Me diu m v olt ag e prod uct

UniGear ZS1
Installation, operation and maintenance instruction manual

1. Your safety first at all times! ................................... 1

2. Sum m ary ................................ ................................. 2
2.1 Introduction ................................ .......................... 2
2.2 General ................................ ................................ 2
2.3 Standards and specifications .................................. 2
2.4 Operating conditions ................................ .............. 2
3. T echnical data ................................ .......................... 4
3.1 Electrical data ................................ ...................... 4
3.2 Resistance to internal arc fa ults.............................. 5
3.3. Dim ensions and w eights ................................ ........ 6
4. Panel design and equipm ent ...................................... 8
4.1 Basic structure and v ariants ................................... 8
4.2 Enclosure and partitioning ...................................... 8
4.3 Com partm ents in the panels ................................. 1 4
4.4 Interlock/protection against incorrect operation ...... 1 9
4.5 Plug connector coding ................................ ......... 2 4
4.6 Ith Lim iters ................................ ......................... 2 5
5. Dispatch and storage ................................ .............. 2 6
5.1 Condition on delivery ................................ ........... 2 6
5.2 Pack ing ................................ .............................. 2 6
5.3 T ransport ................................ ........................... 2 6
5.4 Deliv ery ................................ ............................. 2 6
5.5 Interm ediate storage ................................ ............ 2 7
5.6 Handling ................................ ............................ 2 7
6. Assem bly of the sw itchgear at site ............................ 3 1
6.1 General ................................ .............................. 3 1
6.2 Foundations ................................ ........................ 3 1
6.3 Assem bly of the sw itchgear panels ........................ 4 9 7.3 Serv ice truck s ..................................................... 9 6
6.4 Procedure for setting -up the doors ........................ 5 0 8. Com m issioning ....................................................... 9 8
6.5 Installation of the bushing .................................... 5 4 8.1 Preparatory w ork ................................................. 9 8
6.6 Fixing of the panels ............................................. 5 5 8.2 Measurem ents and tests ................................ ....... 9 9
6.7 Installation of the busbars .................................... 5 6 9. Maintenance ......................................................... 1 0 0
6.8 Installation of the top -m ounted boxes .................... 6 6 9.1 Maintenance strategies ................................ ...... 1 0 0
6.9 Pressure relief ducts ................................ ........... 7 3 9.2 Prev entive m aintenance ................................ ..... 1 0 0
6.10 Cable connection ................................ ............... 7 5 9.3 Inspection ......................................................... 1 0 1
6.11 Earthing the sw itchgear ................................ ...... 8 1 9.4 Serv icing ................................ .......................... 1 0 4
6.12 Installation of interconnecting bundles ................. 8 1 9.5 Repairs ............................................................ 1 0 7
6.13 Final erection w ork ................................ ............ 8 1 9.6 Risk -Based m aintenance ................................ .... 1 0 9
7. Operation of the sw itchgea r ..................................... 8 2 9.7 Spare parts, auxillar y m aterials and lubricants ...... 1 0 9
7.1 Sw itching operations ................................ ........... 8 2 9.8 Operating accessories ................................ ....... 1 1 0
7.2 Test procedure ................................ .................... 9 3 10. Product quality and env ironm ental protection ......... 1 1 1
1. Your safety first at all times!
That is w hy our instruction manual begins w ith the
follow ing recommendations:
Only install switchgear in closed rooms suitable for
electrical equipment.
Ensure that installation, operation and maintenance is
only carried out by qualified competent electricians.
Fully comply with the legally recognized standards
(IEC or local), the connection conditions of the local
electrical utility and the relevant saf ety at work
regulations.
Observe the relevant information in the instruction
manual for all actions involving switchgear.
If you have any further questions about this instruction
manual, ABBs field service team will be pleased to
provide the required information.
W e reserve all rights to this publication. Misuse,
including in particular, duplication and making this
manual - or extracts thereof available to third parties
is prohibited. W e do not accept any responsibility for
the information provided, which is subject to change.

DANGER!
Pay special attention to the hazard notes in the
instruction manual marked w ith this warning
symbol.
Make sure that the specified criteria are not
exceeded under switchgear operating
conditions.
Ensure the instruction manual is accessible to
all personnel involved in installation, operation
and maintenance.
The users personnel must act responsibly in
all matters relating to safety at w ork and
correct handling of the switchgear.

W ARNING
Alw ays follow the instruction manual and
respect the rules of good engineering practice!
Hazardous voltage can cause electrical shocks
and burns.
Disconnect pow er, then earth and shortcircuit
before proceeding w ith any w ork on this
equipment.

W ARNING
Using of safety clothes like safety gloves
according to EN 388 Blade cut resistance class 5,
long sleeved w ork jacket or safety sleeves, safety
shoes is recommended during all acti vities done
with the switchgear.

1
2. Summary
2.1 Introduction 2.4 Operating conditions
The instructions in this publication refer to UniGear 2.3.1. Normal operating conditions
ZS1 medium voltage switchgear with either The switchgear is b asically suitable for normal
withdrawable apparatus or LBS. For correct use of operating conditions for indoor switchgear in
the apparatus, please read the manual carefully. accordance with IEC 62271-200. Among other
Thanks to the advanced design of ABB switchgear, considerations, the following limiting values apply:
UniGear ZS1 is suitable not only for many different
applications, but also allows for further technical and
construction modifications to suit any installation Amb i en t temp e ratu re:
requirements. Consequently, this manual may not Max i mu m +40 C
include some specific instructions concerning special Max i mu m 24 h av era ge +35 C
apparatus configurations. In these cases, it is Mi ni mu m (acc ordi ng t o " min us 5 door class ") - 5 C
therefore strongly recommended to consult both this
manual and the latest technical documentation (circuit
and wiring diagrams, foundation plans and any Amb i en t h u mi d i ty:
protection selectivity studies). Max i mu m 24 h av era ge of relat i v e humid it y 95 % RH
Max i mu m 24 h av era ge of wat e r v apour pressure 2. 2 k Pa
Max i mu m mon ht l y av erage of r elat iv e hu mi dit y 90 % RH
Max i mu m mon ht l y av erage of w at er v apour pressur e 1. 8 k Pa
2.2 General
UniGear ZS1 is three-phase, metal-enclosed, air- The normal operational altitude is up to 1000 m above
insulated, LSC-2B switchgear and all the panels are sea level. The indoor ambient conditions are free of
factory-assembled, type-tested and suitable for indoor significant pollution, such as dust, smoke, corrosive
applications up to 24 kV. The panels are designed as and/or flammable gases, vapors or salt, etc.
withdrawable modules and are fitted with a singl e
busbar system. The withdrawable 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.

2.3 Standards and specifications

UniGear switchgear panels comply with the standards
and specifications for factory -assembled, metal -
enclosed and type tested high voltage switchgear to
IEC publications 62271 -200 (2011) and 62271 -1
(2007). In addition, in accordance with IEC 60529, the
switchgear panels have the following degrees of
protection:
IP 4X for the enclosure and IP 2X for the partitions.
All other corresponding IEC publications, national or
local safety at work regulations and safety regulations
for production materials must be followed during
erection and operation of these systems. Above and
beyond this, the order -related data from ABB must be
taken into account.

2
2.3.2. Special operating conditions
The switchgear is suitable for operation in the W Da
type of climate according to IEC 60721 -2-1.
Special operating conditions must be discussed with
ABB in advance. For example:
At site altitudes above 1000 m, the effects of the
reduction in dielectric strength of the air on the
insulation level must be taken into account (Figure
1).
Increased ambient temperatures must be
compensated in the design of the busba rs and
branch conductors, otherwise the current carrying
capacity will be limited.

Note on special climatic operating conditions:

W hen switchgear is operated in areas with high
humidity and/ or major rapid temperature fluctuations,
there is a risk of dew deposits which must be excluded
under normal operating conditions for indoor
switchgear. Preventive action (e.g. suitable ventilation
and proper air conditioning of the building or housing,
use of dehumidifying equipment, etc.) must be taken
into consideration with ABB to avoid this condensation
phenomenon and any resulting corrosion or other
adverse effects.

F i g u re 1: Cu rve fo r d etermi n in g th e al ti tu d e facto r k in

rel ati o n to th e al ti tud e H.

3
3. Technical data
3.1 Electrical data
M ai n p arameter s fo r p an el s w i th ci rcu i t b reaker s
Rat ed v olt age [ k V] 7. 2 / 12 17. 5 24 ( 1 )
Rat ed po wer f req uenc y w it hst a nd v olt age [ k V1min] 28 ( 2 ) 38 ( 2 ) 50
Rat ed li ght n ing i mpuls e wit hst a nd v olt age [ k V] 75 95 125
Rat ed f requ enc y [ Hz] 50 / 60 50 / 60 50 / 60
Ma in bus bar rat e d current [ A] . . . 4000 . . . 4000 . . . 3150
Circuit - br eak er rat ed current [ A] . . . 4000 . . . 4000 . . . 3150
Peak current [ k A] . . . 125 . . . 125 . . . 80
Int ern al arc wit hst a nd curr ent [ k A 1 s] . . . 50 . . . 50 . . . 31. 5
Rat ed short t i me wit hst and curr ent [ k A3 s] . . . 50 . . . 50 . . . 31. 5
( 1 ) 2 7 . 6 kV w i t h V D 4 a c c o r d i n g t o C S A C 2 2 . 2 N o 3 1 - 1 0 i s a v a i l a bl e
( 2 ) 4 2 kV ( G B / D L )

M ai n p arameter s fo r Un i G ear 17. 5 kV w i th VD4G - 50

Rat ed v olt age [ k V] 17. 5
Max i mu m serv ice v olt age [ k V] 15
T est v olt age (50/ 6 0 H z) [ k V1min] 38
I mpu lse wit hst a nd v olt age [ k V] 95
Rat ed f requ enc y [ Hz] 50 / 60
Rat ed short - t i me w it hst an d current [ k A3 s] 50
Peak wit hst and curre nt [ k A] 137
Int ern al arc wit hst a nd curr ent [ k A 1 s] 50
Rat ed curre nt of t he ma in bus b ars [ A] 4000
Rat ed circu it - break er t her mal c urrent [ A] 4000
F eeders rat ed c urrent wit h n at u ral v ent ilat ion [ A] 3150
F eeders rat ed c urrent wit h f orc ed v ent ilat io n [ A] 3600; 4 000
V D 4 G - 5 0 i s a v a i l a bl e i n t he r a t i n gs o f 3 1 5 0 - 4 0 0 0 A
3 6 0 0 A a nd 4 0 0 0 A a r e w i t h f o r c e d v e nt i l a t i o n
U ni G e a r Z S 1 pa ne l w i t h V D 4 G - 5 0 c i r c ui t - br e a ke r c a n be c o u p l e d w i t h s t a nd a r d U n i G e a r Z S 1 pa ne l w i t h V D 4 / P c i r c ui t - br e a ke r

M ai n p arameter s fo r p an el s w i th sw i tch -d i sco n n ecto r N AL F

Rat ed v olt age [ k V] 7. 2 / 12 17. 5 24
Rat ed po wer f req uenc y w it hst a nd
[ k V 1 min] 28 38 50
v olt age
Rat ed li ght n ing i mpuls e wit hst a nd
[ k V] 75 95 125
v olt age
Rat ed f requ enc y [ Hz] 50 / 60 50 / 60 50 / 60
Rat ed curre nt of busbars [ A] . . . 4000 . . . 4000 3150
Rat ed curre nt of branch es [ A] . . . 630 . . . 630 . . . 630
Rat ed bre ak ing curre nt of swit ch -
[ A] . . . 630 . . . 630 . . . 630
discon nect or (p ower f act or = 0. 7)
Rat ed short t i me wit hst and curr ent
[ k A] . . . 25 . . . 25 . . . 25
of swit ch - disco nn ect or 1 s
Rat ed short circu it mak in g current [ k A] . . . 40 . . . 40 50
Rat ed pe ak wit hst and curre nt [ k A] . . . 62. 5 . . . 62. 5 . . . 63
Auxili ar y v olt age DC [ V] 24 / 48 / 110 / 220 24 / 48 / 110 / 220 24 / 48 / 110 / 220
Auxili ar y v olt age AC [ V] 110 / 230 110 / 230 110 / 230

4
 M ai n p arameter s fo r p an el s w i th vacu u m co n tacto r VSC7/ P VSC12/ P
Rat ed v olt age [ k V] 7. 2 12
Rat ed ins ul at ion v olt age [ k V] 7. 2 12
Rat ed po wer f req uenc y w it hst a nd v olt age [ k V 1 min] 20 ( 3 ) 28 ( 3 )
Rat ed li ght n ing i mpuls e wit hst a nd v olt age [ k V] 60 75
Rat ed f requ enc y [ Hz] 50 / 60 50 / 60
Rat ed short t i me wit hst and curr ent ( 1 ) [ k A] . . . 50 . . . 50
Peak current [ k A] . . . 125 . . . 125
Int ern al arc wit hst a nd curr ent ( 2 ) [ k A 1 s] . . . 50 . . . 50
Max i mu m rat ed curr ent of t he cont act or [ A] 400 400
( 1 ) L i m i t e d b y t he f us e s .
( 2 ) T he i nt e r na l a r c w i t hs t a nd v a l u e s a r e g ua r a nt e e d i n t he c o m pa r t m e nt s o n t he s u p pl y s i d e o f t he f us e s ( b us ba r s a nd a p pa r a t us ) b y t he
s t r uc t ur e o f t he s w i t c h ge a r a nd o n t he l o a d s i d e ( f e e d e r ) b y t he l i m i t i n g p r o pe r t i e s o f t he f us e s .
( 3 ) V S C 7 / P G f o r 3 2 kV po w e r f r e q ue nc y w i t hs t a nd v o l t a ge a nd V S C 12 / P G f o r 4 2 kV po w e r f r e q ue nc y w i t hs t a nd v o l t a ge a r e a v a i l a b l e o n
r e q ue s t i n a d e d i c a t e d pa ne l .

3.2 Resistance to internal arc faults

The fault w ithstand capacity is as follow s: The switchgear panels have been tested according to
IEC 62271-200 standard (Annex A, accessibility type
12 kV - 50 kA 1 s A, IAC classification FLR) and also to PEHLA
17.5 kV - 50 kA 1 s recommendation no. 4. In individual cases, depending
24 kV - 31.5 kA 1 s on the configuration of the switchgear panels and/or
the switchroom conditions (e.g. low ceiling height),
additional measures may be necessary to ensure
compliance with criterion 5.

