a sturdy support.
While handling, pay the utmost attention not to put any stress on the insulating parts and on the circuit-
breaker terminals.
26
Figure 37: Handling by means of fork lift trucks
For handling and inserting the apparatus into the switchgear, use the truck 1 supplied by ABB (Figure 38).
• Do not use the racking in/out truck for any purpose other than handling our apparatus.
• Fix the circuit-breaker to the truck before moving it.
In order to handle the circuit-breaker by means of the relevant truck, follow the instructions below (figure 38):
• hook the lifting bolts to the circuit-breaker supports and align it above the truck (1):
• press the handles (2) towards the circuit-breaker centre (*) to make the horizontal check pins go in
(3);
• put the circuit-breaker on the truck;
• push the circuit-breaker towards the circuit-breaker compartment and insert the truck into the guides
until the handles (2) are released (**) outwards and the horizontal locking pins go into the slots (4),
locking the circuit-breaker.
3 3
4 4
2 2
1
(*)
(**)
Figure 38
27
5. Assembly of the switchgear on site
In order to obtain an optimum installation sequence and ensure high quality standards, site installation
of the switchgear should only be carried out by specially trained and skilled personnel, or at least by
personnel supervised and monitored by responsible persons.
5.2 Foundations
The following 3 basic installation methods of switchgear in the switchroom are distinguished:
Method A – installation on the base irons of “C” profile shape
As standard it is recommended to install the switchgear on the base irons of “C” profile shape set into
the concrete floor of switchroom. In this case the units are fastened using the special bolt blocks (ABB
delivers by request).
Method B – installation on the levelled concrete floor
Installation directly on the levelled concrete floor makes much higher demands on the floor levelling,
which must, in this case, fulfill the same tolerances as the base irons during installation method A.
The fastening is carried out by means of anchoring bolts in the concrete floor.
Method C – installation on the raised false floor
In this case fastening of units is carried out by welding of outside panels to the steel floor frame in the
place where the frame exceeds the switchgear bottom, this means on the outside lateral walls of unit row.
This method of installation is not recommended if seismic resistance is required.
1)
Pay attention to appropriate national standards.
2)
Applies to low voltage compartments of standard height.
3)
Approximate numbers depending on the type of panels.
28
5.2.1 Method of installation A – Installation of the base irons:
The general foundation drawing is given in figures 39, 40 according to parameters of units.
• The base irons of “C” profile shape can be supplied by ABB manufacturer together with the switchgear.
Their installation is usually carried out by site personnel and should, if possible, be performed under
supervision of an ABB specialist. The base irons must be installed in the slab before finishing the floor;
• Rest the irons in the specified position on the concrete floor as shown in the relevant foundation drawing
and mark out holes for drilling in the place of prepared holes. Then drill the holes for anchoring bolts
i.e. for plugs 14 for fixing the base irons in the floor. Then put the plugs in the holes and attach the
base irons to the floor slightly with the bolts 13 without end tightening to make the required levelling
possible.
• Carefully level base irons both longitudinally and transversally over the entire length and to the correct
height by putting them under strips of suitable thickness and using a levelling instrument.
5.2.2 Method of installation B – Fixing with anchoring bolts to concrete floor (Figure 55).
The general foundation drawing is given in figure 41 according to parameters of units.
• Clean the installation area of the switchgear carefully;
• On the slab, visibly trace the perimeter of all the units making up the switchgear according to the
relevant drawing, taking the minimum wall and obstacle clearances into account;
• Level the floor both longitudinally and transversally; evenness tolerance is ± 1mm within a measuring
length of 1m;
• Drill the floor at the foreseen fixing points, referring to the slab drilling drawings. To make the holes,
use a hammer drill with the bit according to the steel plugs used;
• Insert the plugs in the holes and put the individual panels on the traced perimeters of the units creating
the switchgear;
• Level the units and then bolt them together in the front and rear part;
• Fix the units with bolts with special washers (the coupling material is supplied by request);
• In the case of a metal floor, use the attachment according to the figure (Figure 57 or 58) To make the
holes, use a drill with a suitable bit for the type of fixing to be made (through orthreaded hole).
29
Top view
Section A-A
Figure 39: UniGear ZS1 12÷24 kV (i.e. the above section is related to 12 kV, 2500A nominal current)
Guideline structural data for foundation frame on concrete floor
It is not valid for the panel with switch-disconnector
C Panel depth
G Width of operating aisle (panel width + 800mm)
FT Panel width
TB Door width = FT + 200mm
TH Door height = panel height + 200mm
1) Min. dimensions
2) The dimension must be verified in the documentation of the relevant order
10 Door
11 Rear cover
12 Side end cover
13 Screw
14 Steel dowel
30
Top view
Section A-A
Figure 40: UniGear 12÷24 kV with NAL switch-disconnector (i.e. the above section is related to 12 kV)
Guideline structural data for foundation frame on concrete floor
C Panel depth is C=1340 mm or 1300 mm according to the depth of the other cubicles – however
always consider note 2)
G Width of operating aisle
FT Panel width
TB Door width = FT + 200 mm
TH Door height = panel height + 200 mm
1) Min. dimensions
2) The dimension must be verified in the documentation of the relevant order
10 Door
11 Rear cover
12 Side end cover
13 Screw
14 Steel dowel
31
16 17 6 8
14
10
12 9
A Panel depth
1) Minimum dimensions
2) The dimension must be verified according to the documentation of the relevant order
1 Operator aisle
6 Control cabinet (optional)
8 Opening for ventilation
9 Height of cable base - as required
10 Concrete - see also fig. 5/8
12 Opening for power cables
14 Door
16 Wall opening for pressure relief
17 Pressure relief duct
32
Top view
Section A-A
View B
Rated Panel B C 1)
voltage depth A 2)
kV m m m
Figure 42: Guideline structural data for a raised false floor – 12, 17.5 and 24 kV UniGear ZS1
A Panel depth
G Width of operating aisle
FT Panel width
TB Door width = FT + 200 mm
TH Door height = panel height + 200 mm
1) Min. dimensions
x) Max. dimensions
2) The dimension must be verified in the documentation of the relevant order
33
Figure 43: 12/17.5 kV – 650/800/1000mm wide units Figure 44: 12/17.5 kV – 650/800/1000mm wide units
– anchoring bolt fixing system – base iron fixing system
37
37
37
37
843
843
843
843
60 430 60 60430 60
60 430 60 60430 60
1231
1231
1231
1231
300
300
300
300
50 200
50 200
50 200
50 200
340
340
200
200
340
340
200
200
311
311
311
311
50
50
50
50
70 70 70 70 70 70
70 70
72
72
72
72
105 340 105 105 340 105 105 340 105 105 340 105
550 550 550 550
Figure 45: 12/17.5kV – 550mm wide units Figure 46: 12/17.5kV – 550mm wide units
– anchoring bolt fixing system – base iron fixing system
34
Figure 47: 24 kV – 800 mm wide units Figure 48: 24 kV – 800 mm wide units
– anchoring bolt fixing system – base iron fixing system
Figure 49: 24 kV – 1000 mm wide units Figure 50: 24 kV –1000 mm wide units
– anchoring bolt fixing system – base iron fixing system
35
Figure 51: 12/17.5 kV – cubicle with switch-disconnector Figure 52: 12/17.5 kV – cubicle with switch-disconnector
– anchoring bolt fixing system – base iron fixing system
Figure 53: 24 kV – cubicle with switch-disconnector Figure 54: 24 kV – cubicle with switch-disconnector
– anchoring bolt fixing system – base iron fixing system
36
80
80
16
16
Figure 55: Anchoring bolts on concrete floor Figure 56: Base irons on concrete floor
Figure 57: Through hole on metal structure Figure 58: Threaded hole on metal structure
Any tightening torques which deviate from those in the general table (e.g. for contact systems or device
terminals) must be taken into account as stated in the detailed technical documentation.
It is recommended that the threads and head contact surfaces of bolts should be lightly oiled or greased,
so as to achieve a precise rated tightening torque.
37
The individual installation stages are as follows:
• Remove withdrawable parts 13 (figure 2) from the switchgear panels and store them with suitable
protection;
• Dismantle lifting eyebolts 1.5 (figure 29);
• Transport the switchgear panels to the prepared installation point following the sequence shown on
the switchgear plan;
• Remove vertical partitions 9 in front of the busbar compartments by releasing the fixing screws;
• Release the fixing screws and draw out horizontal partition 20 below the withdrawable part travel rails;
• Release and remove floor cover 17;
• Remove covers 43.2 and 43.3 (figure 59) from the vertical control wiring ducts at the front right and
left of the panel.
