ZX2

ABB Power Distribution

ZX2

Gas-insulated medium voltage switchgear

Instruction manual BA 435/02 E

Your safety first – always!

• Only install switchgear and/or switchboards in enclosed rooms suitablefor electrical equipment.

• Ensure that installation, operation and maintenance are carried out byspecialist electricians only.

• Comply in full with the legally recognized standards (DIN VDE / IEC), theconnection conditions of the local electrical utility and the applicablesafety at work regulations.

• Observe the relevant information in the instruction manual for all actionsinvolving switchgear and switchboards.

• Danger!

Pay special attention to the hazard notes in the instruction manual markedwith this warning symbol.

• Make sure that under operation condition of the switchgear or switchboardthe specified data are not exceeded.

• Keep the instruction manual accessible to all persons concerned withinstallation, operation and maintenance.

• The user’s personnel are to act responsibly in all matters affecting safetyat work and the correct handling of the switchgear.

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

That's why our instruction manual begins with these recommendations:

WARNUNGAnerkannte Regeln der Technik und Betriebsanleitungen

beachten !

Gefährliche Spannung kann elektrischen Schock und Verbrennungen verursachen.

Vor Aufnahme von Arbeiten jeder Art dieses Gerät unbedingt freischalten,erden und kurzschließen.

WARNINGAlways observe the instruction manual and follow the rules

of good engineering practice !

Hazardous voltage can cause electrical shock and burns.

Disconnect power, then earth and short-circuit before proceedingwith any work on this equipment.

4 ABB Power Distribution

Contents Page

1 Summary 6

1.1 General 6

1.2 Standards and specifications 6

1.2.1 Switchgear manufacture 6

1.2.2 Installation and operation 6

1.3 Operating conditions 6

1.3.1 Normal operating conditions 6

1.3.2 Special operating conditions 7

2 Technical data 8

2.1 Panel type ZX2 8

2.2 Disconnector/earthing switch typeUX2TE, and disconnector type UX2T 9

2.3 Dimensions and weights 10

2.4 Resistance to internal arc faults 11

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

3.1 Design and equipment of the panels 17

3.2 Gas system in the panels/switchgear 17

3.3 Vacuum circuit-breakers, type VD4 X 17

3.4 Disconnector/earthing switch,type UX2TE 18

3.5 Disconnector, type UX2T 18

3.6 Sensor systems 18

3.7 High voltage connections 18

3.8 Bay control and protection unitREF542 (SCU) 19

3.9 Protection against maloperation/interlockdependencies/earthing of tee-off 19

3.9.1 Interlock dependencies 19

3.9.2 Earthing a tee-off in a singlebusbar system 19

3.9.3 Earthing the busbar in a singlebusbar system 20

3.9.4 Earthing a tee-off in a doublebusbar system 20

3.9.5 Earthing the busbar in a doublebusbar system 21

3.10 Test facilities 22

Contents Page

4 Despatch and storage 28

4.1 Condition on delivery 28

4.2 Packaging 28

4.3 Transport 28

4.4 Delivery 28

4.5 Intermediate storage 28

5 Erection of the switchgearat site 30

5.1 General site requirements 30

5.2 Construction data 30

5.3 Fundamental notes on erection work 31

5.4 Foundation frame 31

5.5 Laying of the foundation frame 31

5.6 Raised false floor 33

5.7 Erection and connection of the panels 38

5.7.1 Preparatory work 38

5.7.2 Erection of the switchgear 38

5.8 Connection of cables and wiring 44

5.8.1 High voltage plastic-insulated cablewith plug connectors 44

5.8.2 Control cables and wiring 44

5.9 Preparing the insulating gas systemfor operation 44

5.10 Final erection work 44

6 Commissioning/operation 45

6.1 Commissioning 45

6.1.1 Preparatory work 45

6.1.2 Initial start-up 45

6.2 Switching operations 45

6.2.1 Circuit-breaker 45

6.2.2 Three-position switch anddisconnector 46

6.2.3 Undervoltage release 46

6.3 Observation of the display andmonitoring facilities 46

6.3.1 Gas monitoring 46

6.3.2 Electrical/mechanical display/monitoring 46

ABB Power Distribution 5

Contents Page

6.4 Test procedures 46

6.4.1 Testing for the off-circuit condition 46

6.4.2 Testing for the in-phase condition 47

6.4.3 High voltage tests 47

6.4.4 Current tests 48

6.4.5 Maintenance earthing 48

6.5 Application of the X-ray regulations 49

7 Maintenance 53

7.1 General 53

7.2 Inspection/servicing 53

7.2.1 Vacuum circuit-breaker 54

7.2.2 Three-position switch anddisconnector 54

7.2.3 Gas system and gas servicing 54

7.2.4 Outlet filter 54

7.3 Repair 54

7.4 Working and auxiliary materials 55

7.4.1 Working materials 55

7.4.2 Auxiliary materials 55

We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual - orextracts – to third parties is prohibited. The information supplied is without liability. Subject to alteration.

© ABB Calor Emag Mittelspannung GmbH, 2000


1 Summary

1.1 General

Fundamental features of the ZX2 panels:

• rated voltage up to 36 kV

• three-phase metal-enclosed

• gas-insulated

• gas-tight metal-clad busbar compartment

• gas-tight metal-clad circuit-breaker compartment

• computerised switchbay control system

• sensor technology for adapted measured valueacquisition

• indoor installation

• factory-assembled

• type-tested.

Basic panel variants:

• incoming and outgoing feeders

• bus sectionalisers in single and double busbarsystems

• bus coupler panels in single and double busbarsystems

• bus riser panels in single and double busbarsystems

• metering panels in double busbar systems

• supplementary equipment:

– busbar metering system in single busbarsystems

Panel equipment, variants:

• vacuum circuit-breaker

• single or double busbar systems:

– busbar system 1 with disconnector/earthingswitch (three-position switch) with functions of:

• busbar connection,

• disconnection,

• earthing.

– busbar system 2 with disconnector withfunctions of:

• busbar connection,

• disconnection.

Details on the technical design and equipment of aswitchgear, such as

• technical data,

• detailed list of equipment fitted,

• detailed circuit diagrams, etc.

can be found in the order documents.

1.2 Standards and specifications

1.2.1 Switchgear manufacture

The panels comply with the following VDE stand-ards and the corresponding IEC publications:

• VDE 0670 and IEC 60056, 60129, 60298 and60694

• VDE 0373 and IEC 60376 and 60480.

1.2.2 Installation and operation

The relevant standards are to be observed duringinstallation and operation, in particular:

• DIN VDE 0101, Power installations exceedingAC 1 kV,

• VDE 0105, Operation of electrical installations

• DIN VDE 0141, Earthing systems for special powerinstallations with rated voltages above 1 kV,

• the accident prevention regulations issued bythe appropriate professional bodies,

• the safety guidelines for production materials,

• the order-related details provided by theswitchgear manufacturer.

1.3 Operating conditions

1.3.1 Normal operating conditions

Designed in accordance with VDE 0670 Part 1000,”Common specifications for high-voltage andcontrolgear standards” and IEC Publication 60694,with the following limit values:

• Ambient temperature:

– Maximum +40 °C

– Maximum 24 hour average +35 °C

– Minimum (corresponding to”minus 5 indoor” class) –5 °C

• Site altitude:

≤ 1000 m above sea level

• Ambient air:

The ambient air is not to be significantlycontaminated by dust, smoke, corrosive orflammable gases, or salt.


1.3.2 Special operating conditions

Special operating conditions are to be agreed bythe manufacturer and operator. The manufactureris to be consulted in advance about each specialoperating condition:

• Site altitude above 1000 m:

– Adjustment of the gas monitoring system isrequired for greater altitudes.

• Increased ambient temperature:

– The current carrying capacity is reduced,

– Additional cooling facilities for heat dissipationare to be provided.

• Climate:

– The risk of corrosion or other impairment, e.g.in the control cabinets, is to be avoided inareas:

• with high humidity and/or

• with major, rapid temperature fluctuations.

– Take countermeasures to prevent con-densation phenomena (e.g. provide electricheaters).


2 Technical data

2.1 Panel type ZX2

1) Higher values in accordance with international standards on request2) 1 bar = 100 kPa3) For details refer to table: "Panel width-classification" section 2.44) Cooling included5) Other operating sequences on request6) For further details see BA 427 - insulating gas system for ZX switchgear

Electrical data

Rated voltage kV 12 17.5 24 36

Rated power frequency withstand voltage kV 28 1) 38 1) 50 1) 70 1)

Rated lightning impulse withstand voltage kV 75 95 125 170

All voltages quoted apply to an insulatinggas pressure, absolute, at 20 °C, of bar 2) 1.0 1.0 1.0 1.0

Rated frequency Hz 50/60

Rated current of busbars A 1250/2500

Rated current of tee-offs 3) A ...2000/25004)

Rated peak withstand current 3) kA ...100 ...100 ...100 ...100

Rated short time current, 3 s 3) kA ...40 ...40 ...40 ...40

Rated short-circuit breaking current ofthe circuit-breaker kA ...40 ...40 ...40 ...40

Rated short-circuit making current ofthe circuit-breaker kA ...100 ...100 ...100 ...100

Rated operating sequence O-0.3 s–CO-3 min–CO5)

Break time:• manual tripping ms 45…90 45…90 45…90 45…90• protection tripping ms 40…55 40…55 40…55 40…55

Closing time:• manual tripping ms 65…95 65…95 65…95 65…95• protection tripping ms 60 60 60 60

Insulating gas system2)6)

Insulating gas N27) SF6

8) SF68) SF6

8)

Design pressure, absolute bar 1.36 1.36 1.36 1.36

Operating pressure, absolute, 20 °C(equals filling pressure) bar 1.3 1.3 1.3 1.3

Rated pressure, absolute, 20 °C(minimum operating pressure) bar 1.2 1.2 1.2 1.2

Motor and release data

Charging motor W <200 <200 <200 <200

Closing coil W 250 250 250 250

Opening coil W 250 250 250 250

Rated supply voltage

DC voltage V 60, 110, 2209)

Degree of protection (IEC 60529, DIN VDE 0470-1)

Gas-tight enclosure IP 65 IP 65 IP 65 IP 65

Control cabinet IP 4X 10) IP 4X 10) IP 4X 10) IP 4X 10)

7) Insulating gas: nitrogen8) Insulating gas: sulphur hexafluoride9) Other voltages on request10) IP 5X on request


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

Test voltages

Rated voltage kV 12 17.5 24 36Rated power frequency withstandvoltage across the isolating distance kV 32 45 60 80

Rated lightning impulse withstandvoltage across the isolating distance kV 85 110 145 195

Insulating gas system 1) 2)

Insulating gas N23) SF6

4) SF64) SF6

4)

Operating pressure, absolute, 20°C( equals filling pressure ) bar 1.3 1.3 1.3 1.3

Rated pressure, absolute,20°C( minimum operating pressure ) bar 1.2 1.2 1.2 1.2

1) 1 bar = 100 kPa2) For further details see BA 427 -

insulating gas system for ZX switchgear3) Insulating gas: nitrogen4) Insulating gas: sulphur hexafluoride

Rated voltage kV 12/17.5/24/36

Test currents

Rated current A 630 5) 12501) 2500 2)

Rated peak withstand current kA …63 …80 ...100

Rated short time current, 3 s kA …25 …31.5 ...40

Motor data

Motor power, max 3). W 180 180 180

Motor running times, max 3).:

• Centre position to BB s 18 18 20

• Centre position to earth s 18 18 20

Rated supply voltage

DC 4) V 60,110,220

1) Panel width: 600 mm2) Panel width: 800 mm3) At rated supply voltage4) Other voltages on request5) Panel width: 400 mm


220

1232

B

30600800 1710

2600

2100 2300

895

A C D A

BZX2ZX2

X

View X

n panels 2)

1)

1)

2.3 Dimensions and weights

Figure 2/1: Dimensions, double busbar systemFigure shows panels with rated currents ≤ 2000 A.