5
3.3. Dimensions and weights
Di men si o n s o f 12 / 17. 5 kV p an el s
Di men si o n [mm]
Heig ht A 2200 / 25 95 ( 1 )
W idt h:
650
- F eeder pan els u p t o 1250 A ( 31. 5 k A) ( 4 )
- F eeder pan els u p t o 1250 A ( 31. 5 k A) B 800
- F eeder pan els 1 600 - 20 00 A 800 ( 2 )
- F eeder pan els a bov e 2000 A 1000
Dept h:
1340
- Up t o 2500 A, 31. 5 k A
- 3150 A, 40 k A 1355
C(3)
- 4000 A, 40 k A 1390
- 3150 A, 50 k A 1390
- 4000 A, 50 k A 1455
D 2100
Heig ht of t he basic part of pan el
E 1495
(1) H e i g ht o f t he l o w v o l t a ge c o m p a r t m e nt i s 7 0 5 / 1 1 0 0 m m .
(2) 1 0 0 0 m m o n r e que s t .
(3) D e e pe r u ni t s a r e a v a i l a bl e o n r e q ue s t .
(4) F e e d e r s e q ui p pe d w i t h t he V S C c o n t a c t o r a r e 6 5 0 m m w i d e u p t o t he 5 0 kA s ho r t t i m e c ur r e n t a nd u p t o 1 2
kV r a t e d v o l t a ge .

Di men si o n s o f 24 kV p an el s
Di men si o n [mm]
Heig ht A 2325 / 27 20 ( 1 )
W idt h:
800 ( 2 )
- F eeder pan els u p t o 1250 A B
- F eeder pan els a bov e 1250 A 1000
Dept h C(3) 1700 ( 4 )
D 2200
Heig ht of t he basic part of pan el
E 1620
(1) H e i g ht o f t he l o w v o l t a ge c o m p a r t m e nt i s 7 0 5 / 1 1 0 0 m m .
(2) 1 0 0 0 m m o n r e que s t .
(3) D e e pe r u ni t s a r e a v a i l a bl e o n r e q ue s t .
(4) F o r s ho r t - t i m e c ur r e n t u p t o 2 5 kA a 1 5 6 0 m m d e p t h v e r s i o n i s a v a i l a bl e .

W ei g h t o f th e p an el in cl u di n g w i thd raw abl e ci rcu i t - b reaker p art

Rated cu rren t 12 / 17. 5 kV 24 kV
. . . 1250 A 800 - 85 0 k g 1000 - 1 050 k g
1600 A 850 - 90 0 k g 1200 k g
2000 A 850 - 90 0 k g 1200 k g
2500 A 1200 k g 1200 k g
3150 A 1200 k g x
4000 A 1400 k g x

Di men si o n s o f p an el w i th th e sw i tch -d i sco n n ecto r

Di men si o n 12 / 17. 5 kV 24 kV
Heig ht [ mm] A 2200 / 25 95 ( 1 ) 2325 / 27 20 ( 1 )
W idt h - O ut going an d inco ming
[ mm] B 800 ( 4 ) 1000
pane ls:
Dept h [ mm] C 1300 / 13 40 ( 2 ) 1700 ( 3 )
D 2100 2200
Heig ht of t he basic part of pan el [ mm]
E 1495 1620
N o t e : T he d i m e ns i o ns m us t b y v e r i f i e d a c c o r d i n g t o t he r e l e v a nt o r d e r d o c um e nt a t i o n .
N o t e : W e i gh t o f pa ne l i nc l ud i n g o f s w i t c h - d i s c o n ne c t o r ( 1 2 a nd 1 7 . 5 / 2 4 kV ) i s c c a 7 5 0 / 9 5 0 k g .
( 1 ) H e i g ht o f l o w v o l t a ge c o m pa r t m e n i s 7 0 5 / 1 1 0 0 m m .
( 2 ) T he d e pt h o f pa ne l w i t h t he s w i t c h - d i s c o n ne c t o r i n c o m b i na t i o n w i t h H D 4 c i r c ui t br e a ke r pa ne l s i s
r e c o m m e nd e d t o be 1 3 4 0 m m , i n o t he r c a s e s 1 3 0 0 m m .
( 3 ) 1 5 6 0 m m d e pt h v e r s i o n a v a i l a bl e o n r e q ue s t .
( 4 ) 6 3 0 A ( m a x . c ur r e nt o f L B S pa n e l l i m i t e d b y c o o r d i na t e d f us e s ) .

6
F i g u re 2: Di men si on s o f UniG ear Z S1 p an el .
4. Panel design and equipment
4.1 Basic structure and variants
The basis for the UniGear panel is the incoming /
outgoing feeder panel with SF6 or vacuum circuit-
breaker using insertion technology. It is divided into
busbar compartment I., circuit breaker compartment
II., cable compartment III. and low voltage
compartment IV. for the secondary equipment. Apart
from this, there are variants for all operating needs.
For busbar sectionalising, two panels are necessary,
the coupling panel with the withdrawable circuit -
breaker part and a bus riser panel (optional with
busbar metering and earthing). In equipment without
busbar sectionalising, a direct bar connection between
the busbars will be established.
The UniGear switchgear also includes the variant of
incoming / outgoing panel with the NALF switch -
disconnector with the stationary mounting of the
switch-disconnector. The panel is divided into busbar
compartment A, switch -disconnector compartment
including cables B and low voltage compartment for
the secondary equipment D.
Further details about installation and switchgear
equipment can be obtained from the relevant order
documents.
4.2 Enclosure and partitioning
The enclosure and internal partitions of the panels are
of 2 mm thick high quality galvanized steel sheets.
The three high voltage compartments (busbar
compartment, circuit -breaker compartment and cable
connection compartment) are equipped with top-
mounted and secured pressure relief flaps. These
open in the case of overpressure due to an internal
arc fault. The front of the panel is closed off by
pressure resistant doors which open to an angle of
130.
Cable and circuit-breaker compartments have their
own doors, both compartments can be equipped with
inspection windows made of security glass.
Neighbouring panels are partitioned from one another
by the side walls of each panel and, as a result of the
design, the air cushion remains between these walls
when the panels are jointed together.
The enclosure is completed on the roof by top -
mounted pressure relief flaps which, according to the
rated branch conductor current, are made of sheet
steel or expanded metal and at the base by means of
floor-covering 18 (Figure 3), made of Al sheet.
The pressure-relief flaps are secured with steel
8
screws on one longitudinal side and on the other
longitudinal side with plastic screws. In the case of
internal overpressure, the plastic screws are the
rupture point.
Arc fault current limitation can be achieved by
undelayed circuitbreaker release, carried out by
auxiliary switches operated by the pressure wave. The
switchgear can be equipped with Ith limiter: the
auxiliary switches (Figure 28) are operated by the
pressure relief flaps.
The necessary safety measures to counteract the
effects of an internal arc fault must be ensured in
relation to the ceiling height. In individual cases, this
may require additional operator protection measures
on the switchgear panels. These measures include:
1. Mounting a pressure relief duct 1 (Figure 124) on
the top of the switchgear, with further channels
leading out of the switchgear room in a form
appropriate for the design of the building. The shock
wave and arc discharge are channelled off in ducts.
2. Mounting a pressure relief duct with blow -out
apertures located above the duct at the ends of the
switchgear and pointing towards the centre of the
switchgear (diverter duct). The shock wave and arc
discharge then emerge in an extremely attenuated
form and in a location which is not critical for the
operating personnel.
The rear wall of the busbar compartment 12 (Figure
3), intermediate wall 19, mounting plate 13 with
shutters 20/24 and horizontal partition 29, form part of
the internal partitioning . The internal partition ing
makes safe access to the circuit -breaker and cable
compartments possible even when the busbars are
live.
The low voltage compartment for the secondary
equipment is completely protected from the high
voltage area thanks to its steel -sheet casing.
On the end sides, cover plates ensure a good
appearance and are mechanically and thermally arc
fault proof should such an event occur in the end
panel.
Doors and cover plates are thoroughly cleaned and
treated against corrosion before receiving a high
quality double coating of paint. The finishing coat is in
the standard RAL 7035 color (special colors by
agreement). Stoving completes the procedure and
provides considerable resistance 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).
Ventilation of the panels
Openings in the outer enclosure are needed for
ventilation in the case of certain rated currents in the
busbars and branch bars.
For incoming air to the circuit -breaker compartment,
the horizontal partition is provided with air -vents 28
IP4X degree of protection and safety in the case of
any release of hot gas due to an arc fault is provided
by flap 27 in the horizontal partition 29. For outgoing
air, the pressure relief flaps 8 incorporate vents which
provide the IP4X degree of protection (Figure 3).
In cases of higher ambient temperature (> 40 C) it is
necessary to apply derating of rated current. It is
necessary to use forced fan ventilation in 3600 A and
4000 A panels for 12 / 17.5 kV rated voltage and in
3150 A panels for 24 kV rated voltage.

I n stru cti o n fo r sw i tch in g o f co o l in g fan s:

I n co mer, 12 / 17. 5 kV, 3600 A
Current (a mb ient Current (a mb ient Current (a mb ient Current (a mb ient F AN 1 F AN 2
t emp erat ure max. t emp erat ure max. t emp erat ure max. t emp erat ure max. Circuit Current Not e
40C) 45C) 50C) 55C) Break er t ransf ormers
f an is
< 3200 A < 3070 A < 2940 A < 2800 A No -
st oppe d
f an st art s
3200 A 3070 A 2940 A 2800 A Yes -
operat i on

I n co mer, 12 / 17. 5 kV, 4000 A

Current (a mb ient Current (a mb ient Current (a mb ient Current (a mb ient F AN 1 F AN 2
t emp erat ure max. t emp erat ure max. t emp erat ure max. t emp erat ure max. Circuit Current Not e
40C) 45C) 50C) 55C) Break er t ransf ormers
bot h f ans
< 3200 A < 3070 A < 2940 A < 2800 A No No
are st opp ed
bot h f ans
3200 A 3070 A 2940 A 2800 A Yes Yes st art
operat i on

I n co mer, 24 kV, 2500 A

Current (a mb ient Current (a mb ient Current (a mb ient Current (a mb ient F AN 1 F AN 2
t emp erat ure max. t emp erat ure max. t emp erat ure max. t emp erat ure max. Circuit Current Not e
40C) 45C) 50C) 55C) Break er t ransf ormers
f an is
< 2200 A < 2110 A < 2020 A < 1920 A No -
st oppe d
f an st art s
2200 A 2110 A 2020 A 1920 A Yes -
operat i on

I n co mer, 24 kV, 3150 A

Current (a mb ient Current (a mb ient Current (a mb ient Current (a mb ient F AN 1 F AN 2
t emp erat ure max. t emp erat ure max. t emp erat ure max. t emp erat ure max. Circuit Current Not e
40C) 45C) 50C) 55C) Break er t ransf ormers
f an is
< 2700 A < 2590 A < 2480 A < 2360 A No -
st oppe d
f an st art s
2700 A 2590 A 2480 A 2360 A Yes -
operat i on

9
F i g u re 3: Uni g ear feed er p an el 17. 5 kV, 40 k A.
A Busbar co mp art ment 16 Current t ransf or mer
B Circuit - br eak er compart ment 17 Volt age t ra nsf ormer
C Cabl e co mpart me nt 18 F loor cov er split
D Low v olt age co mpart ment 19 Part it ion re mov ab le
20 T op shut t er
1 Spind le mec han is m 21 T erminal ra ck
2 Spigot o n spin dle 22 Cont rol w irin g plu g con nect or
3 Hole i n spin dl e f or insert io n lev er 23 Cont rol w irin g duct
4 Vent ilat i on gr id 24 Lower sh ut t er
5 Eart hing sw it ch op erat in g mech anis m 25 W it hdrawable p art
6 O perat ing s haf t f or eart hing sw it ch 26 Spind le mec han is m
7 Slide 27 Back f lap
8 Pressure rel ief f lap 28 Vent ilat i on gr id
9 Enclosur e 29 Hori zo nt al part it i on, re mov abl e
10 Branch con duct or 30 Eart hing sw it ch op erat in g mech anis m
11 Busbar 31 Cont rol w irin g duct
12 Part it ion 32 Cabl e seal in g end
13 Mo unt in g pl at e 33 Cabl e cla mp
14 Isol at ing bush ing 34 Ma in eart h in g bar
15 Eart hing sw it ch

10
F i g u re 4: Uni G ear Di g i tal p anel (vo l tag e meteri n g i n cab l e co mp artmen t).
A Busbar co mp art ment 12 Mo unt in g pl at e
B Circuit - br eak er comp art ment 13 Isol at ing bush ing
C Cabl e co mpart me nt 14 Eart hing sw it ch
D Low v olt age co mpart ment 15 Volt age s ensor i n cabl e co mpar t ment
16 F loor cov er split
1 Spind le mec han is m 17 Part it ion re mov ab le
2 Spigot o n spin dle 18 T op shut t er
3 Hole i n spin dl e f or insert io n lev er 19 Cont rol w iri n g plu g con nect or
4 Eart hing sw it ch op erat in g mech anis m 20 Cont rol w irin g duct
5 O perat ing s haf t f or eart hing sw it ch 21 Lower sh ut t er
6 Slide 22 W it hdrawable p art
7 Pressure rel ief f l ap 23 Current sens or
8 Enclosur e 24 Hori zo nt al part it i on, re mov abl e
9 Branch con duct or 25 Cabl e seal in g end
10 Busbar 26 Cabl e cla mp
11 Part it ion 27 Ma in eart h in g bar

11
F i g u re 5: Uni G ear Di g i tal p anel (vo l tag e meteri n g i n b u sb ar co mp artmen t).
A Busbar co mp art ment 12 Mo unt in g pl at e
B Circuit - br eak er compart ment 13 Isol at ing bush ing
C Cabl e co mpart me nt 14 Eart hing sw i t ch
D Low v olt age co mpart ment 15 Volt age s ensor i n cabl e co mpar t ment
16 F loor cov er split
1 Spind le mec han is m 17 Part it ion re mov ab le
2 Spigot o n spin dle 18 T op shut t er
3 Hole i n spin dl e f or insert io n lev er 19 Cont rol w irin g plu g con nect or
4 Eart hing sw it ch op erat in g mech anis m 20 Cont rol w irin g duct
5 O perat ing s haf t f or eart hing sw it ch 21 Lower sh ut t er
6 Slide 22 W it hdrawable p art
7 Pressure rel ief f lap 23 Current sens or
8 Enclosur e 24 Hori zo nt al part it i on, re mov abl e
9 Branch con duct or 25 Cabl e seal in g end
10 Busbar 26 Cabl e cla mp
11 Part it ion 27 Ma in eart h in g bar