43.1
1.8
20
43.2
Figure 59: View into the high voltage area at the front
1.8 Central catch
1.11 Bore, for control wiring bushing 24
20 Horizontal partition, removable
43.1 Duct cover for external control cables in LV comp.
43.2 Duct cover for external control cables in cable comp.
43.3 Duct cover for external control cables in circuit breaker comp.
• If any top-mounted enclosures with busbar earthing switches or instrument transformers have been
removed for transport, bolt these in place in the specified position where the rear and middle pressure
relief plates would otherwise be located on the switchgear panels, and make the internal connections
again.
• Fit and screw the separate mechanism enclosures for any top-mounted earthing switches in the speci-
fied position on the low voltage compartment with the front edge flush.
Note the correct positions of the parts fitted on the hexagonal drive shaft supplied loose, and then remove
the parts from the shaft, discarding the rubber ring at the front.
Insert the drive shaft step by step at the front of the mechanism enclosure until it is completely fitted,
threading on the individual parts in the correct positions for the open position of the earthing switch.
Secure the setting rings. Adjust the mounting positions and operating moments of the auxiliary switches:
1. Adjust the positions of the auxiliary limit position switches in their slots in such a way that there is a
run-on of 0.5 mm in the fully operated position before the plunger reaches the stop (for safety reasons);
2. The auxiliary limit position switch 78.4 (Figure 60) or earthing switch ON must operate immediately
after the dead centre position of the toggle spring mechanism is reached in the closing process and
the automatic quick-closing process has started;
3. The auxiliary limit position switch 78.5 for earthing switch OFF must be operated during the opening
movement of the slide (78.2) 1 mm before the tab of the slide makes contact with the armature of the
de-energised locking magnet 78.6 (Figure 60).
38
77 78
78.1
Figure 60: Panels - 12/17.5 kV - Top-mounted box with earthing switch for busbar earthing
39
5.4. Installation of the bushing
Before fixing the panels side by side (according the general drawings) bushings 29 (12÷24 kV) must be
fixed (for switchgear with busbar barriers only; refer to the table on page 9).
30
31
32
28
37
36
29
35
40
5.5 Fixing of the panels
Fit and screw down the lids.
• Align the switchgear panels on the floor frame for correct positioning and vertical alignment (devia-
tions of the panel edges from the vertical must not exceed 2 mm, especially at the front) and bolt the
panels together (figure 63). It is advisable to start from the centre when assembling switchgear with
more than ten panels.
The junction points where you have to fix the panels are the followings:
- Nr.6 in the front side (A-B-C-D-E-F).
- Nr.4 in the middle part (L-M-N-O).
- Nr.5 in the rear side (G-H-I-J-K).
The nuts on the carpentry are already fixed on the right side of the panel (except in the middle part);
on the left side there is the empty space where the screws are to be fixed.
The screws needed are the followings:
- 10x30 screws (complete with M10 washer) for front and rear side.
- 10x35 screws (complete with washer and M10 nuts) for middle part.
41
• When the switchgear has been properly assembled, fix the panels to the floor using plugs, or weld or
adequately bolt them to the foundation frame.
Figure 64: Fixing to the floor - method of installation “A” with base irons
Figure 65: Fixing to the floor - method of installation “B” with anchoring bolts to concrete floor
Figure 66: Fixing to the floor - method of installation “C” to raised false floor
42
5.6 Installation of the busbars
Before to fix the panels side by side be sure that the bushings are fixed according to the chap-
ter 3.3.1 at page 9.
• Clean the insulation on the busbar sections with a soft, dry cloth, and check for insulation damage.
Remove greasy or adhesive dirt as described in section 7.3;
• Busbar connections:
- The silver plated surfaces of the connections must be cleaned with a metal-free non-woven cleaning
cloth and thinly and by appling a thin layer of mechanical grease;
- The non-silver plated surfaces of the connections are either brushed with a wire brush, preserving
the grease film, or cleaned with a metal-free non-woven cleaning cloth and evenly greased with a
thin layer of mechanical grease;
• Prepare insulating covers 58 and lids 58.5 (figure 3, 67, 68) to suit the relevant busbar connections
and thread them onto the busbar. (For insulated busbars only).
Figure 67: 12/17.5kV panels, installation of the busbars. The lower picture shows the installation at the busbar ends.
29 busbar bushing
58 insulating cover
58.1 support for cover (at end panels only)
58.5 lid
58.6 washer, ISO 7089
58.7 washer, 25mm diameter
43
(10) 58.5 58.1 165 165 58 2 58.5 3
During assembly, cut out the insulating cover and lid to fit the cross-
section of the feeder bar or busbar.
Figure 68: 24 kV panels - Arrangement of the busbar and branch conductors at the busbar ends. In continuous busbars, the
connections are similar, but without the lid holder 58.1 and without the spacer plate 3.5.
2 Branch conductor
3 Busbar section
3.5 Spacer plate
58 Insulating cover
58.1 Lid holder
58.5 Lid for insulating cover
(58.6) Washer ISO 7089
58.7 Washer 25 mm diameter
163 M10 hexagon socket head screw
164 M10 nut
165 10mm spring washer
44
5.6.2 Busbar compartment access
Access to the busbar compartment is possible
either from the top of the panel after dismounting
the pressure relief plate 1.1 (figure 2) before the
mounting of the gas duct, or from the front of the
circuit-breaker compartment.
After circuit-breaker 13 (figure 2) has been with-
drawn from the panel, it is possible to dismount
horizontal partition 20 by unscrewing nr.4 screws
holding the partition from the inside.
After that, the partition 9 can be dismantled (by
unscrewing nr.7 screws) and taken out of the panel,
which makes access to busbars from the circuit-
breaker compartment possible.
20 9
• Bolt one holder 58.1 (figure 67, 68) to each end of the busbars to support insulating cover 58. The
screws for holder 58.1 must be tightened with a lower torque. (For insulated busbars only).
• Position insulating covers 58 and lids 58.5 over the relevant bolted joint, and slide the lid onto the
cover until it clicks into place. (For insulated busbars only).
Note:
Busbar connection is carried out with so-called “stabilized connections”.
This means that quality of the copper busbar connections does not change according to the operating
time and therefore it is not necessary to inspect tightness of busbar connections regularly. But this is
on condition that correct assembly is carried out as described above and especially that all connections
are tightened with the prescribed torque according to the above table.
We recommend only inspecting tightness of busbar connections during inspections (see chapter 7).
45
5.6.3.1 Busbars for 12/17.5kV units
Busbars are made of copper and have a flat cross-section for rated current up to 2500A. For 3150,
3600 and 4000A, the busbars have a double D-shaped cross-section. Branch conductors always have
a flat cross-section.
12/17.5kV bushings are made of epoxy resin castings and are arranged as a single casting for all three
phases (figure 61). For bus-tie units the bushings are single and are arranged in the lower part of the
unit. Bushings are held in bushing plates.
For 12 kV, the busbars are bare (without insulation) and without insulating covers up to 2500A.
3150, 3600 and 4000A D-shaped busbars are insulated by means of shrink sheaths and are fitted with
insulating covers.
For 17.5 kV, the busbars are insulated and fitted with covers over the whole current range.
40
42
43
41
42
43
44
46
41
42
45
43
41
42
43
44
47
41
42
45
43
1250 A
41
42
43
1250 A
48
41
2500 A
42
43
1250 A
41
42
2500 A
43
2500 A
49
Important note:
Always check that there is good contact between the metal tube in the bushing and the busbar via contact
spring 29.3. Ensure that the contact spring is in the correct position! (figure 78).
Important note:
The contact springs 29.3 must be inserted
during the installation of busbars. These contact springs make the connection between the busbar 3 and the metal
tube 29.4 and prevent damage caused by partial discharges inside the bushing on live busbars.
Always check that there is good contact between the metal tube 29.4 in the bushing and the busbars via the contact spring.