A Pressure relief duct with absorberB Pressure relief duct, topC Pressure relief duct, sideD End coverE Pressure relief duct, rear

1) Panels with rated currents greater than 2000 A are also fitted with a cooling fan. The panel height is then increased by 200 mmto 2500 mm or 2800 mm.

2) n ≥ 1

ZX2ZX2

110

5

1710

26

00

2100 23

00

775

A

B

View X

B

30220600800

A C D

X

n panels

1)

2)

1)

E

Figure 2/2: Dimensions, single busbar systemFigure shows panels with rated currents ≤ 2000 A.

A Pressure relief duct with absorberB Pressure relief duct, topC Pressure relief duct, side

Optionally also with voltage sensors for busbar meteringD End coverE Pressure relief duct, rear

1) Panels with rated currents greater than 2000 A are also fitted with a cooling fan. The panel height is then increased by 200 mmto 2500 mm or 2800 mm.

2) n ≥ 1


Panel width

400 mm 600 mm 800 mm

Core modul/BB-compartment 25 kA, 1s 31.5 kA, 1s 40 kA, 1s

Cable compartment 20 kA, 1s, three-pole 25 kA, 1s, three-pole 25 kA, 1s, three-pole

Weights:

• Weight of a standard panel, double busbar,panel width 400 mm, rated current ≤ 630 A: approx. 650 kg

• Weight of a standard panel, double busbar,panel width 600 mm, rated current ≤ 1250 A: approx. 1200 kg

• Weight of a standard panel, double busbarpanel width 800 mm, rated current ≤ 2000 A: approx. 1700 kg

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

2.4 Resistance to internal arc faults

Resistance to internal arc faults:

Criteria 1 - 6 of PEHLA directive no. 4 (in conjunction with VDE 0670 Part 6 and IEC 60298) are fulfilled.

The panels have integrated pressure relief ducts with the opportunity for:

• channelling out of the switchroom in a manner suitable for the building dimensions, or

• channelling through an absorber on the last two panels (when the ceiling height is sufficient).

Table: Panel width-classification

Rated voltage kV 12 17.5

IK, 3s kA 25 31.5 31.5 40 40 20 25 31.5 40

IP kA 63 80 80 100 100 50 63 80 100

Itee-off A 630 1250 2000/ 1250 2000/ 630 1250 2000/ 1250/2500 2500 2500 2000/

2500

Panel width mm 400 600 800 600 800 400 600 800 800

Rated voltage kV 24 36

IK, 3s kA 20 25 25 31.5 40 25 31.5 40

IP kA 63 63 80 100 63 80 100

Itee-off A 630 1250 2000/ 1250/ 1250/ 1250 1250/ 1250/2500 2000/ 2000/ 2000/ 2000/

2500 2500 2500 2500

Panel width mm 400 600 800 800 800 600 800 800


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

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

1.1 Control cabinet door3 Three-position switch operating mechanism8 Circuit-breaker operating mechanism20 Disconnector operating mechanism

Figure 3/3: Bay control and protection unit REF542

5 Bay control and protection unit5.1 LCD display (example)5.2 LEDs6 Measuring sockets for capacitive voltage indicator

system

3

8

1.1

20

5

5.1

5.2

6


Figure 3/4: Panel, double busbar, with pressure relief ducts at topand rear

The side walls of busbar compartments 1 and 2, of thecircuit-breaker compartment and the cable terminationcompartment have been cut open to provide a betterview.

B Pressure relief duct, topE Pressure relief duct, rearG Control cabinetH Circuit-breaker compartmentI Cable compartment

2 Disconnector/earthing switch (three-position switch)in busbar compartment 1

19 Disconnector -Q2 in busbar compartment 220 Operating mechanism for item 1923.5 Bushing for plug-in busbar connection

Figure 3/5: Pressure relief disk for a busbar compartment in theupper pressure relief duct

Figure 3/6: Vacuum circuit-breaker type VD4 X (before installationin the works)

I

B

2G

23.5

19

20

EH


-Q11-Q16 -Q12-Q15-Q1-Q5

-Q0

-Q1-Q5

-Q0

-Q5 -Q1-Q1 -Q2 -Q25 -Q2-Q15

-Q0 -Q0 -Q0

-Q11-Q16 -Q12-Q15 -Q26 -Q21 -Q22-Q25

-Q0

-Q11-Q16 -Q26 -Q21 -Q12 -Q22-Q15 -Q25 -Q1 -Q52-Q51 -Q2

Feeder Coupler Riser Busbar meteringCable connection

Feeder Bus sectionaliserBus coupler

Bus sectionaliser

(without C.B.)

Busbar meteringTrunking barconnection

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

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


Figure 3/8: ZX2 panel, single busbar, 1250 A Figure 3/9: ZX2 panel, single busbar, 2000 A

Figure 3/10: ZX2 panel, double busbar, 2000 A


Figure 3/11: ZX2 panel, double busbar, 1250 A, fundamentalstructure

SS1 Busbar system 1SS2 Busbar system 2B Pressure relief duct, topE Pressure relief duct, rearG Control cabinetH Circuit-breaker compartmentI Cable termination compartment

1 Panel enclosure2 Disconnector/earthing switch -Q1/-Q5

(three-position switch)3 Three-position switch operating mechanism(4) Pressure sensor for busbar compartment 15 Bay control and protection unit REF5426 Measuring sockets for capacitive voltage indicator

system7 Pressure sensor for circuit-breaker compartment8 Circuit-breaker operating mechanism9 Cable or test plug socket10 Cable socket11 Cable plug12 Surge arrester13 Floor plate, split14 Connecting link panel/panel for item 1515 Main earthing bar16 Combined current and voltage sensor17 Pressure relief disk18 Circuit-breaker19 Disconnector -Q220 Disconnector operating mechanism(21) Pressure sensor for busbar compartment 222 Tee-off conductor23 Busbar connection, plug-in type24 Busbar25 Drying agent bag26 Pressure relief disk

Inert gas

-Q0 Circuit-breaker-Q1 Tee-off disconnector-Q2 Tee-off disconnector-Q5 Tee-off earthing switch-T1 Current sensor-R1 Voltage sensor-C1 Capacitive voltage divider

-Q5 -Q1 -Q2

-Q0-T1

-C1-R1

B B

20

8

5

7

9

11

18

23

25

26

19

17

15

SS2 SS1

G

K

I

H

16

14

22

24

13

(4)

2

1

12

10

(21)3


3.1 Design and equipment of the panels(Figures 2/1, 2/2, 3/1 to 3/11)

The metal-enclosed ZX2 panels are laser cut andwelded panel enclosures, completely earthed andthus protected against accidental contact.

The stainless steel encapsulation and the insulatinggas protect all live parts in the high voltage areapermanently from soiling, humidity, foreign bodiesand other injurious influences.

The modular structure provides the conditions nec-essary for all panel variants normally required in arelatively simple manner.

Facilities are also provided, for instance, for:

• one or two busbar systems,

• three-position switch or disconnector,

• different connection methods, such as multiplecables.

Relieved pressure is guided into pressure reliefducts (A), (B), (C) and (E):

• In the case of internal arcing fault, the followingpressure relief disks open:

– Pressure relief disk 17 on circuit-breakercompartment (H) into pressure relief duct (E).The gases are channelled out via ducts (C)and (A).

– Pressure relief disk 26 on the busbar com-partment into pressure relief duct (B).

• In the case of an arc in the cable compartment(I), a pressure relief flap in pressure relief duct (E)opens. The gases are channelled out via ducts(C) and (A).

Each panel is a unit, They are linked together byplug-in busbar connections 23.

Basic equipment in the panels:

• Circuit-breaker VD4 X

• Three-position switch UX2TE

• Disconnector UX2T

• Sensor system

• Control cabinet with the bay control and protec-tion unit REF542

• Cable and test plug sockets.

The insulation test criteria of VDE and IEC list 2 arefulfilled by the ZX2 standard series up to andincluding 36 kV even when the gas filling is atatmospheric pressure.

3.2 Gas system in the panels/switchgear(Figures 3/11 and 3/15)

A permanently protected climate for the entire liveprimary area is ensured by the gas-tight encapsula-tion of the panels and their filling with dry insulatinggas.

• The circuit-breaker compartment and thebusbar compartments in each panel are sepa-rate gas compartments with their own filling con-nectors. The gas compartments in the individualpanels set up side by side are not connectedtogether.

• The operating pressure (pe) (equals filling pres-sure) in the individual compartments is moni-tored by temperature compensated pressuresensors:

– Pressure sensor 7 for the circuit-breakercompartment,

– Pressure sensors 4 and 21 for busbarcompartments 1 and 2.

• When the pressure drops below the ”minimumoperating pressure”, a pressure loss signal isoutput.

• With a rapidly rising pressure as a consequenceof an internal arc fault and a correspondinglyhigh current, the bay control and protection unitREF542 shuts the incoming feeders or couplersdown.

• Details on the gas system and gas servicing ofthe ZX2 switchgear can be found in instructionmanual BA 427 – Insulating gas system for ZXswitchgear.

• The gas compartments contain drying agentbags 25.

Further details on the drying agent material can befound in instruction manual BA 427.

3.3 Vacuum circuit-breakers, type VD4 X(Figures 3/2, 3/6 and 3/11, and separate manualBA 436/E)

Functions of the vacuum circuit-breaker 18:

• opening and closing on rated currents,

• short-circuit breaking operations,

• earthing function in conjunction with three-posi-tion switch 2.

The earthing function of the three-position switchprepares - under no current - for the connection toearth. Earthing proper is performed by the circuit-breaker. This integration of functions is advant-ageous, as a circuit-breaker is of higher quality inthe earthing function than any other earthingswitch.

The circuit-breaker poles are installed horizontallyin the circuit-breaker compartment (H). The circuit-breaker operating mechanism is located outsidethe gas compartment and is therefore easily acces-sible. It is connected to the breaker poles by a gas-tight thrust bushing.


3.4 Disconnector/earthing switch, type UX2TE(Three-position switch)

(Figures 3/2, 3/4 and 3/11)

The ZX2 panels are fitted with specially designedthree-position disconnectors and earthing switches-Q1/-Q5. These switches are motor-operated rod-type switches whose live switching components arelocated in busbar compartment 1 (insulating gascompartment), while the operating mechanismblock is easily accessible from the control cabinet(G). The operating mechanism block contains thedrive motor, the position indicators (sensors andmechanical indicators) and the emergency manualoperating system.

The three-position switch performs the functions of:

• connecting,

• disconnecting, and

• earthing.

The three switch positions are unequivocally speci-fied by the operating mechanism. The switch hasits disconnecting position at the centre. In the limitpositions, disconnector ON and earthing switchON, the moving contact (sliding part) driven by aninsulating spindle, reaches the isolating contacts,which are fitted with one or two spiral contacts re-spectively.