12
F i g u re 6: Pan el w i th 12 / 17. 5 kV sw i tch - d i sco nn ecto r w i th fu ses an d earth i n g sw i tch.
A Busbar co mp art ment 13 O perat ing s haf t f or eart hing sw it ch
B Swit ch- disc onn ect or an d cabl e compart ment 14 Slide
D Low v olt age co mpart ment 15 Ma in eart h in g bar
16 Eart hing sw it ch
1 Pressure rel ief f laps 17 T erminal rack
2 Enclosur e 18 Cont rol w ire duct
3 Branch con duct or 19 Insu lat or or curre nt t ransf ormer
4 Busbar 20 Cabl e seal in g end
5 Part it ion 21 Cont rol w ire duct
6 Bushin g 22 F loor cov er - split
7 Posit ion i nd icat or of swit ch - d is connect or 23 Cabl e cla mp
8 O perat ing mec ha nis m of swit ch - discon ne ct or 24 Swit ch- disc onn ect or
9 O perat ing s haf t of swit ch -disco nnect or 25 Insu lat in g part it i on wa ll
10 Slide 26 Mov abl e ins ulat i ng pl at e
11 Posit ion i nd icat or of eart hi ng s wit ch 27 F use or lin k
12 O perat ing mec ha nis m of eart hi ng swit ch 28 Int erl ock ing of eart hi ng swit ch

13
4.3 Compartments in the panels
There are six types of electronic instrument
transformers for UniGear Digital:
KEVA 17,5B2x voltage sensor with ratio 10000:1
KECA 80C104 current sensor with ratio
150mV@80A
KECA 80C165 current sensor with ratio
150mV@80A (for nominal voltage up to 17,5kV)
KEVA 24B2x voltage sensor with ratio 10000:1
KECA 80C184 current sensor with ratio
150mV@80A
KECA 80C216 current sensor with ratio
150mV@80A (for nominal voltage 24kV)

4.3.1 Busbar compartment

The busbars 11 (Figure 3) have a flat cross -section
made of copper and are laid in sections from panel to
panel. For higher rated currents (3150, 3600 and 4000
A), the busbars have a open D -shaped cross-section.
According to the current rating, either single or double
configuration is used. They are held in place by the
flat branch conductor 10 (Figure 3) and, if installed, by
busbar bushings (chapter 6.5). No special connection
clamps are needed.
Busbars and branch conductors for 17.5 and 24 kV are
insulated by means of shrink-on sleeves. The bol t
connections in the 17.5 and 24 kV busbar system are
covered by insulating covers (chapter 6.7). The F i g u re 7: Vo l tag e sen so rs i n b u sb ar co mp artmen t i n
busbars for 12 kV panels up to 2500 A do not have Un i G ear Di g i tal .
covers. Open D-shaped busbars 3150, 3600 and 4000
A are insulated and the connections are covered.
By means of bushing plates and busbar bushings
(chapter 6.5), partitions can be created between
panels. These partitions are necessary for higher
rated short-time currents, see table below.

Un Ik Parti ti o n s
Ev ery lat eral p an el; f rom 1 2
pane ls ad dit io nal p art it on in
25 k A t he mi ddl e; f rom 2 1 pan els on e
addit i on al part it i on in e ach
12 / 17. 5 k V t hird of t he swit chg ear
Ev ery lat eral p an el an d ev ery
31. 5 k A
t hird pan el
40, 50 k A Ev ery pane l
Ev ery lat eral p an el; f rom 1 2
pane ls ad dit io nal p art it on in
25 k A t he mi ddl e; f rom 2 1 pan els on e
24 k V addit i on al part it i on in e ach
t hird of t he swit chg ear
31. 5 k A Ev ery pane l
Mar ine/ Se is mic
All rat ings Ev ery pane l
v ersion

According to customer requirements, this separation

into individual panels by means of busbar bushings
and bushing plates (chapter 6.5) 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 panels.

14
4.3.2 Circuit-breaker compartment
The circuit-breaker compartment contains all the
necessary equipment for reciprocal operation of the
withdrawable part and the panel. Like the busbar
compartment, it is metallically partitioned on all sides.

The tulip isolating contacts 4 (Figure 165), together

with the fixed isolating contacts, are located in
mounting plate 13 (Figure 3). The metal shutters 2/4
(Figure 8), covering the insertion openings, are also
included. The shutters are opened by the actuating
bars of the withdrawable circuit -breaker part, using
the lever when inserting into the service position, and
are closed when the latter is removed. In the test /
disconnected position of the withdrawable part,
partitioning by separation is established in the main
current circuit. Connection of the control wiring,
required for test purposes, need not be interrupted
when in the test / disconnected position. 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 (Figure F i g u re 8: Vi ew in to th e ci rcu it - b reake r co mp artm en t.
11). The socket 1 (Figure 8) for the control wiring is 1 Cont rol w irin g sock et
mounted in the circuit -breaker compartment. 2 T op shut t er
3 Duct cov er, t op right
4 Lower sh ut t er
5 Right - h and t rav el rail

F i g u re 9: Ci rcu i t -b reaker co mp artmen t, o p en . F i g u re 10: Wi th d raw ab l e p art w i th VD4 typ e ci rcu i t - b rea ker ,
p o l e si d e.
W it hdrawable part in t est posit io n, cont ro l w irin g p lu g
connect or ope n
1 Cont rol w irin g plu g
2 W it hdrawable p art
3 Square sp ig ot

15
 F i g u re 13: Cu rren t sen so rs KEC A 80C 165 mo u n ted i n th e
ci rcu i t b reake r co mp artm en t in Un i G ear Di g i tal.

F i g u re 11: Pu sh b u tto n fo r mech an i cal O N/ O F F b reaker

o p erati o n w ith th e d oo r cl o sed (o n req u est).
If t he wit hdr awa ble part is i n t he serv ice posit i on, o per at ion is
carried o ut using t he k nob wh i ch swings a p ush rod ext e nsio n
out .
1 Mec han ical push but t on
2 T urning k nob F i g u re 14: Cu rren t sen so rs KEC A 80C 104 mo u n ted i n th e
ci rcu i t b reake r co mp artm en t in Un i G ear Di g i tal.

F i g u re 12: Vi ew o f th e p u sh ro d exten si o n sw un g o u t b y
th e kn o b at th e fro n t, w ith the w i th d raw ab l e ci rcu i t -b reake r
p art i n servi ce p o si ti o n an d th e d o o r o p en .
1 Swiv ellin g pus h rod

16
4.3.3 Withdrawable parts
1. W ithdrawable circuit -breakers
The withdrawable circuit -breaker forms a complete
module consisting of the vacuum circuit -breakers type
VD4 or VM1, SF6 circuit -breaker type HD4 the
withdrawable assembly 1 (Figure 15), isolated contact
arm 3 with contact system 2 (Figure 165) and control
wiring plug 1 (Figure 9).
The withdrawable assembly and the circuit -breaker
are coupled via a multi -pole control wiring plug
connector.
The withdrawable assembly establishes the
mechanical connection between the panel and the
circuit-breaker. The fixed part is connected to the
panel by a forked connection, which is form coded on
both sides. The moving part with the circuit -breaker is
moved either manually or by a motor by means of a
spindle, between the service or test / disconnected
positions with the front doors closed. Service and test
/ disconnected positions are set precisely by means of
auxiliary switches, which register the final position
reached and the angular position of the spindle. The
earthing connection between the withdrawable part
and the panel is established by its rollers and travel
rails 5 (Figure 8), which are bolted onto the panel.
W ithdrawable parts of the same design and electrical
parameters are interchangeable. In the case where
the withdrawable parts have the same dimensions, bu t
different electrical parameters, the control wiring plug
coding prevents any incorrect connections between F i g u re 15: Wi th d raw ab l e p art w i th ci rcu i t - b reaker, t yp e
the withdrawable part and the panel. VD4, o p erati n g mech an i sm si d e.
1 W it hdrawable ass e mb l y
2. Other withdrawable parts
The withdrawable part can also be fitted with the
following trucks:
Metering voltage transformers truck with fuses.
Earthing truck without making capacity (for main
busbar system and power cables).
Earthing truck with making capacity (for main
busbar system and power cables).
Power cable testing truck.
Isolation truck.
Isolation truck with fuses.
Shutter lifting truck.

3. W ithdrawable contactors
In place of the circuit -breaker type, the withdrawable
part can also be fitted with the VSC type vacuum
contactor. VSC is fitted with MV fuses 1 (Figure 157)
and can be used for rated voltage up to 12 kV. All the
data stated in this chapter for circuit -breakers also
applies to the contactors.
F i g u re 16: Wi th d raw ab l e assemb l y fo r ci rcu i t - b rea ker, w i th
au xi l i ary sw i tch es.
1 T est posit ion i ndic at or
2 Serv ice posit io n ind icat or
3 Square sp ig ot

17
4.3.4 Cable connection compartment
The cable compartment contains cu rrent transformers
16 (Figure 3), fixed and withdrawable voltage
transformers 17, and earthing switch 15, according to
individual operating requirements in each case.
The cable compartment is constructed for installation
of three current transformers. Should all three current
transformers not be required, dummies will be
installed in their place, using the same installation and
connection procedures. The fixed voltage transformers
are connected on the primary side with flexible, fully-
insulated cables which are connected to the
transformers.
The removable voltage transformers are fitted with
HRC fuses. The earthing switch can be used with
either a manual or motor -operated mechanism. Its
switching position will be indicated bot h mechanicall y
by indication on the shaft and electrically by means of
the auxiliary switch. Three fixed surge arrestors can
be mounted instead of one position of single -core
cables.
F i g u re 17: Vol tag e sen so rs KEV A 1 7. 5B2 0 mo u n ted i n th e
cab l e co mp artme n t i n Un i G ear Di g i tal .
Cable connection of 12 / 17.5 kV panels:
In the 650 mm wide panel, up to three parallel plastic
cables can be connected with single -core cable
protection and push on sealing ends with a maximum
cross-section of 630 mm 2 . In the 800 or 1000 mm wide
panel, up to six parallel plastic cables can be
connected with single-core cable protection and push -
on sealing ends with a maximum cross -section of 630
mm 2 .
Customer requests regarding connections to bars,
three-core cables, special ca bles or sealing ends of
different types must be considered during the order -
planning stage.
Cable connection of 24 kV panels:
In the 800 mm wide panel, up to three parallel plastic
cables can be connected with single -core cable
protection and push on sealing ends with a maximum
cross-section of 500 mm 2 . In the 1000 mm wide panel,
up to six parallel plastic cables can be connected with
single-core cable protection and pushon sealing ends
with a maximum cross -section of 500 mm 2 . For more
information regardi ng cable connection (chapter 6.10).
4.3.5 Low voltage compartment
The height of the low voltage compartment is 705 /
1100 mm . If the secondary devices are not intended
for door installation, they are mounted on DIN RAILS
that enable any subsequent changes to the wiring. In
the lower part of the low voltage compartment, there
are three rows of DIN RAILS on the swivelling DIN
RAILS holder and, below these, there is an easily
18
accessible auxiliary switch for the control wiring plug.
Secondary wiring inside the panel is in a duct on the
right side of the panel. The left side of the panel is for
the external wiring. The ducts are c overed with steel
sheet 2, 4 (Figure 73). There are holes for sliding in
the ring conductors at the side of the low voltage
compartment.
4.3.6 Sw itch-disconnector and cable compartment
in the panel w ith switch-disconnector
The switch-disconnector and cable compartment is
merged. The stationary switch -disconnector is
connected to busbars. The interconnection to the
busbar compartment is carried out by bushings, which
secures the separation of busbar compartment from all
other switchgear compartments. The switch -
disconnector and cable compartment is also separated
from other compartments by metal partitions. The
switch-disconnector can optionally contain an
integrated earthing switch. The switching positions of
the integrated earthing switch type E can be indicated
by an auxiliary switch. The closing and opening of the
switch-disconnector is performed manually by a lever
with the door closed. On request, the device can be
also mounted for the motor operation of the switch -
disconnector. The switchdisconnector can therefore be
operated both locally and remotely.
The earthing switch is always operated locally by the
operating lever.
The switchgear is constructed for the use of single -
core cables as standard. The cable compartmen t
usually contains supporting insulators for the
fastening of cables. On request the cable
compartment can contain the instrument current
transformers instead of the supporting insulators. If all
three current transformers are not required, the
relevant insulators are installed instead of them.
Cable connection in the panels for 12 kV, 17.5 kV and
24 kV: In the panel with switch -disconnector plastic
single-core cable can be connected on each phase
with a cross-section up to 240 mm 2 as standard.
Important note:
In the case of any non standard cable connections an
agreement must be reached between the customer
and ABB during the technical preparation stage of the
order.
4.4 Interlock/protection against incorrect operation
4.4.1 Panel internal interlocking
To prevent hazardous situations and incorrect
operation, there is a series of interlocks to protect
both personnel and equipment:
The withdrawable part can only be moved from the
test / disconnected position (and back) when the
circuit-breaker and earthing switch are off (i.e. the
switch must be off before hand.) In the
intermediate position, the switch is mechanicall y
interlocked. W hen the circuit-breakers have an
electrical release, the interlock is also electrical.
The circuit-breaker can only be switched on when
the withdrawable part is in the test or service
position. In the intermediate position, the switch is
mechanically interlocked. W hen the circuit -
breakers have an electrical release, the interlock
is also electrical.
If required, prevention of malfunction of the switch
can also be achieved by means of the control
terminal (i.e. Relion).
In the service or test positions, the circuit -breaker
can only be switched off manually when no control
voltage is applied and it cannot be closed
(electromechanical interlock).
Connecting and disconnecting the control wiring
plug 2 (Figure 142) is only possible in the test / F i g u re 18: A) Cl o sed p o si ti on o f d o o r s h an d l e; B) No t
disconnected position of the withdrawable part. cl o sed p o si tio n o f do o r s h and l e.
The earthing switch 15 (Figure 3) can only be
switched on if the withdrawable part is in the test /
disconnected position or outside of the panel 4.4.3 Interlocks betw een panels
(mechanical interlock).
The busbar earthing switch can only be closed
If the earthing switch is on, the withdrawable part
when all the withdrawable parts in the relative
cannot be moved from the test / disconnected
busbar section are in the test / disconnected
position to the service position (mechanical
position (electromechanical interlock).
interlock).
W hen the busbar earthing switch is closed, the
Optionally there can be interlocking on shutters to
withdrawable parts in the earthed busbar section
prevent manual opening. If it is applied then a
cannot be moved from the test / disconnected
shutter device must be specified.
position to the service position (electromechanical
Details of other possible interlocks, e.g. in
interlock).
connection with a locking magnet on the
withdrawable part and / or earthing switch drive,
can be obtained from the relevant order
documents. 4.4.4 Locking devices
The shutters 2/4 (Figure 8) can be secured
independently of each other with padlocks when
4.4.2 Door interlocking the withdrawable circuit -breaker part has been
The panels are equipped with the following interlocks: removed.
Access to the operating -shaft 30 (Figure 3) of the
The apparatus (circuit -breaker or contactor) can
earthing switch can be restricted with a padlock.
not be racked-in if the apparatus compartment
door is open. Access to the circuit -breaker racking slot can be
restricted with a padlock.
The apparatus compartment door cannot be
opened if the apparatus (circuit-breaker or Access to the circuit -breaker compartment and the
contactor) is in service or in an undefined position. cable compartment can be restricted with a
padlock.
The earthing switch cannot be operated if the
cable compartment door is open.
The cable compartment door cannot be opened if
the earthing switch is open - please see warning
about doors handle in section 4.4.4 Locking
devices. W ARNING
The locking magnet is not installed in the case
Note: of a motor operator; busbar earthing sw itches
W hen the interlocking for circuit -breaker is used then or the w ithdrawable parts are electricall y
it is necessary to use the OFF push button on the door locked. The manual emergency sw itch is not
to provide emergency switching OFF. locked!
This interlock is not available for
motoroperated w ithdrawable apparatus as a
mechanical device.