3 Busbar
29 Busbar bushing
29.2 Busbar support for double conductor
29.3 Contact spring
29.4 Metal tube
50
2.2
3.8
3.2
3.2
Figure 79: 12/17.5kV panels - Bar connection to the top-mounted box. The figure shows the arrangement in panels the bus-
bar ends
2 Branch conductor
2.2 Connection bar
3.2 Spacer plate, 5 mm thick
3.8 Tapped plate
3.10 Spacer plate, 8 mm thick
51
58.5 3.5 (58.6) 3.4 58 162 2.2 58.5 3
(35)
58.1 58.7 163 165 2 3
50
80
80
32
32
32
70
Figure 80: 24 kV panels - Bolted busbar joint for top-mounted box, shown for left-hand busbar end. In continuous busbars is
the connection is similar, but without the lid holder 58.1 and without the spacer plate 3.5.
2 Branch conductor
2.2 Branch conductor to the top-mounted box
3 Busbar section
3.3 Spacer plate, 10 mm thick
3.4 Threaded plate
3.5 Spacer plate
58 Insulating cover
58.1 Lid holder
58.5 Lid for insulating cover
(58.6) Washer 2 mm
58.7 Washer 3 mm
162 Cylinder screw
163 M10 hexagon socket head screw
165 10 mm spring washer
52
79
79.2 79.3 79.1
28.3
Figure 81: 12/17.5kV panels - Top-mounted box with voltage transformers for busbar metering. The figure shows the ar-
rangement in panels without the busbar bushing plate 28 (see the notes in section 5.7.1)
28.3 Partitioning
79 Top-mounted box with voltage transformer
79.1 Intermediate box
79.2 Conductor tube
79.3 Reducer ring
79.4
79
79.2 79.3 79.1
2.3
28
Figure 82: 24 kV panels - Top-mounted box with high voltage transformers for busbar metering. The figure shows the ar-
rangement in panels with busbar bushing plate 28 and bushings 29
53
the earthing switch. Sequence and angles of the part must be restored!
• Connecting bars 2.2 with the branch conductors 2 at the junction point must be screwed together ac-
cording to figure 5/26 and 5/34. However, if necessary, additional spacer plate 3.3 or 3.2 and threaded
plate 3.4 or 3.8, as well as the screw fixing material from the “top-mounted box for earthing” set of
bags must be used;
• Insulating cover 58 must be brought into position as described in section 5.4.
Note
The auxiliary switches for the earthing switch are adjusted at the works. Problem-free operation is only
guaranteed if the working elements on the hexagonal shaft are correctly mounted.
Because of final installation of the earthing switch and operating mechanism on site, it may be necessary
to make precise adjustment of the auxiliary switches.
In that case, the following is important:
• The auxiliary switch OFF 78.5 must be operated:
- before slide 78.2 has uncovered half of the opening in front of the hexagonal shaft and;
- before the lower edge of the slide has touched the anchor of locking magnet 78.6;
• The auxiliary switch ON 78.4 must be operated:
- before the toggle spring of the earthing switch has reached its dead centre point;
• The push-rod of the auxiliary switch must still have about 0.5 mm to go to the end position in the oper-
ated position.
77 78
78.1
Figure 83: 12/17.5kV panels - Top-mounted box with earthing switch for busbar earthing
54
77
78.1 78
2.2
Figure 84: 24 kV panels - Top-mounted box with earthing switch for busbar earthing. The arrangement is the same as the
figure above
2.2 Flat branch conductor for earthing switch
77 Top-mounted box for earthing switch
78 Operating mechanism box
78.1 Hexagonal shaft
UniGear ZS1 switchgear is available with the following solution of gad duct:
• Standard duct;
• Compact duct;
• Compact duct with top chimneys.
The pressure relief duct is supplied dismantled in single parts. The rear and front wall correspond, as
far as length is concerned, with the appropriate panel width. They are joined together by means of the
attachment strips.
The screw fixing material is contained in the “pressure relief duct” set of bags. Rivet nuts are already
provided in the metal sheets.
Note
The rear pressure relief flap must be mounted according to figure 85.
Details regarding connection to the wall and a discharge grating for pressure relief outside the switchroom
will be agreed on with the customer.
55
50
1)
Figure 85: Schematic diagram of the pressure relief duct. The components are assembled panel by panel and bolted to-
gether with overlaps at the panel joints.
Figure 86: Fixing points on the front. Figure 87: Fixing points on the rear.
With nr. 6 screws 8x20 and nr. 6 washer M8, fix the front and rear part of the gas duct sheets
(figures 88, 89).
56
Once that the two sheets are fixed to the panel, it is possible to fix the two sheets between them (figure
90) using nr.6 screws.
Fix the central connection plate between the two gas duct panels (figures 92).
57
Fix the rear connection plate between the two gas duct panels (figures 93).
The last operation in order to complete the gas duct is the fixing of the gas duct extension on both sides
(figure 94).
58
Figure 95: Overview of the standard gas duct.
59
5.8.3 Compact gas duct with top chimneys
In order to mount the compact gas duct with top chimneys must be followed the operations described
for the compact gas duct.
The difference between the two solutions is that in this case there are no side exits, but the gas gener-
ated from an internal arc goes out from the duct through the top chimneys located on the top part of the
gas duct on each panel.
On the top of the gas duct there are two openings (figure 97); for each opening it must be fix the net
and the nr.6 spacers (figure 98).
At this point it is possible to fix the top cover with nr.12 M8 screws.
Figure 97: Openings on top of the gas duct. Figure 98: Net and spacers of top chimneys.
60
5.9 Cable connection
39
6.1
23
17
Figure 100: View into the cable connection compartment, Figure 101: Partial view of the cable compartment,
max. six parallel cables are possible prepared here for connection of
triple cables.
6.1 Earthing switch position indicator 17 Floor cover, split
17 Floor cover, split 17.2 Reducer ring
17.2 Reducer ring 19 Main earthing bar
23 Cable connection bar 19.1 Connecting link
19.2 Earthing connection pin
21 Cable clamp
39 Mounting rail, connected to earth
potential
Cable sealing ends are mounted on the cable cores according to the manufacturer’s instructions. It is
possible to use cable sealing ends of different manufactures (e.g. Pirelli, Raychem etc.), but it is neces-
sary to keep the length of the cable ends, including cable sealing ends, which is given by the distance
of cable connecting bars 23 from the panel floor covering.
These bars have different versions, hich differ in their number of parallel cables and the values of rated
and short-circuit currents. See ig. Figure 102÷106.
The bars are equipped with holes for M16 screws. If M12 screws are used for cable connections, special
washers with the diameter for M12 screws must be used. In all cases, the earthing of cable screens is
carried out on the strip-holding cable clamps. The cable strip is connected to the earth potential.
It is also possible to place the removable arrangement of voltage transformers in the cable compart-
ment. These can be fitted with HV fuses similar to those in the measuring panel. Three fixed mounted
surge arresters can also be installed here. But in both these cases the number of parallel cables must
be reduced – see the table.
The cable connections bars are equipped with holes for M16 screws, but they are supplied
without screws, washer and nuts.
The supply of this material, according to the cable termination, is at Customer charge.
61
Connection of cables in typical panels:
12 550 3 600
650 3 1)
800 3 1)
24 500
1000 6 2)
1) In the case where there are removable voltage transformers on the truck, or surge arresters are used, the number of parallel cables
is reduced to a max. of 2 per phase.
2) In the case where there are removable voltage transformers on the truck, or surge arresters are used, the number of parallel cables
is reduced to a max. of 4 per phase.
12/17.5 800
1 240 35 - 54 27 - 62
24 1000
Important note
Connection with single-core plastic insulated cables is presumed in the typical panels. In the case of
any atypical cable connections or of special cables (e.g. three-core cables, cables with paper or special
insulation etc.), an agreement must be reached between the customer and manufacturer.
Mounting procedure:
• Insert the cables into the control wiring duct 1.2 (figure 2) on the left-hand side. The duct is covered
by covers 43.1, 43.2 (figure 59);
• Fasten the control cables at the top end of the duct, strip the insulation and convey cable control cores
into the low voltage compartment D, after the terminal strip frame has been swung up (figure 107);
• Connect control cables to the terminal strip according to the circuit diagram;
Make the control wiring connections to adjacent panels using bushing 24 (figure 59).
62
Dimension of power cable connection of UniGear ZS1 12/17.5 kV classic panels
23
A
C C C C C B
D1)
17.2 21
630 1 840 –
1000 650 31.5 535
1250 3 480 180
1250 40 465
1600 800
2000
1600 31.5/40 440
2000 6 460 100
2500 1000
3150
40 455
4000
Figure 102: Dimension of power cable connection of UniGear ZS1 12/17.5 kV classic panels.