3.5 Disconnector, type UX2T(Figures 3/2, 3/4 and 3/11)

Disconnector -Q2 is a motor-operated rod-typeswitch. Its live switching components are located inbusbar compartment 2 (insulating gas compart-ment). The operating mechanism block is split andlocated outside the gas compartment. The drivemotor is located at the rear of the panel behind aremovable cover. The position indicators (sensorsand mechanical indicators) and the emergencymanual operating system are accessible from con-trol cabinet (G). Disconnector -Q2 is structuredsimilarly to the three-position switch, but withoutthe earthing switch assembly.

3.6 Sensor systems(Figures 3/3, 3/11, 3/12 to 3/15, 6/3 and 6/7)

In comparison with conventional inductive instru-ment transformers, sensors require much lessspace. They facilitate measured value acquisitionsuitable for the control and automation systemREF542.

The following sensors are used in ZX2 panels:

• Sensors for current measurement 16

• Sensors for voltage measurement 16

• Capacitive pick off for voltage display

• Sensors 4, 7 and 21 for insulating gas pressuremonitoring

• Sensors to detect the switch positions of the cir-cuit-breaker, disconnector/earthing switch anddisconnector

• Sensor to detect the charging condition of thecircuit-breaker spring energy store.

Arrangement of the sensors:

• Current and voltage sensors are located in therear part of the circuit-breaker compartment.The external connections allow wiring to be fedthrough the cable compartment (I) to theREF542.

• Sensors for pressure monitoring:

– B0G for the circuit-breaker compartment:on the circuit-breaker base plate in controlcabinet (G).

– B1G for busbar compartment 1:beside the operating mechanism for thedisconnector/earthing switch -Q1/-Q5 in thecontrol cabinet (G).

– B2G for busbar compartment 2:beside the base plate for the drive motor ofdisconnector -Q2 at the rear of the panel.

• Sensors for detection of the switch positions:

– B0E and B0A for the circuit-breaker:on its mechanism shaft.

– B1E, B1A, B5E and B5A for thedisconnector/earthing switch:on its operating mechanism in the controlcabinet.

– B2E and B2A for the disconnector:beside its emergency manual operatingmechanism in the control cabinet.

• Sensor B0S for detection of the charging condi-tion of the spring energy storage mechanism:above the spring drum in the circuit-breakeroperating mechanism.

3.7 High voltage connections(Figures 3/4, 3/8 to 3/11, 5/15 and 5/16)

Cable plug connector systems:

• high voltage plastic-insulated cable with internalcone cable plug connector system and socketsto DIN 47 637.

Plug-in cable sockets 9 and 10 mounted in a gas-tight manner in the floor plate of the circuit-breakercompartment maintain the partitioning betweenthe insulating gas compartment and the cabletermination compartment.


3.8 Bay control and protection unit REF542(Figures 3/3 and 3/15)

The following functions are integrated in the baycontrol and protection unit REF542:

• Busbar protection

• Tee-off protection

• Control

• Measurement

• Position indication

• Hazard and fault signalling

• Connection to control systems.

Panel interlocks and the sequence of switchingoperations (e.g. isolation, testing of the off-circuitcondition and earthing) are controlled by theREF542 panel unit.

The single-line diagram providing information onswitching device positions is made visible on LCdisplay 5.1.

Measured values such as conductor currents,phase voltages, energy metering and active andreactive power, number of operating cycles andnumber of operating hours appear numericallyand/or as a bar diagram on the display. Further in-formation, such as alarm and fault signals, is dis-played with text by LEDs 5.2.

The bay control and protection unit REF542 can beconnected to a control system via optical fibre ca-bles. Electromagnetic interference is avoided by theuse of optical fibre cables.

Please consult the REF542 instruction manual no.BA 453 for details on handling of the bay controland protection unit and the detailed technicaldescription.

3.9 Protection against maloperation/interlockdependencies/earthing of tee-off

In order to prevent dangerous situations andmaloperation, a series of interlocks are provided toprotect the operators and the switchgear itself.

In ZX2 panels with digital control systems, protec-tion against maloperation is fundamentally effectedby the software in the panel unit.

The circuit-breaker, three-position switch anddisconnector can be controlled directly at the panelor from the control room using the local/remotelock-switch. Operation at the panel is by selectionon the REF542.

3.9.1 Interlock dependencies

1. Limit position blocking of the switching devices.

2. Dependence of the disconnectors -Q1 or -Q2 onthe earthing switch -Q5 and vice versa.

3. Dependence of the disconnectors -Q1 or -Q2 onthe circuit-breaker -Q0.

4. Dependence of the circuit-breaker -Q0 on theearthing switch -Q5.

5. Interdependence of the disconnectors -Q1 and-Q2.

6. Dependence of the disconnectors -Q1 and -Q2on bus coupler circuit-breakers and vice versa.

7. Dependence of the bus section disconnector onthe busbar tee-off disconnectors and vice versa(for bus sectionalising without circuit-breakeronly).

Details of interlocks/dependencies over and abovethose listed in points 1 to 7 (e.g. with neighbouringsystems) can be found in the individual orderdocuments.

The interlock polling between panels is effected byloop lines from panel to panel.

Operation on failure of the auxiliary power supply:

On failure of the auxiliary power supply, the devicescan be operated manually.

No provision is however made for interlockedemergency manual operation of the three-positionswitches and disconnectors.

Emergency manual operation:

Intervention in the interlock concept is possible byopening the control cabinet door. Emergencymanual operation without maloperation preventionis possible by means of a hand crank and mechani-cal push-button.

3.9.2 Earthing a tee-off in a single busbar system

(Figure 3/7)

1. Manual earthing

Operating sequence for tee-off earthing:

• Circuit-breaker -Q0 OFF.

• Disconnector -Q1 OFF.

• Earthing switch -Q5 ON.

• Test for off-circuit condition (display onREF542 or capacitive voltage indicator sys-tem (see section 6.4.1)).

• Circuit-breaker -Q0 ON (only possible whenthe REF542 has detected the off-circuit con-dition and enabled the switching operation).

• Secure panel to prevent reconnection (m.c.b.F101 and F106 OFF).

• Label the panel to indicate that earthing hasbeen effected.


2. Automatic earthing by selecting the earthingsequence on the REF542 display (this facilitydepends on the order placed)

• Condition: circuit-breaker -Q0 OFF.

• Select and start the automatic earthing se-quence:

– Disconnector -Q1 OFF.

– Earthing switch -Q5 ON.

– Check on off-circuit condition by REF542.

– Circuit-breaker -Q0 ON.

– M.c.b. F101 and F106 OFF.

– Feedback message ”Earthed and secured”.


3. Cancelling the earthing of a tee-off

• Open the control cabinet door and switch onthe m.c.b. F101 and F106 manually.


3.9.3 Earthing the busbar in a single busbar system

(Figures 3/7 and 6/7)

Earthing of the busbar or a busbar section isdependent on the switchgear configuration. Sy-stems with bus ties / risers permit the earthing of asingle busbar section.

1. Manual earthing of a busbar section using thebus tie / riser

Operating sequence:

• Circuit-breaker -Q0 in the bus tie (tie breaker)OFF.

• All disconnectors -Q1 in the busbar section tobe earthed OFF.

• Disconnectors (-Q11 or -Q12) between thebusbar section to be earthed and the tiebreaker ON.

• Earthing switch (-Q15 or -Q16) on theopposite side of the tie breaker ON.

• Tie breaker -Q0 ON.

• M.c.b. F101 and F106 OFF.

• Label the busbar section to indicate thatearthing has been effected.

The busbar section is then earthed. Alldisconnectors in the earthed busbar section areblocked.

2. Automatic earthing of a busbar section by se-lecting the earthing sequence on the REF542display (this facility depends on the order placed)

• Condition:

– Circuit-breaker -Q0 in the bus tie (tiebreaker) OFF.

– All disconnectors -Q1 in the busbar sectionto be earthed OFF.


– Disconnectors (-Q11 or -Q12) between thebusbar section to be earthed and the tiebreaker -Q0 ON.

– Earthing switch (-Q15 or -Q16) on theopposite side of the tie breaker -Q0 ON.

– Tie breaker -Q0 ON.

– M.c.b. F101, F102 and F106 OFF.

– Feedback message ”Earthed and se-cured”.


The selected busbar section is then earthed.All disconnectors in the earthed busbar sec-tion are blocked.

3. Cancelling the earthing of a busbar section

• Open the control cabinet door and switch onthe m.c.b. F101, F102 and F106 manually.

• Circuit-breaker -Q0 in the bus tie OFF.

4. Maintenance earthing of a busbar via free sock-ets in a tee-off

Condition:

• The tee-off is earthed.

• All disconnectors in the busbar to be earthedOFF.

Operating sequence:

• Fit a short-circuiting bridge to the free socketsand connect to main earthing bar 14.

• Circuit-breaker OFF.

• Earthing switch OFF.

• Disconnector ON.

• Circuit-breaker ON.

• M.c.b. F101 and F106 OFF.

• Label the busbar to indicate that earthing hasbeen effected.

All relevant panels are to be secured to preventswitching operations, e.g. tripping m.c.b.

3.9.4 Earthing a tee-off in a double busbar system


1. Manual earthing

Operating sequence for tee-off earthing:


• Disconnectors -Q1 and -Q2 OFF.

• Earthing switch -Q5 ON.


• Test for off-circuit condition (display onREF542 or capacitive voltage indicator sys-tem (see section 6.4.1)).

• Circuit-breaker -Q0 ON (only possible whenthe REF542 has detected the off-circuit con-dition and enabled the switching operation).

• Secure panel to prevent reconnection (m.c.b.F101, F102 and F106 OFF).


2. Automatic earthing by selecting the earthingsequence on the REF542 display (this facilitydepends on the order placed)

• Condition: circuit-breaker -Q0 OFF.


– Disconnectors -Q1 and -Q2 OFF.

– Earthing switch -Q5 ON.

– Check on off-circuit condition (by REF542).

– Circuit-breaker -Q0 ON.

– M.c.b. F101, F102 and F106 OFF.

– Feedback message ”Earthed and secured”.


3. Cancelling the earthing of a tee-off



3.9.5 Earthing the busbar in a double busbar system


Earthing of the busbar or a busbar section is de-pendent on the switchgear configuration. Systemswith bus couplers permit the earthing of a singlebusbar section.

1. Manual earthing of a busbar section

Operating sequence:

a) Busbar 1:

• Circuit-breaker in the bus coupler OFF.

• Disconnector -Q2 in the bus coupler OFF.

• All disconnectors -Q1 in the busbar sectionto be earthed OFF.

• Disconnector -Q1 in the bus coupler ON.

• Earthing switch -Q15 in the bus couplerON.

• Circuit-breaker in the bus coupler ON.

• M.c.b. F101, F102 and F106 OFF.


The busbar section of busbar 1 is thenearthed. All disconnectors in the earthed bus-bar section are blocked.

b) Busbar 2:

• Circuit-breaker in the bus coupler OFF.

• Disconnector -Q1 in the bus coupler OFF.

• All disconnectors -Q2 in the busbar sectionto be earthed OFF.

• Disconnector -Q2 in the bus coupler ON.

• Earthing switch -Q25 in the bus couplerON.

• Circuit-breaker in the bus coupler ON.

• M.c.b. F101, F102 and F106 OFF.


The busbar section of busbar 2 is thenearthed. All disconnectors in the earthedbusbar section are blocked.