19
 W ARNING
The doors handle w hich is an integral part of
doors has to be push to its final close position
see (Figure 18) of closed and not closed
position of doors handle.
In case the doors hand le is not in its final
close position the doors are not closed yet. In
this case the interlock function cannot be
ensured.

4.4.5 Internal interlocking of panel w ith switch -

disconnector
To prevent hazardous situations and incorrect
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 HV cable part of the panel F i g u re 19: Sw itch - d i sco nn ecto r co mp artmen t - o p en
can only be opened if the earthing switch is on. p o si ti on . I n su l atin g p l ate i n th e i so l ati ng di stan ce o f
During the closing of the earthing switch the sw i tch -d i sco n n ecto r.
insulating plate 26 (Figure 6) is automatically 1 Posit ion i nd icat or of swit ch - d is connect or
inserted in the isolating distance of switch- 2 Swit ch- disc onn ect or
disconnector, which increases safety. This plate is 3 Mov abl e ins ulat i on pl at e
automatically removed again during the opening of 4 Insu lat io n part it i on wa ll
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 be open and closed only
manually. The manual operation of switch -
disconnector and earthing switch can be prevented
if the slides 10 and 14 (Figure 6) of the operating
openings are locked up.
In panels with digital control techniques the
protection against incorrect operation is basically
carried out by the panel software. But the earthing
switch is operated locally by the operating lever 1
(Figure 20). The mechanical interlocking 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.

W ARNING
The door of the upper HV part of 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 low er contacts of the
sw itch-disconnector.
F i g u re 20: Prep arati o n fo r the o p erati o n o f earth i n g sw itch
i n p an el w i th th e sw itch - d i sco n n ecto r.
O perat ing l ev er prepar ed f or t he O F F operat ion
1 O perat ing l ev er

20
Types of interlocks
Stan d ard safet y i n terl o cks (m an d ato ry)
T yp e Desc ri p ti o n Co n d i tio n to b e fu l fi l l ed
A Apparat us rack in g - in/ o ut Apparat us i n O F F posit ion
1
B Apparat us cl osi ng Def ine d t ruck posit ion
A Apparat us rack in g - in Apparat us mult i - co nt act plug p l ugge d
2
B Apparat us mult i - co nt act plug u nplu gg ing T ruck in t est posit ion
A Eart hing sw it ch closi ng T ruck in t est posit ion
3
B Apparat us rack in g - in Eart hing sw it ch in O F F posit ion
A Apparat us c o mpart me nt door o peni ng T ruck in t est posit ion
4
B Apparat us rack in g - in Apparat us c o mpart me nt door cl osed
A F eeder co mp art ment do or ope n ing Eart hing sw it ch in O N pos it ion
5
B Eart hing sw it ch op eni ng Cabl e co mpart me nt door cl ose d
N o t e : A p pa r a t us a r e c i r c ui t - br e a ke r s a nd c o n t a c t o r s .

Ke ys (o n req u est)
6 Apparat us rack in g - in l ock Can on l y be re mov ed wit h t he t ruck in t he rack ed - out posit ion
7 Eart hing sw it ch closi ng l ock Can on l y be re mov ed wit h t he eart hin g swit ch o pen
8 Eart hing sw it ch op eni ng lock Can on l y be re mov ed wit h t he eart hin g clos ed
9 Insert i on of t he ap parat us rak in g - in/ out crank lev er Can al wa ys be re mov ed
10 Insert i on of t he eart h ing sw it ch operat in g lev er Can al wa ys be re mov ed

Pad l o cks
11 Apparat us c o mpart me nt door o peni ng
12 Cabl e co mpart me nt door o pen i ng
13 Insert i on of t he ap parat us rak in g - in/ out crank lev er
14 Insert i on of t he eart h ing sw it ch operat in g lev er
15 Shut t ers ope nin g or closi ng
I t i s ne c e s s a r y t o us e pa d l o c ks w i t h 5 - 8 m m ha s p d i a m e t e r

L o cki n g mag n ets (on req u est)

16 Apparat us rack in g - in/ o ut Ma gnet e nerg i zed
17 Eart hing sw it ch O N/ O F F Ma gnet e nerg i zed

Ac ce sso r y d e vi ces
T he dev ice lock s t he shut t ers in t he close d posit i on wh en t he appar at us is re mov ed f ro m t he
18 Shut t ers f ail - saf e compart ment . T he operat or can not ope n t he shut t ers manu all y. T he shut t ers can onl y b e
operat e d b y t he ap parat us t ruc k or t he serv ice t ruck s.
Apparat us - s wit chg ear T he apparat us mult i - c ont act pl ug an d relat iv e swit chg ear un it sock et are equip ped w it h a
19 unit co mpat i bi lit y mec han ical mat rix, t hat disabl e s apparat us rack ing - in i nt o a swit chge ar unit wit h an
mat rix inap propr iat e rat e d current .
T he apparat us co mp art ment is equi pp ed wit h a mec han ical d e v ice, t hat enables circu it - break er
Circuit - br eak er
closin g an d/ or ope nin g direct l y by me ans of t he f ront oper at ing mech anis m p ush but t ons, k eepi ng
20 mec han ical oper at ing
t he door cl osed. T he cont rols can be o perat e d wit h t he circu it - break ers in t he op erat io n and
mec han is m
rack ed- out posit i on.

21
F i g u re 21: Ci rcu i t - b reaker co mp artmen t d o o r en ab l i ng d evi ce ( A) an d d o o r l o cki ng pi n (B).

F i g u re 22: Ci rcu i t - b reaker tr u ck en ab l i n g sl o t (A).

F i g u re 23: Ci rcu i t - b reaker co mp artmen t d o o r l o cki n g d evice (B).

22
F i g u re 24: Cab l e co mp artmen t d oo r en ab l in g d evi ce (C).

F i g u re 25: Cab l e co mp artmen t d oo r en ab l in g slo t (C1) and earth i n g sw itch en ab li n g p in (C2).

F i g u re 26: Cab l es co mp artmen t d o o r l o cki n g p in (D).

23
4.5 Plug connector coding
The control wiring plug connector coding allows
withdrawable parts for switching devices to be
assigned to particular panels. This ensures, for
example, that withdrawable parts with different rated
currents or different control wiring circuits can only be
used in the panels they are intended for. Coding pins
are fitted in the control wiring sockets (Figure 9) or
control wiring plugs and engage with the
corresponding bores of the relevant plug 1 (Figure 9)
or socket 3 when the two parts are connected.
The plug connector coding is order -related, and is
noted in the relevant wiring documentation.

F i g u re 27: Co n trol w i ri n g p lug co n n ecto r co di n g, sh ow n

fo r a 58 - p o l e co n n ecto r.
1 Bore f or act uat in g pin of t he co nt rol wiri ng pl ug f or
cont roll ing t h e auxi liar y sw it ch
2, 4 Cent eri ng st rik ing t abs
3 Cont rol w irin g sock et

Coding:
The corresponding coding designation for the control
wiring plug is given in brackets. The coding pins can
be fitted in the control wiring socket 3 (Figure 27)
and/or in the control wiring plug.

Basic design:
The number of sockets is optional, but the basic
assignment is 1, 8, 10, 20, 21, 31, 33 and 40. Sockets
and pins can be mixed as required in the control
wiring socket 3 and control wiring plug.

24
4.6 Ith Limiters
It is additional safety feature on the top of each panel.
The microswitch generates an immediate fault signal
when the overpressure flap is opened. Reaction time
is less then 15 ms. The signal from the microswitch
can be sent directly to trigger the circuit-breaker OFF.

F i g u re 30: Val id p ro mi cro sw i tch o f typ e Cro u zet.

1 It h li mit er
2 Pressure rel ief f lap

F i g u re 28: Au xi l i ar y I th l i mi ter sw i tch . I t may b e n eces sar y

to mo ve th e au xi i ary sw i tch es i n to th ei r servi ce p o si ti o n
w h en th e l i ftin g eyeb o l ts h ave b een remo ved .

It is necessary to adjust the centre of the switch knob

of the auxiliar y switch to the centre of the pressure
relief flaps hole. Correct value of the adjustment of
the auxiliary switches height in the pressed position
according to the particular type of the switch is
indicated in following pictures.

F i g u re 31: Val id p ro mi cro sw i tch o f typ e M 1S 6610.

1 It h li mit er
2 Pressure rel ief f lap

F i g u re 29: Val id fo r mi cro sw itch o f typ e L XW 37.

25
5. Dispatch and storage
5.1 Condition on delivery
At the time of dispatch, the UniGear panels are factory
assembled, the withdrawable parts are in the test
position and the doors are closed. The factory-
assembled panels are checked for completeness in
terms of the order and simultaneously subjected to
routine testing (normally without AC voltage testing of
the busbars) to IEC publication 62271 -200, and are
therefore tested for correct structure and function. T he
busbars are not assembled. The busbar material,
fasteners and accessories are packed separately.

5.2 Packing
Available packing methods:
F i g u re 32: Han d li n g b y cran e .
Polythene foil - storage time 1/2 year in clean and
dry environment.
OSB boards - storage time 1/2 year in outdoor
environment according to IEC.
W ood boxes - storage time 1 year in outdoor 5.4 Delivery
environment according to IEC.
The responsibilities of the customer when the
According to the kind of transport and country of switchgear arrives at site include, but are not limited
destination, the panels remain unpacked or are to, the following:
packed in seaworthy crates. A drying agent is
provided to protect them against moisture: Checking the delivery for completeness and
damage (e.g. also for moisture and its detrimental
Panels with basic packing or without packing. effects). In case of doubt, the packing m ust be
Panels with seaworthy or similar packing (including opened and then properly resealed, inserting new
packing for containerised shipments): drying agent bags, when intermediate storage is
-Sealed in polyethylene sheeting. necessary.
-Transport drying agent bags included. If any quantities are short, or defects or transport
damage are noted, these must be documented on
the respective shipping document and notif ied to
the relevant carrier or forwarding agent
immediately in accordance with the relative liability
regulations.
5.3 Transport
The transport units normally comprise individual Note:
panels and, in exceptional cases, small groups of Always take photographs to document any major
panels. The panels are each fitted with four lifting damage.
eyebolts.
Transport panels upright. Take the high centre of
gravity into account. Only ever carry out loading
operations 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 j ack

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
Suspend the unit using ALL four eyebolts!

For detailed information on switchgear handling,

please refer to (chapter 5.6).

26
5.5 Intermediate storage
Optimum intermediate storage, where this is -Lift the cubicles by the crane following the
necessary, without any negative consequences instructions below.
depends on compliance with a number of minimum -Remove the pallet.
conditions for the panels and assembly materials. -Position the unloading shims.
-Put the switchgear on the loading shims using the
1. Panels with basic packing or without packing: crane.
A dry well-ventilated store room with a climate in After unpacking, lift the panel groups by crane (Figure
accordance with IEC 62271-1. 32). Use the eyebolts and the safety ropes.
The room temperature must not fall below 5 C. After installation of the panels, remove the eyebolts
There must not be any other negative used for lifting.
environmental influences.
Store the panels upright and do not stack panels.
Panels with basic packing - Open the packing, at
least partially. W ARNING
Panels without packing
- loosely cover with protective sheeting. Only use a suitable balanced lifting system.
- ensure that there is sufficient air circulation. Should an accidental fault cause a leakage of
Check regularly for any condensation until SF6, ventilate the room and carefully follow the
installation is started. safety procedures prescribed in the IEC 1634
Standards.
2. Panels with seaworthy or similar packing with
internal protective sheeting:
Store the transport panels:
- protected from the weather.
- in a dry place.
- safe from any damage.
Check the packing for damage.
Check the drying agent (chapter 5.2).
- on arrival of the delivery.
- subsequently at regular intervals.
W hen the maximum storage period, starting from
the date of packing, has been exceeded:
- the protective function of the packing can no
longer be guaranteed.
- take suitable action if intermediate storage is to
continue.

W ARNING
Do not w alk on the roof of the panels (rupture
points in pressure relief devices!). The pressure
relief devices and/or Ith Limiters could be
damaged.

5.6 Handling
5.6.1 Sw itchgear
The switchgear sections are usually fixed to wooden
pallets. Handling should be carried out by overhead or
mobile cranes. Otherwise, use rollers or fork lift
trucks. W eights and dimensions of each section are
listed in the shipping documents and in the plant F i g u re 33: Han d li n g th e sw i tch g ear i n th e w oo d en crate.
drawings.
5.6.1.1 Handling w ith overhead crane or mobile
crane and unpacking - Handling the sw itchgear in
the w ood packing.
The switchgear must be lifted by crane and circular
slings. The slings must be inserted according to the
lifting symbols marked on the crate. W eight and lifting
opening angle must be taken into account when
choosing the circular slings.

Unpacking
-Remove the nails and crate lid and sides.
-Open the compartment door and loosen the bolts
fixing the switchgear to the pallet.

27
5.6.1.2 Handling by rollers 5.6.1.3 Handling by transpallet or fork lift trucks
Lift the switchgear section by overhead or mobile To guarantee stability, the switchgear must not be
crane or using jacks; remove the wooden pallet lifted too high. Check the alignment of the forks.
loosening the screws fixing it to the switchgear
section base. Put a sturdy metal sheet between the
rollers and the panel base and place the switchgear
on the sliding rollers.

W ARNING W ARNING
Only use rollers on a level floor. Move the Only use transpallets or fork lift trucks on a level
sw itchgear section avoiding any possible tilting. floor. Move the sw itchgear section avoiding any
tilting.

F i g u re 34: Han d li n g b y ro l l ers. F i g u re 35: Sw itch i ng h and l ing .

1 Slidi ng rol lers

2 Met a l sheet

5.6.2 Apparatus
The apparatus can be handled by cranes, fork lift
trucks or using the truck provided by ABB. For each
piece of apparatus follow the instructions below.

W ARNING
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
F i g u re 36: Li fti ng sw i tchg ear p acked i n a w oo d en crate.
open position.