1) The dimension must be verified according to the documentation of the relevant order
17.2 Reducer ring
21 Cable clamp
23 Cable connection bar
63
Dimension of power cable connection of UniGear ZS1 12/17.5 kV 550 panels
Figure 103: Dimension of power cable connection of UniGear ZS1 12/17.5 kV 550 panels.
64
Dimension of power cable connection of UniGear ZS1 24 kV classic panels
23
21
(1)
Figure 104: Dimension of power cable connection of UniGear ZS1 24 kV classic panels.
(1) The dimension must be verified according to the documentation of the relevant order
21 Cable clamp
23 Cable connection bar
65
Dimension of power cable connection of UniGear ZS1 12/17.5 kV switch disconnector
Figure 105: Dimension of power cable connection of UniGear ZS1 12/17.5 kV switch disconnector.
D The depth of the panel with switch disconnector in combination with HD4 circuit-breaker panel
is 1340 mm, in other cases 1300 mm - however always consider note 1)
1) The dimension must be verified according to the documentation of the relevant order
17.2 Reducer ring
21 Cable clamp
23 Cable connection bar
Figure 106: Dimension of power cable connection of UniGear ZS1 24 kV switch disconnector.
D The depth of the panel with switch disconnector in combination with HD4 circuit-breaker panel
is 1560 mm, in other cases 1520 mm - however always consider note 1)
1) The dimension must be verified according to the documentation of the relevant order
17.2 Reducer ring
21 Cable clamp
23 Cable connection bar
66
Figure 107: Terminal frame swung up for connection works
67
6. Operation of the switchgear
Warning
Do not walk on the top surfaces of the switchgear panels (rupture points for pressure relief).
The pressure relief devices could be damaged!
6.1 Commissioning
6.1.1 Preparatory wok
In preparation for commissioning, the following work must be carried out prior to connection with the
high voltage power supply:
• Check the general condition of the switchgear for any damage or defects;
• Visually inspect the switching devices, withdrawable parts, isolating contacts, insulating parts, etc.;
• Check connection of the main earthing bar to the installation earthing conductor (following the ap-
propriate safety regulations);
• Check the paintwork for damage and, where necessary, touch up as described in section 7.4;
• Remove all residues of materials, foreign bodies and tools from the switchgear;
• Clean the switchgear, rubbing down insulating parts with a soft, dry, clean, non-fraying cloth. Remove
any greasy or sticky dirt as described in section 7.3;
• Correctly remount all covers etc. removed during assembly and testing procedures;
• Transport caps 13.9 (figure 108) on vacuum circuit-breakers - if still fitted - must be removed;
• Pole tube lids 13.10 on vacuum circuit-breakers may be fitted in certain systems and on certain circuit-
breakers. Check that they are fitted correctly;
• Lifting eyebolts 13.13 on high current vacuum circuit-breakers must be removed if still fitted;
13.9
13.13
Figure 108: Withdrawable part with VD4 type high current circuit- breaker - pole side
68
• Preparatory works for SF6 circuit-breakers:
- Clean the insulating parts with clean dry cloth;
- Check that the upper and lower terminals are clean and free of any deformation caused by shocks
received during transport and storage;
- It is advisable to check the SF6 gas pressure;
• Perform AC voltage testing of the main circuits according to IEC 62271-200 where necessary. Pay
special attention to voltage transformers and cables, etc. during this procedure. A testing and earthing
module 142 (figure 129) can be used to make the connections (see section 6.3.2);
• Switch the auxiliary and control voltage on;
• Carry out testing operations on switching devices manually or by electrical control, and simultaneously
observe the relative position indicators;
• Check mechanical and electrical interlocks for effectiveness, without using force;
• Set the protection devices in the switchgear to the required values and check their function with test
equipment;
• In switchgear panels with an additional ventilation system for high current circuit-breakers (required
for ambient temperature higher than > 40 °C and/or higher frequency - 60Hz -according to section 1.3
and figures 109 and 110), flap 20.3 hanging in partition 20 must rest loosely against leaf spring 20.4
(with the centrifugal fan at a standstill, if fitted ). This is not standard.
To check:
- Insert a suitable screwdriver through opening 20.5 in horizontal partition 20 and into bracket 20.6 on
flap 20.3;
- Swing flap 20.3 upwards and allow it to rest loosely again on leaf spring 20.4;
- If the flap is in the locked position, use the screwdriver to press leaf spring 20.4 downwards by ap-
prox. 5 mm to release the lock before swinging the flap;
- If any centrifugal fans controlled in relation to primary current are fitted, also check that these function
correctly;
69
• On motorized withdrawable parts, check the direction of rotation of the travel motor in accordance
with section 7.5.4;
• For any other matters regarding operation of the withdrawable circuit-breaker part and testing facilities
for the withdrawable part, see section 7.5;
• Instruct local operators regarding the basic details of regular handling of the switchgear;
• Check readiness for operation and switching status of electrical systems upstream and downstream
of the switchgear.
Depending on allocation of responsibilities, it may also be necessary to check the following equipment
in areas adjacent to the switchgear:
• power cables;
• auxiliary cables;
• auxiliary power source;
• remote control system;
• complete earthing system;
• switchroom equipment;
• switchroom conditions.
6.1.2 Start-up
• Comply with all relevant safety regulations;
• Ensure that the circuit-breakers in the system are in the OFF position;
• Remove any existing earthing and short-circuiting connections in the critical switching area;
• Energize the feeder cables;
• Connect the switchgear step by step, observing the signals and indicators;
• Check that relative conductors are in phase, where necessary, when there are several incoming feeder
cables and switchgear sections (also see section 6.3.2);
• Carry out all measurements and check all functions which depend on high voltage power supply being
connected;
• Watch out for irregularities of any kind.
70
145
32
10.2
10.1
121.1
Figure 111: Control wiring plug connector blocked to it is Figure 112: Before inserting the hand crank, necessary to
prevent disconnection with the withdrawable open the hole for it - turn the slide by means of
part in the service position. the key.
121
Figure 113: Movement of the withdrawable part between. The test/disconnected position and the service position, clockwise
up to the stop to the to the service position and anti-clockwise for the test/disconnected position
121 Hand
71
Note
The withdrawable part must not be stopped in any intermediate position in the travel range between the
service and test/disconnected position!
Manual withdrawal from the service position into the test/disconnected position
• Ensure that the apparatus is in the OFF position;
• Reverse the procedure described above for insertion into the service position.
Important note
Insertion and withdrawal of circuit-breakers (and other withdrawable parts) must be gradual, in order to
avoid any shocks which could deform the mechanical interlock. If the operations are prevented, do not
force the interlocks and check that the operating sequence is correct.
The force normally applicable to the insertion/withdrawing lever is 260 N. In any case, the maximum
applicable force must never exceed 400 N.
Please also refer to the technical documentation of the circuit-breakers for installation operations.
Caution: the insertion and withdrawal must always be carried out with the apparatus open!
Do not use force to move withdrawable parts with locking magnet Y0 or RL2 in the event of an auxiliary
voltage drop. If this occurs, they are locked along the whole travel range between the service and test
positions.
To remove the interlock, consult the technical documentation of the circuit-breakers.
Note
When the drive motor is faulty, the withdrawable part can be moved using the emergency manual operation.
If the drive motor fails during movement of the withdrawable part, the withdrawable part must be moved
into a limit position using emergency manual operation.
Emergency manual operation is carried out with hand crank 121 (figure 113) on spindle mechanism 18,
in a similar way to operation of a withdrawable circuit-breaker part with manual systems. To disengage
the motorized withdrawable part, consult section 7.5.1.
• Switch off the auxiliary power (m.c.b.), since the motor would otherwise be braked electrically;
• Turn hand crank 121 in the required direction.
When the withdrawable part moves, the motor turns. In this case, the motor functions like a generator,
i.e. it can lead to reserve voltages in the terminals.
The motor fuse must not be changed from the specified type and rated value, otherwise the behaviour
of the permanent magnet motor could be irreversibly impaired!
Caution
In emergency manual operation of a motorized withdrawable circuit-breaker part, the interlock with the
earthing switch is not effective!