2. Automatic earthing by selecting the earthing se-quence on the REF542 display (this facility de-pends on the order placed)

• Condition:

– Circuit-breaker -Q0 in the bus couplerOFF.

– All disconnectors in the relevant busbarsection OFF.

• Select the operating sequence:

a) Busbar 1:

– Disconnector -Q2 in the bus coupler OFF.

– Disconnector -Q1 in the bus coupler ON.

– Earthing switch -Q15 in the bus couplerON.

– Circuit-breaker in the bus coupler ON.

– M.c.b. F101, F102 and F106 OFF.

– Feedback message ”BB1 earthed andsecured”.

– Label the busbar section to indicate thatearthing has been effected.


b) Busbar 2:

– Disconnector -Q1 in the bus coupler OFF.

– Disconnector -Q2 in the bus coupler ON.

– Earthing switch -Q25 in the bus couplerON.

– Circuit-breaker in the bus coupler ON.

– M.c.b. F101, F102 and F106 OFF.

– Feedback message ”BB2 earthed andsecured”.


– Label the busbar section to indicate thatearthing has been effected.


3. Cancelling the earthing of a busbar section


• Circuit-breaker -Q0 in the bus coupler OFF.

3.10 Test facilities

The panels are properly filled with insulating gas atthe works and tested to the VDE or IEC standards.Testing on completion of switchgear installation istherefore unnecessary. Should there be any needto perform tests, the tests are to be performed asfollows:

• For voltage and current tests, direct access tothe conductors in the connection area is possi-ble without removing the cable connection orextracting the insulating gas. Access is effectedvia free cable connecting sockets or via the ca-ble sockets for the surge arresters.

The surge arresters must be removed duringvoltage tests.

• Voltage tests:

– cable tests with DC voltage,

– cable fault location measurements with im-pulse voltage and

– system tests (without cables) with a AC volt-age

can be performed with a test plug as shown inFigure 6/8.

• A test plug for current tests as shown in figure6/9 can be used to test the protection devicesby primary current injection (see also the notein section 6.4.4). This configuration is short-cir-cuit proof and can also be used as anadditional maintenance earth.

The possible testing processes are described in thefollowing sections:

• testing for the off-circuitcondition: Section 6.4.1

• testing for the in-phasecondition: Section 6.4.2

• high voltage tests: Section 6.4.3

• current tests: Section 6.4.4.



S1 - S2: 320...1280AS1 - S3: 120... 480AS1 - S4: 40... 160A

Working area

80A/

150mV240A/

150mV

640A/150mV

P1

P2

S1

S2

S3

S4

a

n

1

2

Terminaldesignation

Front view

-XI.. ,-XU..

-XU.. Pick-off: 10 000 :1

Primary conductor

In = 1250 AIp = 100 kA

Ith 3sec = 40 kA

1

2

CK20kV/ V3

2V/ V3 Class 1

80A /240A /640A /150mV

Class 1 without correction factor 3 Capacitance C1 ≥ 35pF

max 55pF

Leakagecapacitance ≤ 25pF

1

2

-XI..

-

Figure 3/12: Combined current and voltage sensor with capacitive pick-off KEVCI 24 AE1, for ratedvoltages up to 24 kV and panel width 600 mm

The following changes apply to rated voltage 36kV:

• Sensor: KEVCI 36 AE1

• Pick-off: 20 000:1 bzw. 30 kV / 31,5 V / 3

• Capacitance: C1 ≥ 18 pF, max. 22 pF

Figure 3/13: Combined current and voltage sensor with capacitive pick-off KEVCA 24 BE1, for ratedvoltages up to 24 kV and panel width 800 mm

The following changes apply to rated voltage 36kV:

• Sensor: KEVCI 36 BE1

• Pick-off: 20 000:1 bzw. 30 kV / 31,5 V / 3

• Capacitance: C1 ≥ 18 pF, max. 22 pF

1600A/150mV

P1

P2

S1

S2

a

n

1

2

Terminaldesignation

Front view

-XI.. ,-XU..

-XU.. Pick-off: 10 000 :1

1

2

CK

Capacitance C1 ≥ 35pFmax 55pF

Leakagecapacitance ≤ 25pF

1

2

-XI..

-

S1 - S2: 800...3200A

Working area

1600A/150mV Class 1 without correction factor 3

Primary conductor

In = 2500 AIp = 100 kA

Ith 3sec = 40 kA

20kV/ V3

2V/ V3Klasse 1


Figure 3/14: Current and voltage sensors in an outgoing cable feederpanel, up to 24 kV, double busbar

The circuit diagram is identical for the single busbar system,but without tee-off disconnector -Q2.

-Q0 Circuit-breaker-Q1 Busbar tee-off disconnector-Q2 Busbar tee-off disconnector-Q5 Tee-off earthing switch-T1... Current sensors-R1... Voltage sensors-C1... Capacitive voltage divider

Inputs and interfaces of the bay control and protection unitREF542:

IL... Measurement inputs for “current”UL... Measurement inputs for “voltage”-XI... Interfaces of the current sensors-XU... Interfaces of the voltage sensors-XIt... Test interfaces of the current sensors and the inputs-XUt... Test interfaces of the voltage sensors and the inputs-A200 Bay control and protection unit REF542

measurement,metering

-R1L1..L3

IL1

IL2

IL3

d28

z28

d24

z24

S1

S.

S1

S.

S1

S.

d20

z20

d16z16

an

an

an

d12z12

d8z8

UL1

UL2

UL3

L1 L2

T1L1

T1L2

T1L3

R1L1

R1L2

R1L3

Current andvoltagesensors

Tee-offprotection;

-X3

GND

-XIL1

-XIL2

-XIL3

-XUL3

-XUL2

-XUL1

L3

-XItL1

-XItL2

-XItL3

-XUtL1

-XUtL2

-XUtL3

-A200

-Q0

3

3

-T1L1..L3

20kV/ V 3 2V/ V 3

150mV

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

-Q1/Q5

P1 P1 P1

P2

P2

P2

P1

P2

IL0d4

z4

1

2

12

-XItL0

3 single core cables

-C1L1..L3

1

2

Terminaldesignation

Front view

-XI.. ,-XU..

I

II

-Q2

-XIL0


A15

X4:

z18

X4:

d18

X4:

d10

X4:

z10

X5:

d6

X5:

z6

X5:

z4

X5:

d4

X5:

d2

X5:

z2

X7:

d22

X7:

d20

X7:

z20

X7:

z22

11

-F102

- F100

-A200

+

12

-

23

M-M2

2

1

4

3

X7:

d18

A14

24

A13

A12

-F106:24

X4:

d28

X4:

z28

X4:

d20

X4:

z20

11 11 11

121212- F101 - F102 - F106

+

-

(1)

(2)

-B2E

BU

BN

BK

-B2A

BK

BN

BU

E15E16E17

65

3

4

140

kPa

140

kPa

110

kPa

110

kPa

E5

65

3

4

140

kPa

140

kPa

110

kPa

110

kPa

E9

65

3

4

140

kPa

140

kPa

110

kPa

110

kPa

E10 E14

-B0G -B1G -B2G

X7:

z18

Figure 3/15b:Continued from figure 3/15a

Figure 3/15a:

X4:

z16

X4:

d16

X4:

z14

X4:

d14

-B5E

BK

BN

-B5A

BK

BN

BU

-B1E

BU

X4:

z8

- F116

-A200

+

2 4

1 3

MMK

E12 E4

-

X1:

1

X1:

3

SPA - BUS

23

M-M0

M-M1

232 4

1 3 24

-Y3 -Y2

24

2342

1 3

2

1

4

3

B F

X6:

d12

X6:

z12

X6:

d4

X6:

z4

X6:

z8

X6:

d8

-F100

-F106- F101

X6:

d18

X6:

z18

X6:

d10

X6:

z10

X6:

d2

X6:

z2

X6:

d6

X6:

z6

X6:

d20

X6:

z20

C1 C2 C2C1

X6:

d22

X6:

z22

A5

A7

24

-B0S

X4:

d2

X4:

z2

BU

X4:

d4

X4:

z4

BK

BN

-B0E

BK

BN

BU

-B0A

BK

BN

BU

X4:

d12

X4:

z12

E6E1E2

-B1A

BK

BN

BU

E7

-B5E3

E8

4

3

2

1

-B5E2

-B5E1

A6

A3 A4

A2 A1

-V3 -V2

(2)

BK

BN

BU

X4:

d6

X4:

z6

E3

X4:

d8

X4:

z24

X4:

d24

(1)

-F102: 24


Figure 3/15: Circuit diagram of the panel controller for a double busbar system

The circuit diagram is identical for the single busbar system, but without M2, B2G,B2E, B2A and F102. Inputs E15, E16 and E17 and outputs A12 to A15 on theREF542 are not then used.

-B0A Sensor, “Circuit-breaker -Q0 OFF signal”-B0E Sensor, “Circuit-breaker -Q0 ON signal”-B0S Sensor, “spring energy store charged signal”-B5E Sensor, “Earthing switch -Q5 ON signal”-B5A Sensor, ”Earthing switch -Q5 OFF signal”-B5E1…3 Reed contacts, ”Earthing switch -Q5 ON” signal-B1E Sensor, “Disconnector -Q1 ON signal”-B1A Sensor, “Disconnector -Q1 OFF signal”-B2E Sensor, “Disconnector -Q2 ON signal”-B2A Sensor, “Disconnector -Q2 OFF signal”-B0G Pressure sensor for circuit-breaker compartment-B1G Pressure sensor for busbar compartment 1-B2G Pressure sensor for busbar compartment 2-M0 Charging motor for spring energy store, circuit-breaker-M1 Drive motor for disconnector/earthing switch -Q1/Q5-M2 Drive motor for disconnector -Q2-MMK Man/machine communications-Y2 and -V2 Shunt release off with series rectifier for -Q0-Y3 and -V3 Shunt release on with series rectifier for -Q0-A200 Bay control and protection unit REF542-F100 M.c.b. for charging motor, circuit-breaker-F101 M.c.b. for drive motor, disconnector/earthing switch -Q1/-Q5-F102 M.c.b. for drive motor, disconnector -Q2-F106 M.c.b. for controller, circuit-breaker ON/OFF-F116 M.c.b. for auxiliary power supply to the REF542


4 Despatch and storage4.1 Condition on delivery

The factory-assembled panels are checked forproper assembly and function.

Condition on delivery:

• Compliance of the equipment with the orderchecked.

• Routine testing to VDE 0670 Part 6 or ICE 60298performed.

• Installation material and accessories packagedseparately.

• Bushings for the busbars closed off withtransport covers.

• Condition of the gas compartments:– Filled with insulating gas at rated operating

pressure,

– Fitted with drying agent bags.

Note:

Air freight is to be discussed and agreed inindividual cases.

4.2 Packaging• Panels with basic packaging or without packaging.

• Panels with seaworthy or similar packaging (alsocontainerised for overseas transport):

– sealed in polythene sheeting,

– transport drying agent bags inserted,– moisture indicators inserted,

– sight window fitted for checking of the indicatorwhen AL composite sheeting is used.

• Observe the directions for the drying agent bagsto DIN 55 473. The following applies:

– Coloured indicator blue: contents dry.– Coloured indicator pink: contents moist (e.g.

relative humidity over 40%).

4.3 Transport(Figures 4/1 to 4/3)

Note:

Do not walk on the tops of the panels (rupture pointfor the pressure relief system!).