28
5.6.2.1 Handling by crane
Circuit-breaker
Hook the lifting bolts to the relevant supports (Figure
37). W hile handling, pay the utmost attention not to
put any stress on the insulating parts or on the circuit -
breaker terminals (Figure 38). Before putting into
service, remove all the lifting eyebolts.

Contactor
To lift the contactor use removable support shown on
(Figure 39).

F i g u re 37: Co rrect h an d l in g .
F i g u re 39: M ou n tin g th e l iftin g eq ui p men t.

5.6.2.2 Handling by fork-lift trucks

Handling by fork-lift trucks can be carried out only
after the apparatus has been positioned on a sturdy
support. W hile handling, pay the utmost attention not
to put any stress on the insulating parts or on the
circuit-breaker terminals.

W ARNING
Do not insert the truck forks straight underneath
the apparatus but put the apparatus on a sturdy
support.

F i g u re 38: W ron g h an d li n g.

F i g u re 40: Han d li n g b y fo rk - l i ft tru cks.

29
5.6.2.3 Handling by service truck Further w arnings
For handling and inserting the apparatus into the W hen moving the switchgear on cylinders always put
switchgear, use the service truck (Figure 43). the cylinders collinear (in parallel) with the front side
of the switchgear and always keep the switchgear in
In order to handle the circuit -breaker with the relevant the vertical position!
truck, follow the instructions below.
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 insert the horizontal check pins (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 (**) Do not try to open the cable or the circuit -breaker
outwards and the horizontal locking pins go into compartment doors, close the earthing switch or
the slots (4), locking the circuit-breaker. withdraw the circuit breaker if an auxiliary voltage is
not connected to the switchgear! Do not s tep on the
pressure relief flaps!

W ARNING
Do not use the service truck for any purpose
other than handling ABBs apparatus.
Fix the circuit -breaker to the truck before
moving it.

F i g u re 44: (*) Han d li n g d i recti o n fo r h o ri zo n tal l o cki n g p in

en tr y, (**) Han d l i n g d i recti o n fo r exi t o f th e h o ri zon tal
l o cki n g p i n s.

F i g u re 43: Servi ce tru ck.

30
6. Assembly of the switchgear at site
To carry out the 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 people.
In case higher IP is needed please follow the
instructions described in manual 1VLG100101 -
available on request.
2. Further structural data guidelines given provide a
rough calculation of the space required a nd the
plan for designing the room for a switchgear
project.
If seismic resistance is not required, it is not
necessary to attach each switchgear panel to the floor
or frame, but it suffices to fix outside panels in each
row of switchgear only.

If seismic resistance is required, it is necessary to

6.1 General attach each switchgear panel to the floor or frame. To
achieve seismic resistance the special fixing system is
On commencement of installation on site, the switch -
used. This system preferably uses a steel floor frame
room must be completely finished, provided with
with C profile shape but moreover wit h an addition
lighting and the electricity supply, lockable, dry and
special fixing element please contact ABB for
with facilities for ventilation. All the necessary
details.
preparations, such as wall openings, ducts, etc., for
laying the power and control cables up to the
W hen the final building construction documents are
switchgear must already be complete. W here
drawn up, the binding data supplied by ABB for a
switchgear panels have top -mounted structures for
particular case must always be taken into account!
earthing switches or instrument transformers, it must
be ensured that the ceiling height is sufficient for the
opening travel of the pressure relief plates. The
Di men si o n ch art o f stru ctu ral d ata - p an el s 12 / 17. 5 kV
ceiling must be high enough to allow the assembly of
Panel w idt h F T [ mm] 650 800 1000
the pressure relief duct and/or top mouted VT box and
earting switch box. See table in (chapter 6.7). Aisle wi dt h G ( 1 ) [ mm] 1450 1600 1800
Compliance with the cond itions for indoor switchgear Swit chge ar roo m do or widt h [ mm] 850 1000 1200
according to IEC 62271-1, including the conditions for Swit chge ar roo m do or
[ mm] 2400 2400 2400
heig ht ( 2 )
the indoor temperature class must be ensured.

O penin g in ce iln ing if t ransp ort ed t hrou gh roof :

W idt h [ mm] 1000 1000 1200
6.2 Foundations Lengt h [ mm] 1500 1500 1500
Ceil ing l oa d ( 3 ) [ k g/ m2] 1200 1400 1400
The following three basic methods of installing
switchgear in the switchroom are identified:
Di men si o n ch art o f stru ctu ral d ata - p an el s 24kV
Panel w idt h F T [ mm] 800 1000
Method A installation on C profile for concrete
Aisle wi dt h G ( 1 ) [ mm] 1600 1800
floor
Swit chge ar roo m do or widt h [ mm] 1000 1200
As standard, it is recommended to install the
switchgear on C profile base irons set into the Swit chge ar roo m do or he ight ( 2 ) [ mm] 2525 2525
concrete floor of the switchroom. In this case, the
panels are fastened using the special bolt blocks (ABB O penin g in ce iln ing if t ransp ort ed t hrou gh roof :
deliv ers these on request). W idt h [ mm] 1000 1200
Lengt h [ mm] 1800 1800
Method B installation on anchoring bolts Ceil ing l oa d ( 3 ) [ k g/ m2] 900 850
Installation directly on the levelled concrete floor ( 1 ) P a y a t t e nt i o n t o a p pr o pr i a t e na t i o na l s t a nd a r d s .
makes much higher demands on the floor levelling, ( 2 ) A pp l i e s t o l o w v o l t a ge c o m pa r t m e n t s o f s t a nd a r d he i g ht .
which must, in this case, fulfil the same tolerances as
( 3 ) A pp r o x i m a t e n um be r s d e pe nd i n g o n t he t y pe o f pa ne l s .
the base irons during me thod A installation. Fastening
is carried out by anchoring bolts in the concrete floor.

Method C installation on bolts for raised floor

In this case, fastening of the panels is carried out by
welding outside panels to the steel floor frame in the
places where the frame is larger than the base of the
switchgear, i.e. on the outside lateral walls of the
panel row. This method of installation is not
recommended if seismic resistance is required.

Generally, the following procedure for switchgear

anchoring can be recommended for any of the
installation methods mentioned:

1. The switchgear panels are bolted together in the

front and rear part to make one unit.

31
6.2.1 Method of installation A Installation on C Attachment of the panels to the C" shape base
profile for concrete floor irons
The general foundation drawing is given in following The switchgear is attached to the base irons by
figures according to the parameters of the panels. special bolt blocks, which can be supplied on request.
The C" shaped base irons can be supplied by ABB Place the individual panels of the switchgear in
together with the switchgear. Their installation is sequence onto correctly levelled and installed
usually carried out by personnel on site and base irons and level them according to the
should, if possible, be performed under relevant foundation drawings.
supervision of an ABB specialist. The base irons Level the panels and then bolt them together in the
must be installed in the slab before finishing the front and rear part.
floor To attach them to the base irons, insert specially
Rest the irons in the specified position on the prepared bolt blocks in the fixing holes in the
concrete floor as shown in the relevant foundation bottom of the panels and tighten them.
drawing and mark out the places for drilling the
holes. Then drill the holes for anchoring bolts, i.e.
for plugs for fixing the base irons in the floor. Then
put the plugs in the holes and attach the base
irons to the floor loosely with bolts, without final
tightening so that any required levelling is
possible.
Carefully level the base irons both longitudinall y
and transversally over the entire length and to t he
correct height by putting strips of suitable
thickness under them and using a levelling
instrument.

Tolerances for laying the floor frame are:

- Evenness tolerance 1 mm over a measuring length
of 1 m
- Straightness tolerance 1 mm per 1m, but not more
than 3 mm over the entire length of the frame.
After levelling the base irons, tighten bolts 13. The
adjusted position of the base irons on the concrete F i g u re 45: Fi xi n g to th e fl oo r - M eth o d A - I n stal l ati on on C
floor must not be changed during this operation! p ro fi l e fo r con rete fl o o r.
Check again and, if necessary, correct an y
dev iations.
W eld Individual parts of the base irons together
inside the C" profile at the seams so that there is
a mutual conductive connection.
Take any necessary measures for perfect earthing
of the base irons with galvanized steel strips with
minimum dimensions of 30 x 4 mm. Two earthing
connections are recommended for a panel ro w
longer than approx. 5 panels.
W hen the floor top covering is applied, carefully
backfill the floor frame, leaving no gaps. The top
edge of the floor frame should be 2 mm above th e
finished floor surface; the tolerance of this value is
within the limits of 0 to 5 mm. This facilitates
erection and alignment of the switchgear panels. In
some cases, this means that the material thickness
of an additional floor covering to be fitted la ter
must be taken into account separately.
The base irons must not be subjected to any
harmful impact or pressure, particularly during the
installation phase. If these conditions are not
respected, problems during assembly of the
switchgear and possibly wi th movement of the
withdrawable parts, as well as opening and closing
of the doors cannot be ruled out.

32
6.2.2 Method of installation B Installation on
anchoring bolts
The general foundation drawing is given in following
according to the parameters of the units.
Clean the switchgear installation area carefully
On the slab, v isibly 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 over a
measuring length of 1 m
Drill the floor at the intended fixing points,
referring to the slab drilling drawings. To make the
holes, use a hammer drill with a 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 to
create 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 on request)
In the case of a metal floor, use the attachment
according to the figure. To make the holes, use a
drill with a suitable bit for the type of fixing to be
made (through or threaded hole)
F i g u re 46: Fi xi n g to th e fl oo r - M eth o d B - I n stal l ati on on
an ch o ri n g b o l ts.
6.2.3 Method of installation C Installation on
bolts for raised floor
The general foundation drawing is given in (Figure 48)
- (Figure 72) according to the parameters of the
panels. In most cases, the floating floor is created by
a steel structure in which the welded steel frame is
installed. A frame produced using suitable steel
profiles is used. ABB does not supply this frame.
- Evenness tolerance 1 mm over a measuring length
of 1 m.
- Straightness tolerance 1 mm per 1 m.
Clean the installation area.
After installation of the frame, take any necessar y
measures for perfect earthing of the frame with
galvanized steel strips with min. dimensions 30 x
4mm. Two earthing connections are recommended
for a panel row longer than approx . 5 panels.
Place the panels on the frame according to the
relevant foundation drawings, taking the minimum
wall and obstacle clearances into account.
Level the panels and then bolt them together in the
front and rear part.
Carry out attachment by welding the outside
panels to the steel floor frame in the place where
the frame juts out from the switchgear bottom, i.e.
on the outside lateral walls of the unit row. This
method of installation is not recommended if
seismic resistance is required.
In the case of a metal floor, use attachment
according to the figure. To make the holes, use a
drill with a suitable bit for the type of fixing to be
made (through or threaded hole).
F i g u re 47: Fi xi n g to th e fl oo r - M eth o d C - I n stal l ati on on
b o l ts fo r rai sed flo o r.
33
F i g u re 48: Un iG ear 12 / 17. 5 kV u p to th e no mi n al cu rren t o f T - offs 2500 A. G u i d el in e stru ctu ral d ata fo r fo u nd ati o n frame
o n co n crete fl o o r. I t i s n o t val i d fo r th e p an el w i th sw i tch -d i sco n n ecto r.
C T ypical pa ne l dept h C = 13 40 mm ho wev er alwa ys co nsi der annot a t io n 2)
G W idt h of operat ing ais le
FT Panel w idt h
TB Door wi dt h = FT + 200 mm
TH Door he ight = pa nel h eig ht + 200 mm

1 Rear cov er
2 Door
3 Side en d cov er
4 Screw
5 St eel dow el

1) Mi ni mu m d i mens ions; rec o mme nded s pace 5 00 mm.

2) Di mens ion must b e v erif ied in d ocu ment at i on of t he rel ev ant order.

34
F i g u re 49: Un iG ear 12 / 17. 5 kV fo r th e n o min al cu rren t o f T - o ffs 3150 / 4000 A an d / o r 50 k A. G u i d el i n e stru ctu ral d ata fo r
fo u n d atio n frame o n co n crete fl o o r. I t i s n o t val i d fo r th e pan el w i th sw i tch - di sco n n ector.
C T ypical pa ne l dept h C = 13 90 mm ho wev er alwa ys co nsi der annot at i on 2)
G W idt h of operat ing ais le
FT Panel w idt h
TB Door wi dt h = FT + 200 mm
TH Door he ight = pa nel h eig ht + 200 mm

1 Rear cov er
2 Door
3 Side en d cov er
4 Screw
5 St eel dow el

1) Mi ni mu m d i mens ions; rec o mme nded s pace 5 00 mm.

2) Di mens ion must b e v erif ied in d ocu ment at i on of t he rel ev ant order.

35
F i g u re 50: Un iG ear 24 kV. G u i d el i n e stru ctu ral d ata fo r fo un d ati o n frame o n co n crete fl oo r I t i s n o t val id fo r th e p an el
w ith sw itch - d i sco nn ecto r.
C T ypical pa ne l dept h C = 17 00 mm (F or short - t i me curre nt up t o 25 k A, 1560 mm de pt h v ersion is av ailab le)
- howev er alwa ys co nsid er an n ot at ion 2)
G W idt h of operat ing ais le (chapter 6.2)
FT Panel w idt h (chapter 6.2)
TB Door wi dt h = FT + 200 mm
TH Door he ight = pa nel h eig ht + 200 mm

1 Rear cov er
2 Door
3 Side en d cov er
4 Screw
5 St eel dow el

1) Mi ni mu m d i mens ions; rec o mme nded s pace 5 00 mm.

2) Di mens ion must b e v erif ied in d ocu ment at i on of t he rel ev ant o rder.

36
F i g u re 51: Un iG ear 12 / 17. 5 kV w i th NAL sw i tch - d i sco nn ecto r. G u id el i n e stru ctu ral d ata fo r fo u nd ati o n frame o n con crete
fl o o r.
C T ypical pa ne l dept h C = 13 40 mm ho wev er alwa ys co nsi der annot at i on 2)
G W idt h of operat ing ais le
FT Panel w idt h
TB Door wi dt h = FT + 200 mm
TH Door he ight = pa nel h eig ht + 200 mm

1 Rear cov er
2 Door
3 Side en d cov er
4 Screw
5 St eel dow el

1) Mi ni mu m d i mens ions; rec o mme nded s pace 5 00 mm.

2) Di mens ion must b e v erif ed in d ocu ment at i on of t he rel ev ant order.

37
F i g u re 52: Un iG ear 24 kV w i th N AL sw i tch -di sco n n ecto r. G u i d eli n e stru ctu ral d ata fo r fo u n d atio n frame o n co n crete fl o o r.
C T ypical pa ne l dept h C = 17 00 mm ho wev er alwa ys co nsi der annot at i on 2)
G W idt h of operat ing ais le (chapter 6.2)
FT Panel w idt h (chapter 6.2)
TB Door wi dt h = FT + 200 mm
TH Door he igh = p ane l hei ght + 20 0 mm

1 Rear cov er
2 Door
3 Side en d cov er
4 Screw
5 St eel dow el

1) Mi ni mu m d i mens ions; rec o mme nd ed s pace 5 00 mm.