72
13
13.11
124.4
Figure 114: Service truck engaged with the switchgear Figure 115: Withdrawable part standing on service truck
truck and panel. Withdrawable part released for and secured in the catches
withdrawal with the handles slid inwards
13 Withdrawable part
13 Withdrawable part 13.11 Sliding handle
13.11 Sliding handle 13.12 Catch (connected to sliding handle
124 Service truck 13.11)
124 Service truck
124.1 Height adjuster
124.4 Release lever for catch pin (124.3)
130 38
124.2
124.3
124.1
Figure 116: Positioning the service truck with the guide Figure 117: Lower shutter secured with padlock to prevent
Pins on the adjustable height bench top at unauthorized operation.
the correct height for approach to the
switchgear panel, and engaging the catch. 38 Lever for shutter operation
130 Padlock (customer component)
124.1 Height adjuster
124.2 Guide pin
124.3 Catch pin
73
6.2.2 Circuit-breaker - type VD4 and V-max
Charging the stored energy spring system:
• On the circuit-breaker with charging motors, charging is carried out automatically. If the charging motor
should fail, the charging procedure can be carried out or completed manually;
• On breakers with manual charging systems, either open the door with the withdrawable part in the
disconnected position, insert charging lever 128 (figure 118) into the recess and pump for approx. 25
strokes until the charged condition is indicated;
• On breakers where the charging lever is integrated, take the lever and pump 10 times;
• When the charged condition is reached, the charging mechanism is automatically disengaged, and
any further strokes of the lever have no effect. Pumping is effective if the lever is moved in angle 90°
(figure 119).
13.4
13.2
90° 13.8
13.4 128
13.5
128a 13.8
13.5
13.11
13.11
Figure 118: Manual operation of withdrawable part with Figure 119: Manual operation of withdrawable part with
VD4 circuit-breaker (old design). Vmax circuit-breaker.
13.1 Mechanical ON push-button
13.2 Mechanical OFF push-button
13.4 Mechanical switch position indicator
13.5 Mechanical operating cycle counter
13.8 Charging condition indicator
13.11 Sliding handle, connected with the
catch on the withdrawable assembly
13.12 Locking OFF position
128 Charging lever
74
6.2.3 Circuit-breaker - type VM1
The maintenance-free VM1 circuit-breaker applies a combination of moulded-in vacuum interrupters, a
magnetic actuator and an electronic controller without auxiliary switches and with sensors.
Before connecting the primary voltage:
• Connect the auxiliary voltage. OFF command (closed – circuit release) and the closing lock-out must
be energized before the circuit-breaker can be closed;
The auxiliary voltage has been established when the (Ready) LED 31.2 lights up (figure 120).
• Carry out the closing and opening test of the circuit-breaker by pressing pushbuttons 31.3 and 31.4;
• Closing:
- by remote control via closing contacts or locally by pressing ON pushbutton 31.3;
• Opening:
- by remote control via closing contacts or locally by pressing OFF pushbutton 31.4;
• Opening on failure of the auxiliary power supply:
- Electrical opening is still possible within the first 200s;
- After a period of 200s, emergency manual opening is necessary;
- Insert emergency manual operating lever 28 onto the spigot of the emergency shaft 8 in the front
plate and turn it anticlockwise to open the circuit-breaker. Just before the final stop is reached, a
slight resistance on the emergency shaft has to be overcome.
• Closing on failure of the auxiliary power supply:
- Closing is not appropriate and not possible;
• After each operating cycle (ON-OFF), the operating cycle counter 31.5 increases by one full digit.
On termination of a switching operation, the position indicator 31.6 in the window of the front plate
displays the relative switch position.
• Anti-pumping system:
- The circuit-breaker controller ensures that circuit-breaker closing is locked when an opening com-
mand is active;
- When closing on a subsequent opening command, further closing with the closing command still
active is locked. The closing command must be given again for the next closing operation.
For details, refer to the user’s manual.
31.9
31.16
31.2 28
31.3
31.4
31.5 31.6
Figure 120: Withdrawable part with VM1 type circuit-breaker - operating mechanism side
75
6.2.4 Circuit-breaker - type HD4
Manual operation for spring charging:
To manually charge the closing springs, fully insert charging lever 90.8 (figure 122) into seat 90.6 and
turn it until the yellow indicator 90.7 appears.
Electrical operation for spring charging:
On request, the circuit-breaker can be fitted with the following accessories for electrical operation:
• geared motor for automatic charging of the closing springs;
• shunt closing release;
• shunt opening release.
The geared motor automatically recharges the springs after each closing operation until the yellow indi-
cator 90.7 appears. Should there be no voltage during charging, the geared motor stops and then starts
recharging the springs automatically when the voltage is on again. In any case, it is always possible to
complete the charging operation manually.
Circuit-breaker closing:
This operation can only be carried out with the closing springs completely charged. For manual closing
press pushbutton 90.3. When there is a shunt closing release, the operation can also be carried out by
means of a control circuit. The indicator 90.4 shows that closing has been accomplished.
Circuit-breaker opening:
For manual opening, press pushbutton 90.2. When there is a shunt opening release, the operation
can also be carried out with remote control by means of a control circuit. The indicator 90.4 shows that
opening has been accomplished.
An additional control mechanism fitted in the door of the circuit-breaker compartment enables mechani-
cal operation of the circuit-breaker with the door closed and with the withdrawable part in either position
(figures 7, 8);
• Press the relative mechanical pushbutton, having previously turned knob 45.2 anti-clockwise to the
stop, if the withdrawable part is in the service position;
• Observe the switch position indicator.
Detailed information about installation and maintenance can be found in instruction manual.
90.1
90.2
90.3
90.7
90.6
13.15
Figure 121: HD4 type circuit-breaker - side view Figure 122: Operating and signalling parts of HD4 circuit-
breaker
10.2 Control wiring plug 90.1 Signalling device for state of SF6
13.15 Withdrawable assembly pressure (on request)
90.2 Opening pushbutton
90.3 Closing pushbutton
90.4 Operation counter
90.5 Circuit-breaker open/closed indicator
90.6 Shaft for manual closing spring
charging
90.7 Signalling device for closing springs
charged/discharged
76
6.2.5 Vacuum contactor - type V-Contact
The V-Contact type vacuum contactor is ideal for controlling users in a.c. requiring a high number of
operations. The contactors basically consist of a moulded resin monobloc, where the vacuum interrupt-
ers, moving apparatus, control electromagnet, multivoltage control feeder and auxiliary accessories
are housed.
The monobloc is also the support for assembly of the fuse-holder frame.
Closing of the main contacts is carried out by means of the control electromagnet. Opening is carried
out by means of a special opposing spring. The contactor can be equipped with electrical or mechani-
cal latching.
The fuses are positioned in special supports to be connected in series between the contactor and the
user. The supports can house fuses in compliance with DIN or BS standards.
For details, please refer to installation manual.
91.15
91.13
91.14
Figure 123: V-Contact type vacuum contactor - front view Figure 124: V-Contact type vacuum contactor - pole side
91.13 Signalling device ON/OFF
91.14 Operating cycle counter 91.15 MV fuses
95.2
95.1
95.3
Figure 125: Withdrawable part with metering unit Figure 126: 95.3 Mini circuit-breakers of transformers
secondary circuits (mounted in the
95.1 Voltage transformer cabinet of auxiliary circuits as
95.2 Cast resin tube (with fuse cartridge) standard)
77
6.2.6 Withdrawable metering parts
Handling of the withdrawable metering part in the metering panel is as described in section 6.2.1,
without, however, the switching operations and interlocking functions.
Withdrawable metering parts in incoming and outgoing feeder panels are put into the cable compart-
ment using a ramp. They reach their service position immediately and engage in the panel earthing by
means of the two locking pins at the sides. The voltage transformers used correspond to the type used
in the metering panel, and therefore HRC fuses can also be used along with the voltage transformers.
Caution
If the operation is prevented, do not force the interlock and check that the operation sequence is correct.
• Fit operating lever 122 onto hexagonal shaft 14.1,(figures 127, 128) which is now released for
operation.
Note
Put operating lever 122 in pointed upwards or downwards on the hexagonal shaft so that there is suf-
ficient room for movement of the operating lever even if space is limited at the sides.
• Turn the lever clockwise through approx. 180° until the stop is reached to close the earthing switch,
or anticlockwise until the stop is reached to open the earthing switch;
• Observe the mechanical/electrical switch position indicator;
• Remove operating lever 122. Slide 14.2 remains open if the earthing switch is in the closed position.
Make sure that the operating lever is turned right up to the stop in the opening process, to ensure
that the earthing switch is in its defined limit position. The manual operating mechanism can also be
fitted with a locking magnet.