• The transport units are normally individual panels.

• Take account of the weights of the transportunits.

• Take account of the high centre of gravity.

• Handle the panels in the upright position.

• Only perform loading operations taking accountof all safety precautions to protect personneland the material transported with:

– a crane, and/or

– fork-lift truck.

• Handling by crane:

– Attach suspension ropes of a sufficient load-bearing capacity with shackles (opening ang-le ≥ 30 mm).

– Fit these to the four lifting lugs.

– Attach rope guide harness to the top of thepanel.

• Handling in the switchgear room can be effectedby a trolley with steerable wheels. Take accountof the high centre of gravity of the panels. Dangerof tipping!

4.4 DeliveryThe responsibilities of the consignee include butare not limited to:• Checking the delivery for completeness and

freedom from damage (e.g. also for moistureand its injurious effects).

• Any deficiencies/transport damage noted

– are to be documented on the waybill,

– reported to the shipper/carrier in accordancewith the ADSP or KVO liability conditions forGerman insurance.

Note:

Always document major damage with photographs.

4.5 Intermediate storageConditions for optimum intermediate storage:

1. Panels with basic packaging or without packaging.• Dry and well ventilated storage room. Climate

in accordance with VDE 0670 Part 1000/IEC 60694.

• Room temperature not falling below -5°C.

• No other injurious environmental influences.

• Store the panels upright.• Do not stack panels.

• Panels with basic packaging:

– open the packaging at least partially.

• Panels without packaging:– loosely cover with protective sheeting.

– sufficient air circulation must be preserved.

• Check regularly for any condensation.

2. Panels with seaworthy or similar packaging withinternal protective sheeting:• Store the transport units:

– protected from the weather,

– in a dry place,

– protected from damage.• Check the packaging for damage.

• Check the drying agent (see section 4.2):

– on delivery,

– later at appropriate intervals.• When the service life from the date of

packaging has been exceeded:

– the protective effect of the packaging is nolonger ensured,

– take action for further intermediate storage.


1105

775

565 530

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

Figure 4/2: Preparation for handling by crane, single busbar system Figure 4/3: Preparation for handling by fork-lift truck

1) Note: The forks must support the full section length.

1232

895

ZX2

min

.45o

725 530

(170)

1152 (for panel width 800)

ZX2


(64)

1464

1)



5.1 General site requirements

At the start of erection, the switchgear room at sitemust be complete, fitted with lighting and power forthe erection work, lockable, dry, and with good ven-tilation facilities. All necessary provisions for laying ofthe power and control cables such as openings,ducts, etc. must already be in place.

Compliance with the conditions for indoorswitchgear to VDE 0670 Part 1000 etc., includingthose for the ”minus 5 indoor” temperature class,must be ensured.

5 Erection of the switchgear at siteIn the interests of the best possible erection se-quence, and in order to ensure a high quality stand-ard of the panels, local installation of the switchgearshould only be carried out, or at least responsiblymanaged and supervised, by specially trainedskilled personnel.

Panel width mm 400 600 800 800

Rated current A ≤630 ≤1250 ≤ 2000 > 2000

Ceiling height1)2):• without additional absorber mm 2500 2500 2500 –

• with additional absorber mm 2800 2800 2800 –

• with additional cooling fan andwithout absorber mm – – – 2800

• with additional cooling fan andwith absorber mm – – – 3100

Assembly opening1):

• in ceilings: width mm 500 700 900 900length mm 1810 1810 1810 1810

• in doors: width mm 900 1100 1300 1300height mm 2300 2300 2300 2300

Aisle width3):

• Inspection aisle mm 800 800 800 800

• Operator aisle mm 1100 1300 1500 1500

Panel weight kg ca. 650 ca. 1200 ca. 1700 ca. 1800(outgoing feeder, double busbar)

Floor load kg/m2 ca. 1200 ca. 1400 ca. 1500 ca. 1600

1) Minimum dimensions2) Panel including top pressure relief duct3) Governed by DIN VDE 0101 and the data on maximum panel width.

5.2 Construction data(Figures 5/4 to 5/7)

• The ZX2 switchgear installations are mounted ona foundation frame set into the screed, or on araised false floor.

• The openings shown in figure 5/4 are intendedas an aid to planning. Instead of the large open-ings shown, drill holes can also be used, de-pending on the number of high voltage cables.

• Openings (drill holes) for power cables in thestation floor are to be constructed so as to beeddy-current free.

Note:

The following is to be taken into account indetermining the foundation data:

• Single busbar systems:

Any additional frame available for the voltagesensors in the busbar metering system.

The distance from the additional frame includingend coffer to the side wall of the room should be≥ 500 mm to ensure sufficient room formovement (see also section 2.3).

• Double busbar systems:

From 5 panels onwards, a pressure relief duct isrequired at both ends of the switchgearinstallation.


5.3 Fundamental notes on erection work

DIN-bolts of tensile class 8.8 are to be used.

Recommended

tightening torque1)

Nm

Lubricant2)

Thread Without Oil orgrease

M 6 10 ,5 4 ,5M 8 26 10M 83) 12 4 ,5M 10 50 20M 12 86 40M 16 200 80

1) • The rated tightening torques for fasteners withoutlubrication are based on a coefficient of friction for thethread of 0.14 (the actual values are subject to anunavoidable, partly not inconsiderable, spread).

• Rated tightening torques for fasteners with lubrication inaccordance with DIN 43 673.

2) Thread and head contact surface lubricated.3) These values apply to welded on studbolts only.

Any tightening torques which deviate from those in thegeneral table (e.g. for contact systems or device terminals)are to be taken into account as stated in the detailedtechnical documentation.

It is recommended that the threads and head contactsurfaces of bolts should be lightly oiled or greased, so as toachieve a precise rated tightening torque.

• Remove any dirt from the surfaces in generaland from insulating material surfaces. Observethe cleaning instructions in Section 7.2.

• When handling SF6, avoid any escape of gas intothe switchroom:

– as incorrect readings may be caused duringleakage testing.

– ventilate well if leakage occurs.

5.4 Foundation frame(Figures 5/1 to 5/3)

Switchgear on a foundation frame:

The relevant data for the order in hand can befound in the ABB documentation.

The single or multiple panel foundation frame canbe supplied with the switchgear. It is as a rule laidby site personnel and should be aligned and in-spected under the supervision of a responsiblespecialist.

The specifications of DIN 43 661 are also to bemaintained when laying the foundation frame, inparticular the evenness and straightness toler-ances as a condition for perfect switchgear assem-bly.

Tolerance conditions for laying of the frame to DIN43 661, version A:

• Evenness tolerance: +/- 1 mm per metre.

• Straightness tolerance: max. 1 mm per metre,but max. 2 mm for theentire length of theframe.

5.5 Laying of the foundation frame(Figures 5/1 to 5/3)

• Bolt the individual parts of foundation frameelements 27 together.

• Bolt the individual sections composed of founda-tion frame elements 27 (where the switchgear hasseveral panels) together using connecting links27.1 and bolts 27.5.

• Set up the complete foundation frame on theconcrete floor precisely at the specified position.

• Fasten the foundation frame to the concretefloor sufficiently firmly with the bolts and dishedwashers 27.2, checking the correct dimensionalposition continuously.

• Enter jacking screws 27.3 into the relevantthreaded bores (different lengths to correspondto the height of the screed), inserting a steel shim27.8 below each screw.

• Loosen the compensation bolts 27.4 and care-fully align the entire surface of foundation frame27 in the horizontal plane and at the correctheight, using a levelling instrument and screwingin jacking screws 27.3 to the appropriate depth.The top edge of the foundation frame must be 1to 3 mm above the screed (take account addi-tionally of the material thickness of any additionalfloor covering).

• Tighten the compensation bolts 27.4, perform-ing a final check on the dimensions and horizon-tal position of the frame.

• Weld jacking screws 27.3 firm to prevent inad-vertent changes to their settings.

• Perform the necessary work for proper earthing ofthe foundation frame with 30 x 4 mm galvanisedsteel strip. Two connections are necessary inswitchgear with more than 6 panels.

• Carefully backfill the foundation frame whenapplying the screed.

Note:

Before applying the screed, insert auxiliary bolts27.9. These prevent the screed from penetratinginto the rivet nuts. Remove auxiliary bolts 27.9when the screed has hardened.

• The foundation frame must not be subjected toany undue impacts or pressures, particularly,during the installation phase.


Figure 5/1: Individual parts of a foundation frame element, 2-panelexample version

27.1 Connecting link27.4 Compensation bolt

Figure 5/2: Foundation frame

27 Foundation frame element, individual parts boltedtogether

27.1 Connecting link27.2 Bolt and dished washer for foundation frame

fastening to concrete floor27.3 Jacking screw for foundation frame27.6 Plug27.9 Auxiliary bolt for frame mounting and panel

fastening bolt 1.4

27.127.4

Panel width FT

n x FT = a

(14

23)

27

1333

27.1

27.3

27.9

27.227.6Foundation frame width a

Number of panels nPanelwidth

FT

600

800

600

800

1200

1600

1800

2400

2400

_

1 2 3 4

400 400 800 1200 1600


5.6 Raised false floor(Figures 5/6 and 5/7)

When a raised false floor is used, the manu-facturer’s installation instructions are to be ob-served. The false floor must satisfy all requirementsspecific to the switchgear installation.

Figure 5/3: Foundation frame on concrete floor (showing the panel)

1 Panel1.4 Panel fastening bolt27 Foundation frame element27.2 Bolt and dished washer for fastening of the

foundationframe to the concrete floor

27.3 Jacking screw for foundation frame27.4 Compensation bolt27.5 Bolt for the connecting link27.6 Plug27.8 Steel shim27.9 Auxiliary bolt for frame installationh Screed height 40 to 50 mm

1…3

mm

Section A-A

27.3 27.5 27.9 27.4

27.2,27.627.8h

(without item 1)

A

A

1.5

1.4

1

27

(1423)

1333


Figure 5/4: Guideline construction data for a foundation frame on aconcrete floorSee figure 5/5 for sections

1) Minimum

1 Inspection aisle

2 Operator aisle

3 Basement entrance

4 Platform, approx. 25 kN

5 Pressure relief duct at side, including end cover

6 Instead of individual openings, continuousopenings or drilled holes are possible

7 Earthing bar

8 Panel without cable connection, e.g. bus couplerpanel

9 Door

10 Waste air opening

11 Intake air opening

12 Intake air opening, if required


14 Or as shown in figure 5/7

15 Height of cable basement as required

16 To earthing bar

17 Opening for control cable

18 Opening for power cable, plug size 2

19 Opening for power cable, plug size 3

20 Instrument transformer for billing purposes

21 Screed, see also figure 5/3

Panel width a b c din switchgear

mm mm mm mm

600 mm 1327 1455 1300 1100

800 mm or600 mixed with800 mm 1527 1655 1500 1300

Rated Absorber Room heightcurrentA mm

≤ 2000 with 2800

≤ 2000 without 2500

> 2000 with 3100

> 2000 without 2800

250250

1)

1)

1)

1)

160

)(

27

190 210 210 190580 430

1710

800

660

265

180

3x16

0

230

160

66081

5

150

230

150

150

665

(142

3)

600600 600 600400 800 800 800 800

20005060

(155

)

5

3

6

1

27

4

8

A B C D

DCBA

85500

110

1)

85

1)

1)1)

1)

8x150

150150

1)

a b

c

d1)