2) Di mens ion must b e v erif ied in d ocu ment at i on of t he rel ev ant order.

38
F i g u re 53: Examp l e o f 12 / 17. 5 kV sw i tch g ear fo r 2500 A o n fo un d ati on frame o n co n crete fl o o r. Pan el w i th examp l es o f
g as d u ct i n clu d in g chi mn eys o r p ressu re r el i ef to th e o u tsid e.
A T ypical pa ne l dept h A = 134 0 mm ho wev er alwa ys co nsi der annot at i on 2)

1) Mi ni mu m d i mens ions; rec o mme nded s pace 5 00 mm

2) Di mens ion must b e v erif ied acc ordin g t o docu ment at io n of t he relev ant order

F i g u re 54: Examp l e o f 12 / 17. 5 kV sw i tch g ear fo r 3150 / 40 00 A o n fo u n d ati on frame o n co n crete fl o o r. Pan el w ith
examp l es o f g as d u ct i n cl ud in g ch i mn eys o r p ressu r e rel i ef to th e ou tsi d e.
B T ypical pa ne l dept h B = 134 0 mm ho wev er alwa ys o nsi der annot a t ion 2)

1) Mi ni mu m d i mens ions; rec o mme nded s pace 5 00 mm

2) Di mens ion must b e v erif ied acc ordin g t o docu ment at io n of t he relev ant order

39
F i g u re 55: Examp l e o f 12 / 17. 5 kV, 40 / 50 k A sw i tchg ear o n fo un d ati on frame o n co n crete fl o o r. Pan el w i th examp l es o f
g as d u ct i n clu d in g chi mn eys o r p ressu re r el i ef to th e o u tsid e.
C T ypical pa ne l dept h C = 13 90 mm ho wev er alwa ys co nsi der annot at i on 2).

1) Mi ni mu m d i mens ions; rec o mme nded s pace 5 00 mm.

2) Di mens ion must b e v erif ied acc ordin g t o docu ment at io n of t he relev ant order.

F i g u re 56: Examp l e o f 24 kV, 25 k A sw i tch g ear o n fo un d ati o n frame o n con crete fl o o r. Pan el w i th examp l es o f g as du ct
i n cl u di n g ch i mn eys o r p res su re rel i ef to th e o u tsid e.
D T ypical pa ne l dept h D = 15 60 mm ho wev er alwa ys c o nsi der annot at i on 2).

1) Mi ni mu m d i mens ions; rec o mme nded s pace 5 00 mm.

2) Di mens ion must b e v erif ied acc ordin g t o docu ment at io n of t he relev ant order.

40
F i g u re 57: Examp l e o f 24 kV, 31. 5 k A sw i tch g ear o n fo un dati o n frame o n co n crete fl o o r. Pan el w ith examp l es o f g as d u ct
i n cl u di n g ch i mn eys o r p res su re rel i ef to th e o u tsid e.
E T ypical pa ne l dept h E = 170 0 mm (F or short -t i me curre nt up t o 25 k A a 1560 mm d ept h v ersion is av aila ble)
howev er alw a ys cons ider a nn ot at ion 2).

1) Mi ni mu m d i mens io ns; rec o mme nded s pace 5 00 mm.

2) Di mens ion must b e v erif ied acc ordin g t o docu ment at io n of t he relev ant order.

41
F i g u re 58: Gu i d eli n e stru ctu ral d ata fo r a rai sed fal se fl o or.
A Larger d i mens io n is v alid f or t he cubicl e wit h circu it break er HD4 incl udi ng co mbin at ion w it h t he m,
in ot her cas es small er di me nsi ons are v alid h owev er alw a ys consider a nn ot at ion 2).
G W idt h of operat ing ais le
FT Panel w idt h
TB Door wi dt h = FT + 200 mm
TH Door he ight = pa nel h eig ht + 200 mm

1) Mi n. di mens io ns.
x) Max. di mensi ons.
2) Di mens ion must b e v erif ied in d ocu ment at i on of t he rel ev ant order.
3) In case of re ar access or ins pe ct ion win dow o n t he rear cov er mi n. reco mmen de d dist anc e f rom t he wa ll is 50 0 mm.

Stru ctu ral d ata fo r a rai sed fal se fl o o r

Un [kV] Pan el d ep th A2) B C 1)
12 / 17. 5 up t o 250 0 A 1340 / 13 00 1235 135
12 / 17. 5 - 3150 / 400 0 A 1390 / 13 50 1235 185
12 / 17. 5 - 40 / 50 k A 1390 1235 185
24 1700 / 15 60 / 1520 1590 / 14 50 140

42
F i g u re 59: 12 / 17. 5 kV u p to 40 k A 6 50 / 800 / 1000 mm w id e p an el s A) An ch o ri n g bo l ts B) C p ro fi l e fo r con crete fl o o r.

An ch o ri n g b o l ts fi xi n g syst e m
F T w id th [mm] A [m m] B [mm]
650 440 450
800 590 600
1000 790 800

F i g u re 60: 12 / 17. 5 kV, 50 k A, 1250 - 2 000 A, 80 0 mm w i d e pan el s - A) An ch o ri n g b ol ts B) C p ro fi l e fo r con crete fl o o r.

43
F i g u re 61: 12 / 17. 5 kV, 50 k A, 2500 - 3 600 A, 10 00 mm w i d e p an el s - A) An ch o ri n g bo l ts B) C p ro fi l e fo r co n crete fl o o r.

F i g u re 62: 12 / 17. 5 kV, 50 k A, 4000 A, 1 00 0 mm w i d e p an els - A) An ch o ri n g bo l ts B) C p ro fi l e fo r con crete fl o o r.

44
F i g u re 63: 24 kV, 25 k A, 80 0 mm w id e p an el s - A) An ch o ri n g bo l ts B) C p ro fi l e fo r co n crete fl o o r.

F i g u re 64: 24 kV, 25 k A, 10 00 mm w i d e p an el s - A) An ch o ri n g bo l ts B) C p ro fi l e fo r co n crete fl o o r.

45
F i g u re 65: 24 kV, 31. 5 k A 8 00 mm w i d e p an el s - A) An ch o ri n g b o l ts B) C p ro fil e fo r con crete fl o o r.

F i g u re 66: 24 kV, 31. 5 k A 1 000 mm w i d e p an el s - A) An c h o ri n g b ol ts B) C p ro fi l e fo r co n crete fl o o r.

46
F i g u re 67: 12 / 17. 5 kV cu b i cle w i th sw itch - d i sco nn ecto r - A) An ch o ri n g b o lts B) C p ro fil e fo r co n crete fl o o r.

F i g u re 68: 24 kV cu b i cl e w ith Sw i tch -d i sco n n ecto r - A) An ch o ri n g b ol ts B) C p ro fi l e for co n crete f l o o r.

47
F i g u re 69: An ch o ri n g b o l ts F i g u re 70: C p ro fi l e fo r con crete fl o o r

F i g u re 71: Th ro u gh ho l e on metal stru ctu re. F i g u re 72: Th read ed h o l e o n metal stru ctu re.

48
6.3 Assembly of the switchgear panels
Use screws of tensile class 8.8. The maximum Any tightening torques that deviate from those in the
recommended tightening torques based on each type general tables (e.g. for contact systems or device
of connection are given in the following tables: terminals) must be taken into account as stated in
the detailed technical documentation.
It is recommended that the threads and head contact
T i g h teni n g to rqu es fo r co p p er b ars o r co mb i n ed bu sb ar surfaces of bolts should be lightly oiled or greased to
co n n ecti o n s achieve the precise tightening torque (column Oil or
M ax. reco mmen d ed ti g h teni ng to rq u e Nm ( 1 ) grease in table).
T h read ( 2 )
W it hout (=0. 14) O il of grease (= 0. 10)
M5 ( 3 ) 2. 5 - The preparation work for installation is as follows:
M6 ( 3 ) 10 8
Remove withdrawable parts 1 (Figure 145) from
M8 25 20
the switchgear panels and store them with
M1 0 50 40
suitable protection.
M1 2 85 69
Dismantle lifting eyebolts.
M1 6 200 170
Transport the switchgear panels to the prepared
installation point following the sequence shown on
T i g h t. to rqu es fo r co p p er b ar co n n ecti o n s co mb in ed w ith
the switchgear plan.
ep o xy i n su l ato rs
M ax. reco mmen d ed ti g h teni ng to rq u e Nm ( 1 )
Remove covers 2 and 4 (Figure 73) from the
T h read ( 2 ) vertical control wiring ducts at the front left of the
W it hout (=0. 14) O il of grease (= 0. 10)
panel.
M8 15 12
M1 0 32 26
M1 2 45 36
M1 6 110 90
M2 0 220 180

T i g h t. to rqu es fo r co p p er b ar co n n ecti o n s co mb in ed w ith

AB B CT s
M ax. reco mmen d ed ti g h teni ng to rq u e Nm ( 1 )
T h read ( 2 )
W it hout (=0. 14) O il of grease (= 0. 10)
M1 2 70 57

T i g h t. to rqu es fo r co p p er b ar o r cab l e co n n ecti o n s

co mb i n ed w ith AB B VT s
M ax. reco mmen d ed ti g h teni ng to rq u e Nm ( 1 )
T h read ( 2 )
W it hout (=0. 14) O il of grease (= 0. 10)
M1 0 20 16

T i g h teni n g to rqu es fo r co p p er co n tact p i n s in si d e ep o xy

sp o u t
M ax. reco mmen d ed ti g h teni ng to rq u e Nm ( 1 )
T h read ( 2 )
W it hout (=0. 14) O il of grease (= 0. 10)
M1 0 46 37
M2 0 250 200
N o t e : T h r e a d a nd he a d c o n t a c t s u r f a c e l u br i c a t e d . [ / I nd e x V a l ue ]
( 1 ) T he r e c o m m e nd e d m a x i m um t i g ht e n i n g t o r q ue s a r e ba s e d o n a
c o e f f i c i e nt o f f r i c t i o n f o r t he t hr e a d o f 0 . 1 4 ( w i t ho u t l u br i c a t i o n ) o r
0 . 1 0 ( w i t h l u b r i c a t i o n) .
( 2 ) T he t i g ht e n i n g t o r que s a r e r e c o m m e nd e d f o r s c r e w s IS O 4 0 1 4 -
4 0 1 8 a nd IS O 4 7 6 2 ( t e ns i l e c l a s s 8 . 8 ) . If us i n g o t he r t y pe s o f s c r e w s
pl e a s e c o nt a c t A B B f o r c l a r i f i c a t i o n .
( 3 ) A pp l i c a b l e o n l y f o r f i x i n g o f s u b s i d i a r y c o v e r s o r t e r m i na l
c o n ne c t i o ns .
F i g u re 73: Vi ew i n to th e h i gh vo l tag e area at th e fro n t.
1 Block ing ad just ab le pi n
2 Duct cov er f or ext ernal cont rol cables
3 Hori zo nt al part it i on, re mov abl e
4 Duct cov er f or ext ernal cont rol cables

49
6.4 Procedure for setting-up the doors
Instructions from the standpoint of the safety at work:
The relevant work and adjustments must be carried
out by trained specia lists familiar with the installation,
taking into account all relevant safety regulations
according to IEC and other relevant professional
bodies, and other local and works regulations and
instructions.
The switchgear doors are always mounted and set up
at the factory. It is always necessary to reset these
doors on site and to do this before commissioning the
switchgear. During setting -up, the switching station
must be connected to the control voltage, otherwise it
will not be possible to operate the with drawable part
with circuit-breaker / contactor and earthing switch.
The working method:
a) The circuit-breaker compartment door:
Loosen (but do not dismantle) 2 lock screws M6
(Figure 74) on the lateral side of the door - this
releases the blocking stop and it is possible to
open the door.
W ithdraw the withdrawable part with circuit -
breaker / contactor from the circuit-breaker
compartment onto the service truck and move it
outside of the switchgear.
Dismount the left lateral co ver of the control
cables (Figure 75).
W ithdraw the left lateral cover of the control cables
from the circuit-breaker compartment outside of
the switchgear (Figure 76).
Loosen (but do not dismantle) all M 8 screws at all
hinges (Figure 77).
The setting-up of the door position is based on
rotating the door in the opening on an axis of the
middle hinge (the second hinge from the bottom
edge of door in the case of a door with 4 hinges ).
Set up the door in the position in which its upper
edge is parallel with the gap between the circuit -
breaker compartment and the low voltage
compartment (Figure 78).
Tighten the upper hinge and check the correct
function of the door including the insertion of
blocking lever in the door slot with the blocking
stop.
If the door closes correctly, tighten all screws at
all hinges to a torque of 20 Nm.
Set up the blocking s top so that its lower edge is
in the range of 29.8 -30.3 mm above the level of
the lower edge of the slot in the door draw bar
when the door handle is in the closed position
(Figure 79) (Figure 80). The required position of
the stop can be set up by insertion of the jig
OCA0071, drw.No. 1VL7611226P0101.
Check that the door closes correctly.
50
Mount the left lateral cover of the control cables.
The screw tightening torque must not exceed 2,5
Nm.
Insert the withdrawable part with circuit -breaker /
contactor in the circuit-breaker compartment and
leave in the test / disconnected position.
Close the door and verify the door blocking
function by operation with the withdrawable part.
b) The cable compartment door:
Loosen (but do not dismantle) 2 M6 lock screws
(Figure 74) on the lateral side of the door - this
releases the blocking stop and it is possible to
open the door.
W ithdraw the withdrawable part with m easuring
voltage transformers (if the switchgear is equipped
with them) from the cable compartment outside of
the switchgear (Figure 81).
Dismount the left lateral cover of the control
cables (Figure 82).
W ithdraw the left lateral cover of the control cables
from the cable compartment outside of the
switchgear (Figure 84).
Loosen (but do not dismantle) all M8 screws at all
hinges (Figure 77).
The setting up of the door position is based on
rotating the door in the opening on an axis of the
middle hinge (the second hinge from the bottom
edge of door in the case of a door with 4 hinges).
Set up the door in the position in which its upper
edge of door will be parallel with the upper edge of
the separating cover (Figure 83).
Tighten the upper hinge and check the correct
door function including the insertion of the
blocking lever in the door slot with the blocking
stop.
If the door closes correctly, tighten all screws at
all hinges to a torque of 20 Nm.
Set up the blocking stop so that its lower edge is
in the range of 29.8 -30.3 mm above the level of
the lower edge of the slot in the door draw bar
when the door handle is closed (Figure 79),
(Figure 80). The required stop position can be set
up by insertion of the jig OCA0071, drw.No.
1VL7611226P0101.
Check that the door closes correctly.
Mount the left lateral cover of the control cables .
The screw tightening torque must not exceed 2.5
Nm.
Insert the withdrawable part with measuring
voltage transformers (if the switchgear is equipped
with them) in the cable compartment.
Close the door and verify the door blocking
function by operation wit h the earthing switch.
F i g u re 74: Screw s on l ateral si d e o f do o r. F i g u re 76: CB co mp artmen t w ith ou t l ateral co ver.