Caution
During emergency manual operation of a motor-operated earthing switch, the interlock is not functional!
On emergency manual operation, coupling with the motor operator is automatically released. To dis-
engage the coupling to the motor operator, first turn the lever 122 further in the pre-selected direction
up to the relative stop (small angle of turning). On the next operation with the motor operator after its
function has been restored, the coupling automatically engages again.
Note
The lever may only be fitted temporarily to carry out an emergency manual switching operation.
The power to the motor operator must be switched off for the duration of any breakdown.
78
14.1
122
14.2
Fig. 127: Preparation for operation of branch earthing Fig. 128: Preparation for operation of branch earthing
switch - press the slide downwards. switch - operating lever prepared for switching
on/off
14.1 Hexagonal shaft of earthing switch
operating mechanism 122 Operating lever
14.2 Slide
79
safety reasons, insert the module only with the circuit- breaker compartment door closed and with
door catches 1.8 locked (see Fig. 5/20);
• Display earthing warning label on the switchgear panel door;
• Secure neighbouring areas to prevent inadvertent contact with live parts (e.g. feeder cables);
The procedure for removing earthing is the same, only in reverse order.
80
6.2.10 NALF type switch-disconnector
The NALF type switch-disconnectors, a combination of switch-disconnector with fuses and type E
earthing switches are intended for indoor use in switchgear. The switch-disconnectors are capable of
to opening and closing loaded and unloaded inductive and capacitive circuits. In the open position the
device has a visible isolating distance.
The switch-disconnectors are used in combination with power fuses for short-circuit protection . This
combination excludes two-phase power supply, because interruption of any fuse link causes the opening
of switch-disconnector by means of its tripping system.
The type E earthing switches are constructed with a snap closing mechanism. They are capable of
closing and carrying short-circuit currents.
In the case where the switch-disconnector without HV fuses will be required, the current-carrying bars
will be inserted in holders instead of HV fuses to maintain the same location of the earthing switch.
Note
The switch-disconnector and earthing switch can only be operated with the switchgear panel door closed.
The switch-disconnector and earthing switch are mutually mechanically interlocked.
209
210
207.1
208.1
215
Fig. 130: Preparation for the operation of earthing switch in Fig. 131: Preparation for the operation of earthing
panel with the switch-disconnector switch in panel with the switch-disconnec-
Operating lever prepared for the operation ON tor
207.1 Position indicator of earthing switch Operating lever prepared for the operation
208.1 Operating shaft for the earthing switch OFF
209 Lockable operating handle – Chubb lock
210 Lockable operating handle – padlock 215 Operating lever
81
Closing and opening of NALF switch-disconnector
• The switch-disconnector can only be switched on if the earthing switch is open;
• Put operating lever 215 (figure 131) in pointed upwards or downwards on the grooved shaft of the
switch-disconnector so that there is sufficient room for movement of the operating lever even if space
is limited at the sides;
• Turn the lever clockwise through approx. 180° to charge the opening spring;
• Turn the lever anticlockwise to charge the closing spring and to close the switch-disconnector;
• Turn the lever clockwise through approx. 20° to open the switch-disconnector;
• Observe switch positioning indicator 200.1 (figure 21).
Caution
Until the latch of opening or closing spring snaps, the lever is returned back into the starting
position through the action of spring. Proceed with caution during the manipulation to prevent
the lever from slippingfrom your hand – RISK OF INJURY
Note: We recommend using a protection circuit-breaker in the supply circuit of motor operator. The open-
ing time of mechanism A operated with the motor operator is approx. 1s. If faster opening is required, it
is necessary to equip mechanism A with an opening coil
Note: After the manual operation the motor operator will not be synchronous with the switch-disconnector,
which means that it must be manipulated twice to reach synchronization, e.g. opening
- closing.
Caution
The operating lever may only be fitted temporarily to carry out an emergency manual
switching operation - RISK OF INJURY
82
6.3 Test procedure
6.3.1 Testing the off-circuit condition
In switchgear panels which are not equipped with capacitive voltage indication, checking the off-circuit
condition is carried out with a HV tester on the isolating contacts 4.1 (figure 133) in the isolating tulips 5
(figure 132), after the corresponding upper shutter 12.1 or lower shutter 12.2 has been opened. Shutter
opening can be carried out by means of module 129 (figure 134).
If the panels are equipped with capacitive voltage indication, checking the off-circuit condition can be
carried out by means of this device. In this case, proceed according to the manufacturer’s instructions
or the indicators. (Optionally, switchgear can be equipped with various types of indicators coming from
various manufacturers).
In case of any doubt about correct operation of capacitive voltage indication, the off-circuit condition
must be checked using a HV tester.
Checking the off-circuit condition must always be carried out in compliance with the relevant safety
regulations and local operating conditions!
12.1
4.3 5
4.2
4.1
5
12.2
12.2
Figure 132: Withdrawable part during insertion into the Figure 133: View inside the circuit-breaker compartment,
service position, shutters not yet fully open withdrawable part removed, shutters open
4.2 Contact arm, with insulating sleeve
4.3 Contact system 4.1 Isolating contact
5 Isolation tulip 5 Isolating tulip
12.1 Top shutter 12.2 Lower shutter
12.2 Lower shutter
Note
With voltage tests at power frequency withstand voltage and/or impulse voltage, carry out the following
procedure:
• Disconnect any voltage transformers and capacitive dividers and cover them with an insulating plate.
83
6.4 Service trucks
The service trucks are divided into four different types:
84
7. Maintenance
7.1 General
Maintenance serves to preserve trouble-free operation and achieve the longest possible working life of
the switchgear. It comprises the following closely related activities:
Note
When carrying out all maintenance work, the regulations in the country of installation must be strictly
complied with.
Maintenance work may only be performed in a careful manner by trained personnel familiar with the
characteristics of the individual switchgear, in accordance with all relevant IEC safety regulations and
those of other technical authorities, and with other overriding instructions. It is recommended that ABB
service personnel be called in to perform the servicing and repair work detailed below.
The inspection and servicing intervals for some of the equipment/components (e.g. parts subjects to
wear) are determined by fixed criteria, such as switching frequency, length of service and number of
short-circuit breaking operations. On the other hand, for other parts the length of the intervals may de-
pend, for example, on the different modes of operation in individual cases, the degree of loading, and
also environmental influences (including pollution and aggressive air).
The following operating instructions must also be followed, together with this instruction manual in the
individual cases concerned:
• Vacuum circuit-breaker: type VD4;
• Vacuum circuit-breaker: type VD4 - high current;
• Vacuum circuit-breaker with magnetic actuator: type VM1;
• Gas circuit-breaker: type V-max;
• Gas circuit-breaker: type HD4;
• Vacuum contactor: type V-contact;
• Switch-disconnector NAL - catalogue;
• Switch-disconnector - installation, service and maintenance instruction manual;
• Operating mechanisms of the circuit-breakers with high voltage - catalogue;
• Motor operator UEMC 40 K3 - installation, service and maintenance instruction manual (for units with
NALFE earthing switch).
If necessary, further details can be taken from the technical documentation for the switchgear installation
(including, for example, any special operating conditions agreed on).
¹) In more demanding service conditions, we recommend reducing this interval suitably – also see sections 1 and 2.
²) According to the results of the inspection.
³) See the instruction manuals of the circuit-breakers.
*) Earthing switch.
85
7.2 Inspection
• Where necessary, the working area must be isolated and secured against reconnection in accordance
with the Safety Regulations specified by IEC and appropriate national standards before inspection;
• Correct condition of the switchgear should be monitored by regular inspections;
• Under normal operating conditions, inspection should be carried out once every four years by specially
trained professional electricians;
• Under abnormal operating conditions (including adverse climatic conditions) and/or special environ-
mental stresses (heavy pollution and aggressive atmosphere, among others), inspection may be
necessary at shorter intervals.
• Inspection is primarily to carry out 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;
- Traces of leakage current on the insulating material parts;
- Surfaces of the contact systems;
• However, inspection must also include correct mechanical/electrical operation of the following parts:
switching devices, actuating, interlocking, protection and signalling devices.
Special conditions
• On panels with additional ventilation devices due to increased ambient temperature (also see section
1.3):
1. Check flap 20.3 for correct operation. (Also see section 6.1.1 and figures 109, 110);
2. The centrifugal fan (if fitted) does not require any special maintenance. Its working life – depending
on the service conditions, and one significant parameter being the room temperature - is approx.
between 20,000 and 30,000 operating hours.