870

Room height 22 :


Figure 5/5: Sections for figure 5/4See figure 5/4 for legends and dimensional table

1) Minimum

a) Panel width 600 mm, without instrument transformer b) Panel width 600 mm, with instrument transformer

c) Panel width 800 mm, with instrument transformer d) Panel width 800 mm, without instrument transformer

1)23

00

1718

21

16

150

1)

150

200

ZX2

800

15

(1423)

180

d

a

1

9

2 11

13

1412

10

265

(155)(27)

660 b

2800

665

1) 1)

1)

c

2100

1)

1)

Section A - A

2600

1710

18 17

2120

1)23

00

1)

150230

200

ZX2

15

(1423)

180

d

a

1

9

2 11

13

1412

10 16

265

(155)(27)

660 b

2800

815

1) 1)

1)

c

2100

1)

1)

Section B - B

2600

1710800

16

19 17

2120

22

2300

1)

2100

ZX2

15

(1423)

180

d

a

1

9

2 11

13

1412

10

85

870 b

c

160230(155)

(27)

660160

1) 1)

1)

1)

Section C - C

200

1)

1)

1710

2600

800

200

200

221)

1)

(155)

2100

ZX2

160 2300

15

(1423)

180

d

a

9

13

141912 17

10 16

21

85

160

(27)

870 b

5001601)

200

2600

1)

1)

1 2 11

c1) 1)

Section D - D

1710800

200


Panel width a b cin switchgear

mm mm mm

600 mm 1327 1300 1100

800 mm or600 mixedwith 800 mm 1572 1500 1300

Rated Absorber Room heightcurrentA mm

≤ 2000 with 2800

≤ 2000 without 2500

> 2000 with 3100

> 2000 without 2800

100

100

230

1)1)

160

190 210 210 190

1710

3x16

0

230

160

66081

5

150

150

150

665

1333

600600 600 600250400 800 800 800 800

2000

5

3

6

1

27

4

8

A B

BA

500

1)

1)

600 400 100

100

M 10

800

8x150

150150

1)

c1)ba

250

M 10 M 10

Room height 21 :

Figure 5/6: Guideline construction data for a raised false floorSee figure 5/7 for sections

1) Minimum

1 Inspection aisle

2 Operator aisle

3 Basement entrance

4 Platform, approx. 25 kN

5 Pressure relief duct at side, including end cover

6 False floor structure, only shown in the area of theswitchgear

7 Earthing bar

8 Panel without cable connection, e.g. bus couplerpanel

9 Door


11 Intake air opening

12 Intake air opening, if required


14 Or as shown in figure 5/5

15 Height of cable basement as required

16 To earthing bar

17 False floor structure, supplied by others

18 Power cable, plug size 2

19 Power cable, plug size 3

20 Instrument transformer for billing purposes


Figure 5/7: Sections for figure 5/6See figure 5/6 for legends and dimensional table

1) Minimum

a) Panel width 600 mm, without instrument transformer b) Panel width 800 mm, with instrument transformer

2100

ZX2

150 2300

15

c

1

9

2 11

1817

1016 150

2800

2600

1333

14

13

12a

(72)

1)

1)

1)

b 1)

200

1)

1)

Section A - A

665

X

1710800

(72)

2100

ZX2

2300

15

c

9

11

1917

21

1016

2600

1333

14

13

12a

160230 660

20

160

1)

1)

1)

b 1)

200

1)

X

1 2

1)

Section B - B

1710800

200

Detail X

3

(72)


5.7 Erection and connection of the panels(Figures 5/3 and 5/8 to 5/14)

Note:

Do not walk on the top of the panels (rupture pointfor pressure relief system!).

5.7.1 Preparatory work

• Grease the upper surfaces of the foundationframe (this facilitates erection and alignment ofthe individual panels).

• Enter the two or four guide pins 35 at the sides ofthe panels into the relevant bores (see figure 5/10,section A-A).

5.7.2 Erection of the switchgear

• Erect the end panel of the switchgear at the pre-cise position specified on the foundation frame.

• Lightly enter panel fastening bolts 1.4 into the re-levant threaded bores in the foundation frame.

• Align the panel if necessary.

• Perform a final check on the aligned position ofthe panel and fasten it to the foundation frame bytightening the panel fastening bolts 1.4.

• Remove the protective caps from the busbarsockets 23.1.

• Carefully check insulating parts 23.2 andcontact tubes 23.3 for any dirt, and clean ifnecessary (see also section 7.2).

Note:

Only prepare insulating parts and contact tubesfor the panel currently being erected. Protectthem from further contamination!

• Evenly apply a thin coating of assembly paste APto the conical surfaces A of insulating parts 23.2.

Note:

Leave no ungreased areas on conical surface A.

• Carefully insert contact tubes 23.3 andinsulating parts 23.2 into the busbar sockets23.1.

• Slide the adjacent panel carefully and evenly(without tipping) against the erected panel insuch a way that the contact tubes, insulatingparts and guide pins slide into the correspond-ing bores without the use of force.

If necessary, align the panel appropriately withthe panel height adjustment bolts 1.5.

• As soon as the distance between the two panelsis so small that bolts 36 and 37 can be entered inthe bores in the erected panel, insert these, eachwith nuts and dished washers respectively.Spacer 38 is also to be fitted on socket head bolt37 (see figure 5/9, section B-B).

• Then join the two panels together by tighteningbolts 36 and 37 step by step.

• Completely bolt the panels together with bolts40, each with dished washers (see figure 5/8).

• When the panels have been completely joined,check the second panel again for correct align-ment and fasten it to the foundation frame withthe panel fastening bolts 1.4.

• Dismantle connecting link 14 for the main earth-ing bar 15 in the cable compartment and lead itthrough to the adjacent panel. Bolt the connect-ing link to the main earthing bar with bolts 39 andone dished washer at each of the bolt head andnut ends.

• Check the bolted connection between mainearthing bar 15 and the connecting link 14 in thepreviously erected panel and tighten bolt 39 ifnecessary.

• Erect the further panels by following the sameprocedure.

• Assembly of the top pressure relief duct, the ab-sorber and the cooler if fitted can be effectedduring installation of the individual panels orwhen all panels have been joined together.


b) Single busbar

Figure 5/8: Switchgear erection(See figure 5/9 for sections and details)

23 Busbar connection, plug-in type23.1 Busbar socket23.2 Insulating part23.3 Contact tube35 Guide pin37.1 M8 hexagon nut37.2 Dished washer 840 Socket head bolt M8 x 25

a) Double busbar

A

A B

B

C

C

X

View X

4037.2

23

4037.2

4037.2

4037.2

4037.2

4037.1

4037.2

37.2

35

23.1 23.2

23.3

4037.137.2

A

A

C

C

B

B

4037.2

4037.2

4037.2

4037.2

4037.2

4037.1

4037.2

37.2

4037.137.2


Figure 5/9: Switchgear erection(section for figure 5/8)

14 Panel/panel connecting link15 Main earthing bar23 Busbar connection, plug-in type23.1 Busbar socket23.2 Insulating part23.4 O-ring35.1 M10 hexagon nut35.2 Dished washer 1037 Socket head bolt M8 x 4037.2 Dished washer 838 Spacer39 Socket head bolt M10 x 35

Section B-B

10

Panel division

38 37.2 37

Section C-CPanel division

35.135.2

14

35.2

3915

10

23.4

Section A-A

Panel division

23.1

23

ca. 50

23.2

A1)

Busbar connection Insulating part

Panel/panel connection Earthing bar connection

1) Evenly greased withassembly paste AP


Figure 5/10: Switchgear erectionpanel/panel connection, view from top(without pressure relief duct)

35 Guide pin35.1 M10 hexagon nut35.2 Dished washer 1036 Socket head bolt M10 x 50

AA

B B

35 36Section A-A

3535.2

35.1

Section B-B35.2

35.1

35.2

36

a) Panel joined up from the right

b) Panel joined up from the left

36 35


Figure 5/11: Busbar end in an end panel

35.1 M10 hexagon nut35.2 Dished washer 1037.2 Dished washer 840 Socket head bolt M8 x 2541 Plate for blanking plug42 Blanking plug43 Socket head bolt M10 x 30

Figure 5/12: Pressure relief duct, side, double busbar,right-hand side mounting shown

A Pressure relief duct with absorberB Pressure relief duct, topC Pressure relief duct, sideD End coverF Panel

X

Y

Evenly greased,assembly paste AP

42

41

42

Detail X

35.2

43

35.2

35.1

Detail Y

37.2

40

44

B

665

A

C DF

1330

2600

45

220

250

44 Fastening material, packed in bag group ”Screwfasteners for side pressure relief duct”

45 Plug


Figure 5/13: Busbar connection

23.1 Busbar socket23.2 Insulating part23.3 Contact tube

Figure 5/15: Plug connector for single-core plastic-insulated cable

10 Socket11 Cable plugK Cable earthing conductor to be connected to

switchgear earth, do not establish cable earthing viathe plug

Figure 5/16: Cable compartment(panel side wall cut out)

12 Surge arrester13 Floor plate, split13.1 Reducer ring13.2 Cable mounting13.3 Supporting section, at earth potential13.4 Insulated earthing point for cable jacket (non-

standard)27 High voltage cable

10

11

Figure 5/14: Assembly of the busbar connection, shown for 1250 A

• L1: Protective cap removed• L2: Contact tube 23.3 fitted• L3: Insulating part 23.2 and contact tube 23.3 fitted

13 13.1

12

13.2

27

13.3 13.4

L323.1 23.2 23.3 L2 L1


5.8 Connection of cables and wiring

The cable compartments (I) in the panels are fittedwith cable connection fittings in accordance withthe cable types and sizes specified in the projectplanning for the switchgear as a whole.

5.8.1 High voltage plastic-insulated cable with plugconnectors

(Figures 3/4, 3/11, 5/15 and 5/16)

• Lay the single-core plastic-insulated cables asspecified in the project planning to the individualpanels.

• Remove the transport covers fitted to protectthe sockets.

• Expose the cable cores, check the correctphase assignment, and secure.

• Fit cable plug 11 in accordance with the manu-facturer’s instructions.

• Fit the plugs to the sockets 10 mounted in thecircuit-breaker compartment floor (without open-ing the insulating gas compartment) and securethem with bolts.

• Align the cables and fasten them at mountings13.2

• Close off any unused sockets, e.g. in sparepanels, with suitable cable blanking plugs toensure the necessary insulation.

5.8.2 Control cables and wiring


• Establish the necessary connections for incom-ing and outgoing cables and wiring, and crossconnections.

• The control cables and wiring are to be laid incable ducts at the right of the cable compart-ment (for external wiring).

• The connections from panel to panel are to bemade by plug connectors in the control cabinets.

5.9 Preparing the insulating gas system for operation

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

5.10 Final erection work

• Clean the external surfaces of the enclosure andcontrol cabinets in the switchgear where neces-sary and check for any damage to the paintwork,touching up with a suitable paint if necessary(see Section 7.3).

• Properly refit any cladding and covers of operat-ing mechanisms, cable ducts, etc. removed dur-ing the erection work.

• Remove all tools and other foreign bodies fromthe switchgear.

• Check the general condition of the switchgear.

• Check that the areas adjacent to the switchgearare in the proper condition.


6 Commissioning/operation

Note on safety at work

• Operation by trained specialists familiar with theparticular switchgear only.