F i g u re 75: L ateral co ver o f co n tro l cab l es. F i g u re 77: M 8 screw s.

51
F i g u re 78: Co rrect p o si ti on of CB co mp artmen t d o o r. F i g u re 80: Setti ng up ri gh t po si ti o n.

F i g u re 79: Setti ng up ri gh t po si ti o n. F i g u re 81: Wi th d raw ab l e p art w i th measu ri n g vo l tag e

tran sfo rme rs.

52
F i g u re 82: L ateral co ver o f co n tro l cab l es in cab l e F i g u re 84: Cab l e co mp artmen t w i th o ut l ateral co ver.
co mp artmen t.

F i g u re 83: Co rrect p o si ti on of cab l e co mp artmen t d o o r.

53
6.5 Installation of the bushing
Before fixing the panels side by side (according to the
general drawings) bushings (12 24 kV) must be fixed
(for switchgear with busbar partitioning only).
6.5.1 Bushing of 12 / 17.5 kV panels
Lower bus-tie system
Insert bushing 1 for the lower rear bus -tie into bushing
plate 5 from the right side in contrast to the procedure
for the other two bushings.
6.5.2 Bushing of 24 kV panels
Assembly procedure for bushings main (upper)
busbar system:
Insert bushing 1 for the lower busbar into bushing
plate 5 from the right side, and for the middle and
upper busbar from the left side.
Lower bus-tie system:
Insert bushing 1 for the lower rear bus -tie into bushing
plate 5 from the right side in contrast to the procedure
for the other two bushings.

F i g u re 87: 24 kV p an el - fi xi ng b u shi n g s.
1 nr. 1 bushi ng
2 nr. 8 10x25 screws
3 nr. 8 M10 w asher
5 nr. 12 M1 0 nut
6 nr. 1 bushi ng pl at e

F i g u re 85: 12 / 17. 5 kV p an els - fi xi n g b u shi n g s.

1 nr. 1 bushi ng
2 nr. 8 8x30 scre ws
3 nr. 8 M8 was her
4 nr. 3 Rubber p art it io n (busb ar support )

F i g u re 88: 24 kV p an el - fi xi ng b u shi n g s.
1 nr. 1 bushi ng
2 nr. 8 10x25 screws
3 nr. 8 M10 w asher
4 nr. 3 Rubber p art it io n (busb ar support )
5 nr. 12 M1 0 nut
6 nr. 1 bushi ng p l at e

F i g u re 86: 12 / 17. 5 kV p an l els - fi xi n g b u shi n g s.

1 nr. 1 bushi ng
2 nr. 8 8x30 screws
3 nr. 8 M8 was her
4 nr. 3 Rubber p art it io n (busb ar support )
5 nr. 12 M8 n ut
6 nr. 1 bushi ng pl at e

54
6.6 Fixing of the panels

W ARNING
Before fixing the panels side by side be sure that
the bushings are fixed according to (chapter 6.5).

Fit and screw down the side covers.

Align the switchgear panels on the floor frame for
correct positioning and vertical alignment (deviations
of the panel edges from the vertical must not exceed 2
mm, especially at the front) and bolt the panels
together (Figure 89). It is advisable to start from the
centre when assembling switchgear with more than 10
panels.

The junction points where the panels should be fix are

as follows:
Nr.6 in the front side
Nr.4 in the middle part
Nr.5 in the rear side

The nuts are already fixed on the right side of the

panel (except in the middle part); on the left side there
is the an empty space where the screws are to be
fixed. The screws needed are:
10 x 30 screws (complete with M10 washer)

F i g u re 89: Vi ew o f th e fi xi ng p o i n ts.

55
6.7 Installation of the busbars
6.7.1 Preparation of the material
Clean the insulation on the busbar sections with a
soft, dry cloth, and check for any insulation
damage. Remove greasy or adhesive dirt.
Busbar connections:
The silver-plated surfaces of the connections
must be cleaned with a metal -free non-woven
cleaning cloth and thinly and evenly coated with
SYN-setral-EK 339 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 coat of SYN-setral-EK 339
Prepare insulating covers 2 (Figure 90) and lids 3
to suit the relevant busbar connections and pull
them on the busbar. (For insulated busbars only)

F i g u re 90: 12 / 17. 5 kV p an els, i n stal ati o n o f th e b u sb ars. T h e l ow er p i ctu re sh ow s th e in stal l ati o n at th e b u sb ar en ds.
1 Busbar bus hi ng
2 Insu lat in g cov er
3 Lid
4, 7 Support f or cov er (at end pan el s onl y)
5 W asher, ISO 7089
6 W asher, 25 mm d ia met er

56
F i g u re 91: 24 kV p an el s - Arr an g emen t o f th e bu sb ar an d b ran ch co n d u cto rs at th e b u sb ar en d s. I n co n tin u ou s b u sbars,
th e co n n ecti o n s are si mi l ar, b u t w ith ou t th e l id ho l d er an d w i tho u t th e sp acer p l ate. Du ri n g assemb l y, cu t o u t th e
i n su l ati ng co ver an d li d to fi t th e cro ss - secti o n o f th e feeder b ar o f b u sb ar.

F i g u re 92: 24 kV p an el s, 1250 A b ran ch cu rr en t an d 1600 o r 2500 A b u sb ar cu rr en t - Ar ran g emen t o f th e b u sb ar an d

b ran ch co n d u cto rs at th e b u sb ar en d s. I n co n tin u ou s bu sb ars, th e co n n ecti o n s are si mi l ar, b u t w i th o u t th e l i d h ol d er 2
an d w i th o u t th e sp acer p l ate 13.

F i g u re 93: 24 kV p an el s 25 00 A b ran ch an d b u sb ar cu rren t - Arr an g emen t o f th e b u sb ar an d b ran ch co nd u cto rs at th e

b u sb ar en d s. In co n ti n uo u s b u sb ars, th e co n n ecti on s are si mi l ar, b u t w i th o u t th e li d ho l d er 2 an d w i tho u t th e sp acer
p l ate 13.
1, 7 Lid f or insu lat i ng cov er
2 Lid ho l d er
3, 4 10 mm sprin g wash er
5 Insu lat in g cov er
6 Branch con duct or
8 Busbar sect io n
9) W asher ISO 7089
10 M1 0 hexa go n sock et head scre w
11 M1 0 nut
12 W asher 25 mm dia met er
13 Spacer pl at e (on l y f or 2500 A b ranch an d bus bar
current )

57
6.7.2 Busbar compartment access
Access to the busbar compartment is possible either
from the top of the panel after dismounting the
pressure relief plate 8 (Figure 3) before the mounting
of the gas duct, or from the front of the circuit -breaker
compartment.
After circuit-breaker has been withdrawn from the
panel, it is possible to dismount the horizontal
partition 1 (Figure 95) by unscrewing 4 screws holding
the partition from the inside. After that, the partition
can be dismantled and taken out of the panel, which
makes access to busbars from the circuit -breaker
compartment possible.

F i g u re 95: Acce ssi n g b u sb ar co mp artmen t.

1 Hori zo nt al part it i on
2, 3 Cov er

58
6.7.3 Busbars installation
Install the busbars panel by panel according to the
rating of the switchgear. Screw on the individual
busbar elements one above the other (depending
on the system layout) and in line with the flat
branch conductor. For the tightening torque please
refer to the (chapter 6.3). Use tightening material
supplied by ABB.
Bolt one holder to each end of the busbars to
support insulating cover. The screws for holder
must be tightened with a lower torque (for
insulated busbars only).
Position insulating covers and lids over the
relevant bolted joint, and slide the lid onto the
cover until it clicks into place (for insulated
F i g u re 96: W ash er b efo re ti gh ten i n g.
busbars only).

Note:
Busbar connection is carried out wit h stabilized
connections. This means that the quality of the
copper busbar connections does not deteriorate
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 table.
W e recommend only checking tightness of busbar
connections during inspections (chapter 9.3)

Note:
In case that busbars insertion seems to be difficult
then can be exceptionally used appropriate amount of
the DOW CORNING TORAY DC4 silicone grease F i g u re 97: W ash er after ti g h ten i n g .
compound applied on the busbar insulation. After
insertion busbars the rest of DC4 silicone grease
compound on the insulation surface has to be properly
cleaned up by soft dry cloth.
The usage of any other types of grease for insertion of
busbars through the busbar partitioning bushing &
rubber partition is strictly forbidden!

59
Busbars for 12 / 17.5 kV panels
Busbars are made of copper and have a flat cross-
section for rated current up to 2500 A. For 3150, 3600
and 4000 A, the busbars have a double D -shaped
cross-section. Branch conductors always have a flat
cross-section.
12 / 17.5 kV bushings are made of ep oxy resin
castings and are arranged as a single casting for all
three phases. For bustie panels the bushings are
single and are arranged in the lower part of the panel.
Bushings are held in bushing plates. For 12 kV, the
busbars are bare (without insulation) and without
insulating covers up to 2500 A.
3150, 3600 and 4000 A open D -shaped busbars are
insulated by shrink fitting sheaths and are fitted with
insulating covers. For 17.5 kV, the busbars are
insulated and fitted with covers over the whole current
range.

F i g u re 98: 12 kV p an el s - T- off 630 - 125 0 A, b u sb ars 125 0 A.

1 nr. 4 10x35 screws
2 nr. 8 M10 w ashers
3 nr. 4 M10 n ut s

F i g u re 99: 12 / 17. 5 kV p an els - T - o ff 630 - 125 0 A, b u sb ars 1600, 20 00, 250 0 A.

1 nr. 4 10x60 screws
2 nr. 8 M10 w ashers
3 nr. 4 M10 n ut s
4 nr. 1 spacer (15 mm)

60
F i g u re 100: 12 / 17. 5 kV p an el s - T - o ff 630, 1250 A, b u sb ars 315 0, 3600, 40 00 A.
1 nr. 4 10x60 screws
2 nr. 8 M10 w ashers
3 nr. 4 M10 n ut s
4 nr. 1 spacer (15 mm)

F i g u re 101: 12 / 17. 5 kV p an el s - T - o ff 630, 1250 A, b u sb ars 315 0, 3600, 40 00 A, o p en D.

1 nr. 4 10x60 screws
2 nr. 8 M10 w ashers
3 nr. 4 M10 n ut s
4 nr. 1 spacer (15 mm)

61
F i g u re 102: 12 / 17. 5 kV p an el s - T - o ff 1600, 2000, 2 500 A, b u sb ars 160 0, 2000, 25 00 A.
1 nr. 4 10x60 screws
2 nr. 8 M10 w ashers
3 nr. 1 spacer (5 mm)
4 nr. 4 M10 n ut s

F i g u re 103: 12 / 17. 5 kV p an el s - T - o ff 1600 - 4000 A, b u sb ars 31 50, 36 00, 400 0 A.

1 nr. 4 10x60 screws
2 nr. 8 M10 w ashers
3 nr. 1 spacer (5 mm)
4 nr. 4 M10 n ut s

62
F i g u re 104: 12 / 17. 5 kV p an el s - T - o ff 630, 1250 A, b u sb ars 315 0, 3600, 40 00 A, o p en D.
1 nr. 4 10x60 screws
2 nr. 8 M10 w ashers
3 nr. 1 spacer (5 mm)
4 nr. 4 M10 n ut s

Busbars for 24 kV panels
Busbars and branches are made of copper and both
have a flat cross -section. The bushings are different
from the 12 / 17.5 kV versions. They are single for
each phase and have an electrode inside, which must
be connected to the busbar. Busbars for 24 kV pan els
are insulated by means of shrink fitting sheaths and
the connection points are covered by insulating
covers.

F i g u re 105: 24 kV p an el s - T -o ff 1250 A, b u sb ars 1 25 0 A.

1 nr. 4 10x35 screws
2 nr. 8 M10 w ashers
3 nr. 4 M10 n ut s

63
F i g u re 106: 24 kV p an el s - T -o ff 1250 A, b u sb ars 2 50 0 A.
1 nr. 4 10x6 0 screws
2 nr. 8 M1 0 wash ers
3 nr. 4 M1 0 nut s

F i g u re 107: 24 kV p an el s - T -o ff 2500 A, b u sb ars 2 50 0 A.

1 nr. 4 10x6 0 screws
2 nr. 8 M1 0 wash ers
3 nr. 4 M1 0 nut s

64
F i g u re 108: 24 kV p an el s - T -o ff 3150 A, b u sb ars 3 15 0 A.
1 nr. 4 10x6 0 screws
2 nr. 8 M1 0 wash ers
3 nr. 4 M1 0 nut s

Important note:
The contact springs must be inserted during the
installation of busbars. These contact springs
make the connection betw een the busbar and the
metal tube and prevent damage caused by partial
discharges inside the bushing on live busbars .

Important note:
Alw ays check that there is good contact betw een F i g u re 109: 24 kV p an el s - d etai l o f th e b u sb ar bu sh i ng ,
the metal tube in the bushing and the busbars via secti o n al vi ew
contact spring. Ensure that the contact spring is in 1; 2 Cont act sprin g
the correct position!

65
6.8 Installation of the top-mounted boxes
For ease of transportation top mounted boxes are
delivered separate from the panel in pre -assembled
sections.
6.8.1 Voltage transformer for busbar metering
Top-mounted box 1 (Figure 115) with screw fixing
material in the set of bags Top -mounted box for
metering must be mounted on the busbar
compartment.
In panels without busbar bushing plate 5 (Figure
87), the partition between the busbar compartment
and the topmounted box is necessary. They are
installed at the factory in the top-mounted box.
As far as equipment with busbar partitioning is
concerned (i.e. with bushing plate 5), the space
between the busbar compartment and the top -
mounted box must remain ope n for pressure relief.
Connecting bars 1 with branch conductors 5 at the
junction point must be screwed together according
F i g u re 110: Pan el s 12 / 17. 5 kV - Bar co n n ecti o n to th e top -mo u n ti n g b o x. T h e fi g u re sh ow s th e arran g emen t i n p anel s th e
b u sb ar en d s.
66
to (Figure 111) (Figure 113). However, if
necessary, the additional spacer plate 2 (Figure
111) and threaded plate 9 (Figure 113), as well as
the screw fixing material from the top -mounted
box for metering set of bags must be used.
Insulating cover 2 (Figure 87) must be placed into
position as is described in (chapter 6.5).
Intermediate box (Figure 115) (Figure 116) with
the screw fixing material from the top -mounted
box for metering set of bags must be mounted on
the low voltage compartment. Conduction tube
must be positioned and inserted in reducer rings.
Secondary circuits from the voltage transformers
must be led to the terminal strips and connected
according to the cable core markings and circuit
diagram.
F i g u re 111: Pan el s 12 / 17. 5 kV - Bar co n n ecti o n to th e top - mo u n ti n g b o x. T h e fi g u re sh ow s th e arran g emen t i n p anel s th e
b u sb ar en d s.
1 Conn ect io n bar
2 Spacer pl at e, 8 mm t hick
3 T apped plat e
4 Spacer pl at e, 5 mm t hick
5 Branc h con duct or

F i g u re 112: Pan el s 12 / 17. 5 kV - Bar co n n ecti o n to th e top - mo u n ted b o x.