• With regard to the switching devices, their separate Instruction manual should be followed;
• Check all switchgear accessories and auxiliary devices (e.g. storage batteries);
• No partial discharge must occur on the surfaces of equipment at operating voltage. This can, for
example, be detected by characteristic noises, a clearly perceptible smell of ozone, or visible glowing
in the dark;
• Visually checking the contact system. We recommend turning the contact system alternately in order
to clean the inner contact points of the contact system.
The contact points should be cleaned if signs of overheating (discoloured surface) are visible (see
section 7.4);
• If any irregular conditions are detected, then relative repair measures must be taken.
7.3 Servicing
When, during an inspection as per paragraph 7.2, the need to carry out cleaning operations is noted,
proceed as follows:
• Where necessary, the work area must be disconnected and locked against reconnection in conformity
with the safety standards specified in the IEC directive and in the relative national regulations;
86
• Clean the surfaces:
- Remove any dry dust deposits which are not very adherent using a soft dry cloth;
- Remove any more adhering dirt with a low alkaline detergent or with ETHANOL F 25 M;
• Clean the insulating surfaces and the conductive components with ETHANOL F 25 M;
• After cleaning, rinse with clean water and dry carefully;
• Should any partial discharges occur as a consequence of the condensation phenomenon, a temporary
remedy which is often effective is application of a thin layer of silicone over the surface involved. For
a permanent remedy to this type of unusual problem, contact the ABB after-sales assistance depart-
ment.
Figure 134: View of the busbar compartment, shown without insulating covers
2 Branch conductor
3 Busbars
5 Tulip isolating contact
9 Bulkhead, removable
87
7.3.2 Maintenance in cable compartment
6.1
23
17.2
17
Figure 135: Internal view of the cable connection compartment, with a maximum number of six cables in parallel
Note
The cable compartment door cannot be opened if the earthing switch is open.
88
7.3.2.3.2 Cleaning the kinematics and the main contacts
• Carry out a visual inspection of the mechanical connections and check for any presence of dirt, humid-
ity and signs of corrosion on the main operating shaft and on the contact parts of the blades;
• Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated surfaces
(do not use woollen cloths);
• If necessary, grease the moving mechanical parts by applying a thin layer of mechanical grease for
moving parts.
Note
The operation counter is not provided with the switchgear. It is up to the engineering department to
connect the auxiliary closed/open contacts in order to measure the number of operations carried out.
89
19
18
18
Note
The operation counter is not provided with the switchgear. It is up to the engineering department to
connect the auxiliary closed/open contacts in order to measure the number of operations carried out.
90
7.3.2.5.2 Cleaning and checking of the voltage transformers and anti-ferroresonance circuit
95.2
95.3
95.1
91
d) Cleaning and checking the anti-ferroresonance circuit
• Make the plant you want to work on safe (follow the plant safety regulations);
• Make sure that the circuit-breaker is in the open position;
• Rack the circuit-breaker out from the service position to the test/isolated position;
• Manually close the earthing switch;
• Open the miniature circuit-breakers 25 (figure 146) positioned inside the low voltage compartment to
remove the auxiliary power supply to the panel;
• Carry out a visual inspection on the anti-ferroresonance resistance 27 (figure 142) and check for any
presence of dirt;
• Manually check correct insertion of the cabling.
27
Figure 142
21
Figure 143
92
7.3.3.2 Checking functionality of the interlocks
• Carry out a visual inspection of the mechanical parts of the interlocks (key locks 22, door interlocks
23, fail safe 24) and check for any presence of humidity and signs of corrosion on the moving parts.
• Remove any deposits of dust using a dry cloth that does not leave any deposits on the treated surfaces
(do not use woollen cloths).
• Check that the moving parts can slide evenly. If necessary, grease the mechanical moving parts by
applying a thin layer of mechanical grease for moving parts.
23
24
22
Note
To check operation of the protection releases, refer to the operating manual of the protection provided
by the manufacturer.
25
25
26
Figure 146
93
7.3.4.3 Measuring the insulation resistance of the auxiliary circuits
• Make the plant you want to work on safe (follow the plant safety regulations);
• Make sure that the circuit-breaker is in the open position;
• Rack the circuit-breaker out from the service position to the test/isolated position;
• Manually close the earthing switch;
• Open the circuit-breakers 25 positioned inside the low voltage compartment to remove the auxiliary
power supply to the panel;
• From one of the circuit-breakers 25 disconnect the wires on the internal side of the panel, short-circuit
the man apply 500 Vcc;
• Using the Megger instrument, measure the resistance between the phase involved and the conductive
electric part (switchgear structure). The value must not be less than 2MΩ and in any case constant
over time;
• Repeat the operation for the number of circuits (circuit-breakers) inside of the panel (110Vdc, 220Vac,
etc).
• Replace the connections and put the panel into service.
7.4 Repairs
7.4.1 Switchgear in general
Repair of surface damage:
• Carry out repair work immediately after a defect has been discovered;
• Completely remove all rust from damaged paintwork areas on steel sheet and other steel parts by
mechanical means, e.g. with a wire brush;
• Lightly grind the surrounding paint coat and carefully degrease the entire area. Then immediately ap-
ply an anti-rust primer and, after an appropriate hardening time, apply the top coat. Only use suitable
and compatible paint products;
• Apply the top coat in standard RAL 7035 colour, or the relevant special colour;
• Carefully remove any white rust on aluminium/zinc surfaces with a wire brush or cleaning pad, e.g.
Scotch-Brite, and clean loosely adhering particles with a dry, non-fraying cloth. Next treat the cleaned
parts with zinc spray or zinc powder paint and, finally, treat with aluminium spray for colour matching;
• Carefully remove any white rust from passivated operating parts and rust formation on phosphatised
parts with a wire brush or metal-free cleaning pad, e.g. Scotch-Brite, and clean with a dry cloth. Then
grease evenly (with mechanical grease for moving parts).
Apparatus in general:
• Follow the maintenance instructions in the manuals for individual equipment components;
• Check that the bolt connections at the contact points in the busbar system and the earth connections
are tight, and that the contact system functions correctly;
• Where necessary, grease slide plates and bearings in the panel again or thoroughly clean them. Then
grease them again with mechanical grease for moving parts lubricant;
• Top up grease on contact areas in the contact system when corroded or otherwise as necessary, or,
when lubrication is inadequate or missing, thoroughly clean the areas concerned and grease them
again with mechanical grease for moving parts lubricant;
• Remove the contact system for thorough cleaning as described below (Figures 7/1, 7/3):
- Slide in the two inner ring tension springs 4.4 facing the breaker pole to a position beside the other
two outer ring tension springs, thus releasing contact system 4.3, and remove the contact system;
- The contact pin of the contact system and the slot on the contact arm must be cleaned and greased.
Fit contact system back to front on the thin end of arbor 127 and slide it forwards onto the thicker
part of the shank;
- Fit arbor 127 onto the relative contact arm 4.2, slide the contact system 4.3 over onto the contact
arm, and withdraw the arbor;
- Check that all contact fingers and ring tension springs have a perfect fit.
After any required replacement of contact pins 4.1 (figure 147), the latter should be retightened using
the socket head bolts.
94
5
4.1
12.2
Figure 147 View of inside circuit-breaker compartment, withdrawable part removed, circuit-breakers open.
4.1 Isolating contact
5 Isolating tulip
12.2 Bottom circuit-breaker
95
7.4.2 Replacement of complex functional groups
Precise matching of functions for control, interlocking and signalling only permits replacement of indi-
vidual components to a limited extent.
The following assemblies are prefabricated and tested at the works, maintaining high quality standards.
In the case of faults, they must therefore be completely replaced.
1. Withdrawable assembly:
• Disconnect plug connector 10.3 (figure 148);
• Remove interlock rod 13.91 with pin 13.27 from the withdrawable assembly;
• For motor-operated withdrawable assemblies, remove the two socket head bolts (M4), which are ac-
cessible from below the assembly;
• Remove the circuit-breaker from the withdrawable assembly (4 x M12 bolts);
• Mount the circuit-breaker on a new withdrawable assembly in the reverse order, using new circlips
and special pliers for pin 13.27;
• Check the setting of interlocking rod 13.91;
- Turn spindle 18 anti-clockwise to the stop for the disconnected position:
- The distance between lever 13.26 and cam 13.25 must be 2w1 mm;
- The distance between roller 13.24 and angle lever 13.92 must be 0.5 mm;
- Turn spindle 18 clockwise to the stop for the service position:
- The distance between lever 13.26 and cam 13.25 must be 2w1 mm;
- The distance between roller 13.24 and angle lever 13.92 must be 0.5 mm;
- Loosen bolts 13.91.2 or 13.92.1 for any necessary adjustment.