6.1 Commissioning

6.1.1 Preparatory work

In preparation for commissioning, the followingwork is to be performed prior to connection withthe high voltage power supply:

• Connect the auxiliary and control voltage andcheck the correct polarity.

• Check mechanical and electrical interlocks forcompliance with the specified conditions.

• Perform a functional test on the protective de-vices (observe DIN VDE 0141).

• Check the general condition of the switchgearand external conditions for detrimental factors ofany kind.

• Display the instructions for handling SF6 in theswitchroom. The handling specifications for SF6

also apply accordingly to nitrogen.

• Display the ABB instruction manual on the han-dling of insulating gas and behaviour duringfaults in the switchroom.

• Instruct the local operators on the fundamentaldetails of operating the switchgear in normalservice.

• Check the readiness for operation and theswitching condition of the upstream and down-stream electrical equipment.

• Perform further checks where necessary on thefollowing equipment from the areas adjacent tothe switchgear:

– power cables

– control wiring

– auxiliary voltage and its polarity

– remote controls

– external earth with connection to mainearthing bar 15

– switchroom equipment

– switchroom condition.

6.1.2 Initial start-up

• Comply with all relevant safety regulations

• Ensure that the switchgear circuit-breakers arein the OFF position.

• Close the disconnector for the relevant busbarsystem.

• Cancel any existing short-circuiting and earthingconnections in the critical switching area.

• Energise the switchgear step by step, observingthe displays on the REF542.

• Check that corresponding conductor sectionsare in phase where relevant with several incom-ing feeders and switchgear sections.

• Check measurements and functions dependanton high voltage.

• Look out for irregularities of any kind.

6.2 Switching operations

6.2.1 Circuit-breaker

(Figures 3/2, 6/1, 6/2 and 6/4)

The circuit-breaker is fitted with a charging motor.Charging of the spring energy storage mechanismtakes place automatically.

Opening and closing the circuit-breaker:

• Opening and closing are effected by selection onthe bay control and protection unit REF542.

• ON-OFF switching operations may only beperformed with the control cabinet door closed.

• Opening the control cabinet door constitutesintervention in the interlock system.

• Observe the position indicator.


1. On failure of the charging motor, the chargingprocess can be performed or completed byhand:

• Open control cabinet door 1.1.

• Insert charging lever 8.9 into recess 8.8 andpump for approx. 25 strokes until the chargedcondition is displayed.

When the charged condition is reached, thecharging mechanism automatically disengagesand further strokes of the charging lever have noeffect.

Key to the charging condition displays:

Discharged Charged

2. If the control voltage fails with the circuit-breakerclosed, it is possible to open it using themechanical OFF push-button 8.3.

Note:

On failure of the control voltage, there is nomaloperation protection for the circuit-breaker,three-position switch and disconnector duringemergency manual operation.


6.2.2 Three-position switch and disconnector

(Figures 3/2, 3/11, 6/3, 6/5 and 6/6)

• The three-position switch 2 and the disconnector19 are fitted with motor-operated mechanisms.Opening and closing are effected by selection onthe bay control and protection unit.

• ON-OFF switching operations may only be per-formed with the control cabinet door closed.

• Opening the control cabinet door constitutes in-tervention in the interlock system.

• Observe the position indicator on LCD display5.1 or on the control unit.

• Sensors 29 to 32 on the three-position switchoperating mechanism 3 detect the followingswitch positions:

Disconnector -Q1 ON and OFF, and earthingswitch -Q5 ON and OFF.

• Sensors 33 and 34 on disconnector operatingmechanism 20 detect the following switch posi-tions:

Disconnector -Q2 ON and OFF.


In place of motorised operation, the switchingprocess can also be initiated and completed manu-ally.

Caution!

The interlock is ineffective on emergency manualoperation.

• Open control cabinet door 1.1

• Prior to emergency manual operation, switch therelevant m.c.b. (F101 or F102) off.

• Insert the crank in the hollow shaft.

• Three-position switch -Q1/-Q5:

If the three-position switch is in the central posi-tion (i.e. disconnector and earthing switch OFF),the disconnector can be closed with approx. 24clockwise turns, and the earthing switch withapprox. 24 anti-clockwise turns. If the ”earthingswitch ON” position is to be reached from the”disconnector ON” position, or vice versa, thecrank is to be removed in the self-inhibiting cen-tral position (disconnector and earthing switchOFF) and refitted. When the crank is refitted, thefurther switching operation is automatically ena-bled.

• Disconnector -Q2:

Close the disconnector with approx. 24 clock-wise turns and open it with approx. 24 anti-clockwise turns.

Note:

Always perform every switching operation rightup to the stop in the relevant limit position.

• Observe the mechanical and electrical positionindicators.

6.2.3 Undervoltage release

Undervoltage releases may be fitted as an option. Inorder to prevent the circuit-breaker being opened bythe undervoltage release on power failure with tee-off earthing, an interlock rod or wire is provided.

6.3 Observation of the display and monitoringfacilities

6.3.1 Gas monitoring


All high voltage compartments in the switchgearmust have a sufficient insulating gas pressure dur-ing operation. The minimum operating gauge pres-sure (pe) is listed in section 2.1. This is monitored bysensors 4, 7 and 21.

If the gas pressure falls below the minimum operat-ing gauge pressure, an LED on the bay control andprotection unit signals that the gas should betopped up.

Note:

If a panel is isolated for a relatively long period(several weeks), m.c.b. F116 for the auxiliaryvoltage supply to the REF542 must remain on. Onlyin this way is monitoring of the insulating gasensured.

Details on the gas system of the ZX2 switchgearcan be found in instruction manual BA 427.

6.3.2 Electrical/mechanical display/monitoring

During operation of the switchgear, observe all vis-ible operating data and condition displays in thesecondary system and watch out for irregularitiesof any kind, including the external conditions of theswitchgear.

6.4 Test procedures

6.4.1 Testing for the off-circuit condition

(Figure 6/1)

The panels are fitted with the low impedance,capacitive voltage indicator system LRM, includ-ing corresponding (hand-held) display units withconnecting plugs for testing of the off-circuit con-dition.

For details, see draft DIN VDE 0682 Part 415, orIEC 61243 Part 5.


Note:

Only display units which comply with the IEC orVDE standards and the technical design of theindicator system in the relevant switchgear may beused!

Note:

The measuring sockets must on no account beshort-circuited, except during voltage testing of thesystem (e.g. with power frequency withstandvoltage or impulse withstand voltage)!

Testing for the off-circuit condition is performedwith a plug in display unit at corresponding pairs ofmeasuring sockets 6 in the vicinity of the panel con-trols.

Use of the display unit:

• Perform a functional test on the display unit im-mediately before and after use, e.g. with inter-face tester KSP. The display must be clearly vis-ible.

• The presence of operating voltage is indicatedby a signal.

• Observe the individual operating instructions forthe display unit for the relevant switchgear!

Interface testing:

• Perform interface testing as a functional test onall coupling components, e.g. with interfacetester KSP.

• The interface test is a repeat test to IEC 61243Part 5 or draft DIN VDE 0682 Part 415.

6.4.2 Testing for the in-phase condition

Testing for the in-phase condition, e.g. when thereis more than one incoming feeder, can be per-formed with a suitable phase comparator at meas-uring sockets 6 on the capacitive voltage indicationsystem.

Test procedure:

• Only use phase comparators which comply withthe IEC or VDE specifications and the technicaldesign of the display system in the relevantswitchgear!

• Perform a functional test on the equipment at thestart of testing.

• Do not exceed the maximum permissible lengthof measuring leads per phase.

• Connect the measuring leads precisely assignedto the corresponding main conductor sections.

• Always follow the details in the operatinginstructions for the phase comparator!

6.4.3 High voltage tests


The test plugs available for high voltage tests,shown in figure 6/8, are suitable for the followingapplications up to and including 24 kV rated volt-age.

For high voltage tests on the 36 kV rated voltagelevel, separate test facilities are required. Informa-tion on these can be obtained from the switchgearmanufacturer.

Taking account of the sensor systems used andthe bay control and protection unit, the testvoltages must not exceed the following values:

• Cable tests with DC voltage:

– 12 kV switchgear: 48 kV1)

– 24/36 kV switchgear: 70 kV1) up to 1 hour.

Higher values on request.

• Insulation testing of the switchgear at the rele-vant power frequency withstand voltage:

– 12 kV switchgear: 28 kV

– 24 kV switchgear: 50 kV

– 36 kV switchgear: 70 kV.

Performance of voltage tests:

• Isolate the switchgear area in accordance withthe safety rules of VDE 0105 and secure it toprevent reconnection.

• Verify the off-circuit condition with a suitablehand-held display unit at measuring sockets 6on the capacitive voltage indicator system.

• Unscrew surge arresters where fitted, or

• unscrew the cable blanking plugs from the freecable sockets.

• Check the test plug to ensure that the surface isclean and dry, and clean it if necessary.

• Grease the silicone part of the test plugs inaccordance with the directions.

• Insert the test plug into the prepared cablesocket and screw it tight.

Notes:

• Only fit the test plugs for voltage tests for theduration of those tests.

• Short-circuit the measuring sockets 6 in thepanels concerned for the duration of the testingprocess at test voltages up to rated power fre-quency withstand voltage.

1) Applies to integrated voltage sensors. With plug-in voltagesensors/instrument transformers, the cable test voltagespermissible to DIN standards may be used if the sensors arewithdrawn.


• For performance of cable tests, in the switchingcondition ”tee-off disconnected and earthed”,earthing of the cable has to be cancelled by open-ing the circuit-breaker. This is accomplished byusing the mechanical OFF button to open thecircuit-breaker (see also Section 3.9).

6.4.4 Current tests


The test plugs available for current test are suitablefor the following applications:

• Testing of the protection functions in the baycontrol and protection unit REF542 by means ofprimary current injection.

Test instruction:

The following is to be observed when testing theprotection system of the REF542:

In order to prevent damage to the OFF-release coilduring testing, either the OFF-release coil has to bedisconnected or the protection test equipmentmust be deactivated by the trip command.

This ensures that the opening release is notenergised in the meantime by the trip command,which could lead to the coil burning out.

• Establishment of maintenance earthing in con-junction with an earthing and short-circuiting set.

The short-circuit resistance of the current testplugs for the switchgear must correspond to thecondition of the individual switchgear.

Handling of the plugs for current tests:


• Verify the off-circuit condition with a suitable(hand-held) display unit at measuring sockets 6on the capacitive voltage indicator system.

• Unscrew surge arresters where fitted, or

• unscrew the cable blanking plugs on the freecable sockets.

• Check the test plug to verify that the surface isclean and dry, and clean it if necessary.

• Insert the test plug into the prepared cablesocket and screw it tight.

• Only fit the test plugs for the duration of the tests.

6.4.5 Maintenance earthing

a) Double busbar systems:

In the double busbar system, there is an oppor-tunity to earth the busbar via the bus coupler.

b) Single busbar systems:

• Earthing of the busbar with the bus tie / riser,as described in section 3.9.3.

• Earthing with an earthing and short-circuitingset.

Handling during earthing with an earthing andshort-circuiting set:


The plugs for current tests described under 6.4.4are used in conjunction with corresponding cablesets for short-circuiting and earthing to establishmaintenance earths. The short-circuit resistance ofthe cable set must correspond to the conditions ofthe switchgear.

Caution!

Observe the notes in Section 3.9 on the interlockdependencies for all work with earthing and short-circuiting sets!