3.25
3.26
13.91
13.90
13.91.1
13.91.2
3.24 13.92.1
max. 0.5
13.27
3.92
Figure 148 Detail of the withdrawable part of VD4 circuit-breaker with motor operator, seen from the left-hand side.
13.24 Roller
13.25 Plastic cam
13.26 Lever
13.27 Pin
13.90 Motor operator
13.91 Tie-rod
13.91.1 Bolt
13.91.2 Bolt
13.92 Angular lever
13.92.1 Bolt
96
2. Motor operator for the earthing switch
• Disconnect the terminals;
• Loosen the grub-screw in the set collars;
• Withdraw operating shaft 14.1;
• Observe the position of locking disc 14.6 relative to cam 14.7;
• Replace the motor operator;
• Slide the operating shaft through from the front;
• Observe the position of locking disc 14.6 relative to cam 14.7;
• Tighten the grub-screw in the set collars;
• Connect the control wiring;
• Set the operating mechanism manually to an intermediate position and only then perform a test run
to determine the direction of rotation;
• Ensure that the motor shuts down correctly in the final positions!
Note
The auxiliary switches of the interchangeable groups are adjusted at the works.
When final installation of the earthing switch and operator takes place on site, it may be necessary to
carry out further precise adjustment of the auxiliary switch. In this case, the following should be taken
into account:
• There must be a run-on of 0.5 mm in the fully operated position before the plunger reaches the stop
(for safety reasons);
• Auxiliary limit switch 11.4 (figure 149) for earthing switch ON must be operated immediately after the
dead centre position of the toggle spring mechanism has been reached in the closing process and
the automatic quick-closing process has started;
• Auxiliary limit switch 11.3 for earthing switch OFF must
a) be operated on earthing switches with manual mechanisms during the opening movement of slide
14.2 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 operator (no slide 14.2 fitted) immediately after the
toggle spring mechanism has passed the dead centre position during rotation to the OFF position.
11.3
14.6
14.7
14.1
14.3
11.4
11.4 11.3
Figure 149 Manual earthing switch operating mechanism Figure 150 Earthing switch motor operator with auxiliary
with auxiliary contacts, side protection removed contacts installed, protections removed
11.3 Q8S1 auxiliary contact – earthing 11.3 Q8S1 auxiliary contact – earthing
switch OFF switch OFF
11.4 Q8S2 auxiliary contact – earthing 11.4 Q8S2 auxiliary contact – earthing
switch ON switch ON
14.1 Drive shaft (earthing switch) 14.1 Drive shaft for earthing switch
14.2 Sliding closure 14.6 Locking disk
14.3 Cam plate, adjustable 14.7 Cam
97
7.5. Testing withdrawable parts
When functional tests are carried out on withdrawable parts, compliance with the conditions listed below
should also be checked.
Note
When the withdrawable part moves, the motor turns. The motor functions like a generator in these cases,
i.e. it can lead to reverse voltages in the terminals.
7.5.4 Checking the direction of rotation of the travel motors on motor-driven withdrawable
parts
• Move the withdrawable part by hand into a central position between the test/disconnected position
and the service position;
• Remove the hand crank;
• Switch the auxiliary voltage for the travel motor on;
• Use the local electrical controls to check that the withdrawable part moves in the correct direction.
Caution
Do not allow the withdrawable part to run up against a lock when the travel direction is incorrect! Switch
the motor power off immediately (the travel process functions electrically by a seal-in system with limit
position switch-off).
There may be a danger of injury when the door is open!
98
18.2 18.1 S9 S8 10.3
Figure 151 Withdrawable assembly (truck) for circuit-breaker with auxiliary devices.
S8 Test position indicator
S9 Service position indicator
10.3 Control circuit plug connector for withdrawable assembly
18.1 Square rod
18.2 Hole for shaft insertion lever
2. The withdrawable part must only be movable from the service position into the test/disconnected
position with the circuit-breaker open.
Check this condition as follows:
• With the circuit-breaker closed, withdrawal movement of the withdrawable part must be locked after
only half a turn of the crank in anti-clockwise direction, and it must not be possible to switch on the
travel motor on motor-operated withdrawable parts.
3. Closing of the circuit-breaker must only be possible when the withdrawable part is in the defined test/
disconnected position or service position.
The control wiring plug 10.2 (figure 152) must previously have been inserted.
Check this condition as follows:
• It must not be possible to close the circuit-breaker with the withdrawable part in any position between
the test/disconnected position and the service position.
Enabling of switching when the withdrawable part moves into the service position is carried out
electrically by operation of auxiliary switch S9 (figure 151) in the withdrawable assembly, and slightly
earlier mechanically - this corresponds to a position approximately half a turn of the crank before
the stop;
• For movement into the test/disconnected position, the same enabling conditions apply in the same
way, in this case by means of auxiliary switch S8 in the withdrawable assembly.
99
4. It must only be possible to open the circuit-breaker (manually) when the withdrawable part is in the
service position or test/disconnected position and the control voltage has failed.
Check this condition.
5. Withdrawable parts with order-related locking magnet Y0 may not be moved in case of control power
failure, or when there is no control power. Do not forcibly move locked withdrawable parts! The locking
magnet Y0 is only present on manually operated withdrawable parts.
Releasing the locking magnet Y0:
• Remove front plate 13.17;
• Disengage locking magnet Y0 by pulling the magnet armature;
• While doing so, turn crank 121 about one half turn (either direction of rotation is permissible). The
locking magnet is only active in the test position and service position. In intermediate positions it
has no effect.
6. Disconnection of the control wiring plug 10.2 as well as later insertion must be locked in the withdraw-
able part service position. Check this condition.
7. Operation of the earthing switch must only be possible when withdrawable part 13 is in the test/
disconnected position or the removed position (subject to any additional electro-magnetic interlocks
in individual cases).
Check this condition:
• With the withdrawable part in the test/disconnected position, it must be possible to press slide 14.2,
in front of the earthing switch operating shaft 14.1 (figure 127), downwards to the opening position.
The earthing switch can then be operated;
• With the slide pressed down, it must also be impossible to start the travel motor on motor-driven
withdrawable parts;
• If the slide is pressed down slightly when the travel motor is running, the motor must then automati-
cally switch off immediately.
The selected travel direction is continued by pressing the button.
It is only possible to press slide 14.2 down fully with a running travel motor when the latter is in the
start-up phase;
• When the withdrawable part is moved inwards towards the service position, pressing down of slide
14.2 must be locked after only one and a half clockwise turns on the crank.
10.2
13.1
18.1
14
Figure 152 Circuit-breaker compartment, open.Withdrawable part in isolated position, control circuit plug connector open
10.2 Control circuit plug connector
13.1 Withdrawable part
14 Earthing switch operating mechanism
18.1 Square rod
100
7.6 Tests on the panel
Note
Check the direction of rotation of the motor after repair work.
Do not allow the motor to run up against a lock if the direction of rotation is incorrect (also see section 7.5.4).
Halogen-free cleansers
• ETHANOL F 25 M (for general cleaning);
Touch-up paint
• Standard colour RAL 7035.
101
7.8 Operating accessories
145 31.29
147
128
31.28
122 121
90.8
102
8. Product quality and environmental protection
The UniGear ZS1 type panels are produced in compliance with the requirements of international standards
for the quality management system and environmental management system. In these fields, the excellent
level is proved by quality certificates according to ISO 9001 and by the EMS according to ISO 14 001.
The ABB company is committed to complying with the relevant legal and other requirements for environ-
ment protection according to the ISO 14 001 standard.
The duty of company is to facilitate subsequent recycling or disposal at the end of product life.
During disposal of the product, it is always necessary to act in accordance with local legal requirements
in force.
Metal material (Fe, Cu, Al, Ag, Zn, W, others) Separation and recycling
Rubber Disposal
Oil as dielectric (transformer oil) Draining from equipment and further recycling or disposal
103
For more information please contact:
The data and illustrations are not binding. We reserve the right to make
changes without notice in the course of technical development of the
product.