• Verify the off-circuit condition with a suitable(hand-held) display unit at measuring sockets 6on the capacitive voltage indicator system.

• Unscrew surge arresters if fitted, or

• unscrew the cable blanking plugs on the freecable sockets.

• Check the test plugs to ensure that the surface isclean and dry, and clean them if necessary.

• Carefully screw the short-circuiting and earthingcable set to the test plug.

• Connect the common earthing connector of thecable set to the earthing terminal of the panel.

• Insert the test plugs into the prepared cablesockets and screw them tight.


6.5 Application of the X-ray regulations

One of the physical properties of vacuum insulationis the possibility of x-ray emissions when the con-tact gap is open. The specified type test performedby the Physikalisch-Technische Bundesanstalt(PTB) in Brunswick demonstrates that the localdosage output of 1 µSv/h at a distance of 10 cmfrom the touchable surface is not exceeded.

The results are as follows:

• The use of the vacuum interrupters at rated volt-age is completely safe.

• Application of the rated power frequency with-stand voltage specified for the switching deviceby VDE 0670 and IEC 60056 or a DC voltage of48 kV or 70 kV during cable tests is also safe.

• Higher voltages than the rated power frequencywithstand voltage specified in DIN VDE or IECstandards or the DC voltage must not be ap-plied!

• Fulfilment of the above requirement with thevacuum interrupter in the open position is de-pendent on maintenance of the specified dis-tance between the contacts (which is automati-cally ensured with correct mechanism functionand force transmission).


Figure 6/2: Handling of the door-lock

• Opening the control cabinet door:- Open the safety lock (if fitted)- Release the catch with the double bit key- Draw the closing lever out to an angle of 45° and

then swing it upwards to the left through approx.135° until the stop is reached

• Closing the control cabinet door:- reverse the procedure for opening

1.1 Control cabinet door28 Door-lock28.1 Catch(28.2) Safety lock (if ordered)28.3 Double bit key28.4 Closing lever

1.1

28

28.4

(28.2)

28.3

28.1

Figure 6/1: Display area on the panel

1.1 Control cabinet door5 Bay control and protection unit REF5425.1 LCD display (example)5.2 Light-emitting diode (LED)6 Measuring sockets for capacitive voltage indicator

system

Figure 6/3: Operating mechanisms for the three-position switchand disconnector

3 Three-position switch mechanism3.1 Hollow shaft (emergency manual operation shaft)3.2 Mechanical position indicator3.3 Cam for OFF position of the three-position switch3.4 Drive motor for three-position switch20 Disconnector mechanism20.1 Hollow shaft (emergency manual operation shaft)20.2 Mechanical position indicator29 Sensor, disconnector -Q1 ON30 Sensor, disconnector -Q1 OFF31 Sensor, earthing switch ON32 Sensor, earthing switch OFF33 Sensor, disconnector -Q2 ON34 Sensor, disconnector -Q2 OFF

5

5.1

5.2

6

20.1

20.2

31 30 29 32

20

3.4

3.33.2

3.1

3

34 33

1.1


Figure 6/4: Emergency manual operation, circuit-breaker typeVD4 X

8 Circuit-breaker operating mechanism8.1 Front plate8.2 ON push-button8.3 OFF push-button8.4 Operating cycle counter8.5 Mechanical position indicator8.6 Rating plate8.7 Charging condition indicator8.8 Recess for charging lever 8.98.9 Charging lever for emergency manual operation

Figure 6/5: Emergency manual operation, three-position switchUX2TE

Figure 6/6: Emergency manual operation, disconnector UX2T Figure 6/7: View of the stored-energy spring mechanism for thecircuit-breaker, front plate removed

8.9

8.8

8.7

8.6

8

8.18.2

8.3

8.4

8.5


Figure 6/9: Test plug for current tests

Also usable as a maintenance earth in conjunction withan earthing and short-circuiting set

Figure 6/8: Test plug for high voltage tests up to 24 kV ratedvoltage


7 MaintenanceMaintenance serves to preserve trouble-free op-eration and achieve the longest possible workinglife of the switchgear. In accordance with DIN 31 051and IEC 61208, it comprises the following closelyrelated activities:

Inspection: Determination of the actual condition

Servicing: Measures to maintain the specifiedcondition

Repairs: Measures to re-establish the speci-fied condition

7.1 General

It is essential to observe the following during allmaintenance work:

• The relevant regulations in section 1.2.2

• The notes on safety at work in section 6

• Standards and specifications in the countrywhere the switchgear is erected.

It is recommended that ABB after sales servicepersonnel be called in to perform servicing andrepair work.

Follow/observe the instructions on SF6 systemsand the ABB instruction manual on the handling ofinsulating gases and procedures for fault con-ditions. The handling regulations for SF6 also applyaccordingly to nitrogen.

• Keep these instructions and manual perma-nently on display and available in the switch-room.

The inspection and servicing intervals for theswitching devices are determined by fixed criteriasuch as switching frequency and number of short-circuit breaking operations.

The length of the intervals for inspection and servic-ing of the control cabinet and its equipment is influ-enced by ambient conditions (for instance pollutionand aggressive atmosphere).

In addition to this instruction manual, the followinginstruction manuals must be observed:

• Insulating gas system BA 427/E

• Bay control and protectionunit REF542 BA 453/E

• Circuit-breaker VD4 X BA 436/E

Further details can be found in the technical docu-mentation for the switchgear installation (including,for example, any agreed special operating condi-tions).

7.2 Inspection/servicing

• Under normal operating conditions (see section1.3), checking of the operating mechanisms is tobe carried out by a suitably qualified electricianafter 10 years at the latest or after 10,000 oper-ating cycles of the circuit-breaker and 2,000 op-erating cycles of the three-position switch ordisconnector.

• In exceptional operating conditions (includingadverse climatic conditions) and/or particularlyadverse environments (including heavy contami-nation and aggressive atmosphere) inspectionat shorter intervals may be required.

• Inspection is first and foremost to be visual ex-amination for contamination, corrosion andmoisture.

• The inspection should however also includechecking of the mechanical and electrical func-tions of the following devices:

– Switching devices

– Bay control and protection unit REF542.

• If an incorrect condition is found, the corre-sponding repair work is to be initiated immedi-ately.

Cleaning

If the necessity of cleaning is established duringinspections, the following procedure is to beadopted:

• Prior to cleaning, isolate and secure the workingarea if necessary in accordance with the safetyrules of DIN VDE and IEC.

• Cleaning of surfaces in general:

– Remove weakly adhering dry dust depositswith a soft dry cloth.

– Remove more strongly adhering contamina-tion with slightly alkaline household cleanser,or with Rivolta BWR 210.

• Cleaning of insulating material surfaces and con-ductive parts (outside the gas compartments):

– Minor contamination with Rivolta BWR 210.

– Strongly adhering contamination with Coldcleanser 716

• Cleaning of busbar insulating parts, cable socketsand busbar sockets with cable cleanser MAB.

• Observe the manufacturer’s instructions and thespecial ABB instruction manuals BA 1002/E andBA 1006/E on safety at work.

• Wipe down after cleaning, using clean water,and dry properly.


7.3 Repair

• Remove all rust from damaged paintwork areason sheet steel and other steel parts mechani-cally, e.g. with a wire brush. Lightly grind the sur-rounding paint coat and carefully degrease theentire area. Then immediately apply an anti-rustprimer and, after an appropriate hardening pe-riod, apply the top coat. Only use suitable andcompatible paint products.

Use top coat paint in the standard colourRAL 7032, or the relevant special colour.

• Carefully remove any white rust from galvanisedand chromium plated functional parts and ruston phosphated parts with a wire brush or acleaning pad, e.g. Scotch-Brite, and clean with adry cloth. Then grease evenly with Isoflex TopasNB 52.

Notes:

• It is essential to observe the section on safety atwork in instruction manual BA 427/E for all workon gas compartments.

• Caution when working in gas compartments!High gas concentrations may result in a dangerof asphyxiation!

7.2.1 Vacuum circuit-breaker

(Figure 6/7)

• The vacuum circuit-breaker has a long servicelife. It has a low maintenance operating mecha-nism and the breaker poles are maintenance-free.

Consult the relevant sections of instructionmanual BA 436/E for further information.

7.2.2 Three-position switch and disconnector

• The three-position switch and disconnector aremaintenance-free for 2000 operating cycles.

7.2.3 Gas system and gas servicing

• Consult the relevant sections of instructionmanual BA 427/E for further information.

7.2.4 Outlet filter

The filter mats in the outlet filter are to be changedas required. Note the information on inspection andservicing in section 7.2.

Replacement procedure:

• Draw off the grille. This is done by prising off withthe fingertips in the recesses at the bottom endof the filter.

• Change the filter mat.

• Replace the grille.

Spare filter mats: Part no. (order ref.)

• Filter mat forfan system: GCE0995403P0100

• Filter mat forcontrol cabinet: GCE0995404P0100


7.4 Working and auxiliary materials

7.4.1 Working materials Part no. (Order ref.)

• Insulating gas system:

– Nitrogen (N2) GCE0990267P0100

Degree of purity 4.6

Delivery form: liquid gas in steel cylinders

Observe the relevant ABB instruction manualBA 1007/E on safety at work! GCEA901007P0102

– Sulphur hexafluoride (SF6) GCE0990253P0103

Delivery form: liquid gas in steel cylinders

Observe the quality requirements to IEC 60376/VDE 0373!

Observe the relevant ABB instruction manual GCEA901004P0102BA 1004/E, pp. 1 to 3, on safety at work!

Note:

If extreme temperatures ≥ 50°C cannot be ruledout where gas cylinders are stored, transported ortemporarily stored in the open air in direct sunlight,a reduced filling factor of 0.75 kg/l cylinder con-tents is to be required when ordering for safetyreasons!

• Drying agent material:

Drying agent bag to DIN 55 473, GCE0990443P0100capacity per bag 210 g

7.4.2 Auxiliary materials

• Lubricants:

Isoflex Topas NB 52, GCE0007249P0100

• Assembly paste AP,for insulating part/cast resin plug connections GCE0009098P0100

• Cleaning agents for general cleaning:

Rivolta BWR 210, GCE0007707P0100

Observe the relevant ABB instruction manual BA 1002/E GCEA901002P0102

• Cleaning agent for conductive parts, parts in insulat-ing material, and all parts with heavy contamination:

Cold cleaner 716, GCE0007706P0100

Observe the relevant ABB instruction manual BA 1006/E GCEA901006P0102

• Cleaning agent for busbar insulating parts,busbar sockets and cable sockets:

Cable cleaner MAB GCE0009100P0100

• Paintwork:

Paint in standard colour RAL 7035

– 1 kg-box GCE9014060R0103

– Spray tin GCE0007895P0100

ABB Calor Emag Mittelspannung GmbH ABB Sace T.M.S. S.p.A

Oberhausener Strasse 33 Petzower Strasse 8 Via Friuli, 4D-40472 Ratingen D-14542 Glindow I-24044 Dalmine

Phone: +49(0)21 02/12-12 30, Fax: +49(0)21 02/12-19 16 Phone: +39 035/395111, Fax: +39 035/395874E-mail: [email protected] E-mail: [email protected]: http://www.abb.de/calor Internet: http://www.abb.com

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Documents

instruction manual markedwith

instruction manual accessible

doublebusbar system

singlebusbar system

gas system

switchgear system

disconnector type ux2t

type ux2te