67
F i g u re 113: Pan el s 24 kV - Bo l ted bu sb ar jo i n t fo r to p - mou n ted bo x, sh ow n fo r l eft - h and b u sb ar en d. In co n ti n uo u s
b u sb ars th e co n n ecti o n i s simi l ar, b u t w i tho u t th e li d h o lder an d w i tho u t th e sp acer p l ate.
1 Conn ect io n bar 12 Busbar sect io n
5 Branch con duct or 13 Lid ho ld er
6 Lid f or insu lat i ng cov er 14 W asher 3 mm
7 Spacer pl at e 15 M1 0 hexa go n sock et head scre w
8 W asher 2 mm 16 10 mm spr ing w ash er
9 T hreaded pl at e 17 Spacer pl at e, 10 mm t hick
10 Insu lat in g cov er
11 Cylin der screw

F i g u re 114: Pan el s 24 kV - Bar co n n ecti o n to th e top - mo un ted b o x.

68
F i g u re 115: Pan el s 12 / 17. 5 kV - T o p - mou n ted b o x w ith vo l tag e tran sfo rmers fo r b u sb ar mete ri n g . Th e fi gu re sh ow s th e
arran g em en t i n p an el s w i tho ut th e b u sb ar bu sh i ng s p l ate.
1 T op mount e d box wit h v olt age t ransf or mer
2 Cond uct or t ube
3 Part it ioni ng
4 Reduc er ring
5 Int er me di at e box

F i g u re 116: 24 kV p an el s - Ar ran g emen t o f th e b u sb ar an d b ran ch co n d u cto rs at th e b u sb ar en d s. I n co n tin u ou s bu sb ars,

th e co n n ecti o n s are si mi l ar, b u t w ith ou t th e l id ho l d er an d w i tho u t th e sp acer p l ate.
1 T op- mount e d box
2 Cond uct or t ube
3 Reduc er ring
4 Int er me diat e box
5 Pressure rel ief f lap
6 Conn ect io n bar
7 Bushin g pl at e

69
6.8.2 Earthing sw itch for busbar earthing
Top-mounted box 1 (Figure 117) with screw fixing
material from the top-mounted box for earthing
set of bags must be mounted on the busbar
compartment.
Operating mechanism box 3 with screw fixing
material from the top -mounted box for earthing
set of bags must be mounted on the low voltage
compartment.
Pre-mounted single parts of hexagonal shaft 2
must be removed. Please pay attention to the
sequence and angling of the parts!
The hexagonal shaft from the operating
mechanism box must be pushed through into the
bevel gear of the earthing switch. The sequence
and angles of the part must be restored!
Connecting bars 4 (Figure 119) with the branch
conductors at the junction point must be screwed
together according to (Figure 111), (Figure 113).
However, if necessary, additional spacer plate 2
(Figure 111) and threaded plate 9 (Figure 113), as
well as the screw fixing material from the top -
mounted box for earthing set of bags must be
used.
Insulating cover 10 (Figure 113) must be brought
into position as described in (chapter 6.7).
F i g u re 117: Bu sb ar earth i n g sw i tch.
1 T op- mount e d box
2 Cond uct or t ube
3 O perat ing mec ha nis m box
70
Note:
The auxiliary switches for the earthing switch are
adjusted at the factory. Correct operation is o nly
guaranteed if the working elements on the hexagonal
shaft are correctly mounted. During final installation of
the earthing switch and operating mechanism on site,
it may be necessary to make precise adjustment of the
auxiliary switches. In this case, t he following is
important:
The auxiliary switch OFF 1 (Figure 118) must be
operated before slide 3 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 4.
The auxiliary switch ON 2 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
operated position.
F i g u re 118: Pan el s 12 / 17. 5 kV - T o p - mou n ted b o x w ith earth i n g sw itch fo r b u sb ar earth i n g.
1 Auxili ar y swit ch O F F
2 Auxili ar y swit ch O N
3 Slide
4 Lock ing mag net

F i g u re 119: Pan el s 24 kV - To p - mo u nted bo x w i th earth i ng sw i tch fo r b u sb ar earth i n g. th e arran g emen t i s th e same as th e

fi g u re ab o ve.
1 T op- mount e d box
2 Cond uct or t ube
3 O perat ing mec ha nis m box
4 Conn ect io n bar

71
6.8.3 Ultra fast earthing switch UFES
For more information see document 1VLG100128
Manual for installation of UFES into UniGear ZS1.

F i g u re 120: T op - mo u n ted b ox w i th UF ES.

1 UF ES
2 T op- mount e d box
3 Cond uct or t ube
4 Reduc er ring
5 Int er me diat e box

6.8.4 Anti-ferroresonant resistor for voltage

transformers open delta connection
W hen using a ferroresonance resistor for VTs open
delta connection is necesary to adjust the position of
this resistor during site installation.
The ferroresonance resistor is placed on the top of
switchgear on the CB relief flap for the transportation
(Figure 121). W hen moving the resistor from relief flap
to LV compartment (LVC) please follow pictogram
(Figure 122) on the top of LVC. The resistor has to be
fixed by means of screws on the top of the LVC
(Figure 123).
Assemble resistor prior to instalation of preassure
relief gas duct. Pay attention to the resistors wires
whilst installing gas duct.
F i g u re 121: T ran sp o rt po si tio n o f an ti - ferro reso n an t
resi sto r.

F i g u re 122: Pi cto g ram o n th e to p o f L VC. F i g u re 123: Co rrect p o si ti o n o f an ti - ferro reso n an t resi sto r .

72
6.9 Pressure relief ducts
The pressure relief duct is supplied dismantled in
single components. The rear and front wall
correspond, as far as length is concerned, with the
appropriate panel width.
The screw fixing material is contained in the pressure
relief duct set of bags. Rivet nuts are already
provided in the metal sheets.
Detailed instructions for gas exhaust duct assembly
are described in document Assembly manual
1VLM000034.

Note:
The rear pressure relief flap must be mounted
according to (Figure 124). Details regarding
connection to the wall and a discharge grating for
pressure relief outside the switchroom will be agreed F i g u re 126: F i xin g p o in ts o n th e rear.
on with the customer.

F i g u re 124: Sch emati c d i ag ram o f th e p ressu re rel i ef d u ct.

1 Pressure rel ief duct
2) If t he swit ch gear is eq uip ped
duct , t he press ure r eli ef f lap f or
compart ment is f ixe d t o t he rea r side of
t o t he f ront (int o t he duct ) in ca se of an
wit h a press ure re lie f
t he c ab le co nn ect io n
t he pan el an d wil l op e n
arc f ault .
F i g u re 127: Ass emb l y o f p ressu re rel i e ve fl ap s w i th o ut g as
d u ct .
Note:
This side of the preassure relief flaps has to be fixed
by plastic screws. The marked screws must be plastic.

6.9.1 Gas duct w ith outlet

Once the panels are bolted up, and busbars are
installed, it is possible to start fixing the gas duct on
the top of the switchgear. Every panel has three fixing
points in the front part (Figure 125) and three fixing
points on the rear part (Figure 126).

F i g u re 128: Ass emb l y o f p ressu re rel i e ve fl ap s w i th g as

d u ct.

Note:
If a gas duct is used turn off the cable compartment
flap according to figure. The marked screws must be
F i g u re 125: F i xin g p o in ts o n th e fro n t plastic.

73
6.9.2 Gas duct w ith top chimneys
In order to mount the gas duct with top chimneys
please follow the approp riate instructions. The
difference between the two solutions is that in this
case there are no side exits, but the gas generated
from an internal the arc exits 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 130); for each opening the perforated metal
plate must be fixed with 6 spacers (Figure 131).
F i g u re 129: O p eni n g s o n to p o f th e g as du ct.
F i g u re 130: Net an d sp acers o f to p ch i mn eys.
F i g u re 131: T op co ver o f top ch i mn eys.
74
Note:
For UniGear ZS1 24 kV; 31,5 kA with gas duct with top
chimneys for a duct height of 500 mm it is necessar y
to use a deflector. Insert the deflector onto gus d uct -
open side in direction of LVC. For fixation use
connecting parts included in gas duct assembly.
Deflector is designed to divert hot gas away of rear
part of panel to shield a staff behind the panel. It is
not necessary to aply the deflector in case o f placing
panels directly to wall. No access from rear side.
F i g u re 132: Defl ecto r.
6.10 Cable connection
6.10.1 Pow er cables
The standard method for entry of power cables in the
switchgear is shown in (Figure 133). The cables are
conveyed from below through floor covering 2, which
is divided at the cable entry point.
The cables go through rubber reducer rings 3, which
can be adapted to the required cable diameter in a
range from 27 to 62 mm. Cables are fastened in the
panel by means of cable clamps mounted on cable
strips, which are part of the panel floor covering.
The clamps make it possible to fasten cables with
diameters between 35 and 54 mm.

F i g u re 134: Vi ew i n to cab l e co n n ecti o n co mp artmen t, max.

F i g u re 133: P arti al vi ew o f the cab l e co mp artmen t, si x p aral l el cab l es p o ssi b l e.
p rep ared h ere fo r co n n ecti o n o f tri pl e cab l es.
1 Eart hing sw it ch pos it ion i ndic at or
1 Ma in eart h in g bar 2 Cabl e con nect io n bar
2 F loor cov er, split 3 Cabl e cla mp
3 Reduc er ring 4 Reduc er ring
4 Eart hing co nn ect ion p in 5 F loor cov er, split

Cable termination kits are mounted on the cable

cores according to the manufactu rers instructions. It
is possible to use cable termination kits from different Important note:
manufacturers (e.g. Prysmian, Raychem etc.), but it is The cable connection bars are equipped w ith holes
necessary to keep the same length of the cable ends, for M16 screws.
including cable termination kits, which is given by the
distance of cable connecting bars (Figure 133) from
the panel floor covering.
These bars have different versions, which differ in
their number of parallel cables and the values of rated
and short-circuit currents.
The bars are equipped with holes for M16 screws. 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 com partment.
These can be fitted with HV fuses similar to those in
the measuring panel.
Three fixed mounted surge arresters can also be
installed here. In both cases the number of parallel
cables that can be installed is reduced - (see table).

75
Co n n ecti o n o f cab l es i n typ i cal p an el s
Rated Pan el w i d th M ax. nu mb er o f p aral l el M ax. cro ss secti o n o f Ran g e o f cab l e Ran g e o f red u cer
vo l ag e [kV] [mm] cab l es i n p h ase cab l es [mm2 ] cl amp [mm] ri n g [mm]
650 3(1)
17. 5 800 630 35 - 54 27 - 62
6(2)
1000
800 3(1)
24 500 35 - 54 27 - 62
1000 6(2)
(1) I n c a s e s w he r e t he r e a r e r e m o v a bl e v o l t a ge t r a ns f o r m e r s o n t he t r uc k , o r s ur ge a r r e s t e r s a r e us e d , t he n um be r o f pa r a l l e l c a bl e s i s r e d uc e d
to a m a x . o f 2 pe r p ha s e .
(2) I n c a s e s w he r e t he r e a r e r e m o v a bl e v o l t a ge t r a ns f o r m e r s o n t he t r uc k , o r s ur ge a r r e s t e r s a r e us e d , t he n um be r o f pa r a l l e l c a bl e s i s r e d uc e d
to a m a x . o f 4 pe r p ha s e .

Cab l e co n n ecti o n i n th e p an el w i th sw i tch -d i sco n n ecto r

Rated Pan el w i d th M ax. nu mb er o f p aral l el M ax. cro ss secti o n o f Ran g e o f cab l e Ran g e o f red u cer
vo l ag e [kV] [mm] cab l es i n p h ase cab l es [mm2] cl amp [mm] ri n g [mm]
17. 5 800 1 240 35 - 54 27 - 62
24 1000 1 240 35 - 54 27 - 62

Important note:
Connection w ith single-core plastic insulated
cables is presumed in typical panels. In the case of
any atypical cable connections or of special cables
(e.g. three-core cables, cables w ith paper or
special insulation etc.), an agreement must be
reached betw een the customer and ABB.

Mounting procedure for power cables (Figure 134):

It is possible to achieve more space - see chapter
6.7.2.
Power cables must be inserted, cut to length and
stripped.
Reducer rings 4 must be adapted to the cable
diameter and fitted onto the cable.
Cable termination kits must be prepared and
mounted on cable cores according to
manufacturers instructions.
Cable eyes must be connected to the prepared
connection bars 2 with strain relief.
Earthing of cables must be connected.
Individual parts of the floor covering must be
mounted.
Reducer rings 4 must be moved down so that nuts
in the rings fit into the corresponding recesses in
the floor coverings. In this way, the cable
passages are sealed.
Cables must be fastened into the prepared cable
clamps 3 (the maximum tightening torque
applicable to the clamp screws is 9 +2 Nm).

76
F i g u re 135: Di men si o n o f pow er cab l e co nn ecti o n o f Un igear 12 / 17. 5 kV p an el s.
D T ypical pa ne l dept h 1 340 (1 39 0 ) mm. Di mens ion must be v erif i ed accord in g t o t he relev ant order docu ment at i on.

1 Cabl e con nect io n bar

2 Reduc er ring
3 Cabl e cla mp

Di men si o n s o f pow er cab l e co n n ecti o n s 12 / 17, 5 kV

M ax. nu mb er o f cab l es p er p hase
I n [A] W i d th [mm] I th [k A] A [m m] B [mm] C [mm]
si n g l e co re tri p l e co re
630 3 3 840 -
1000 650 31. 5 535
1250 3 3 480 180
1250 40 / 50 465
1600 800
2000
1600 31. 5 / 40 / 50 440
2000 6 6 460 100
2500 1000
3150
40 / 50 455
4000

77
F i g u re 136: Di men si o n o f pow er cab l e co nn ecti o n o f Un igear 24 kV, 25 k A p an el s.
D T ypical pa ne l dept h 1 700 mm ( 1560 mm v ersion is av ail abl e b ut dimensi on must be v erif ied a ccordin g t o t he
relev ant order d ocu me nt at ion)

1 Cabl e con nect io n bar

2 Reduc er ring

Di men si o n o f p ow er cab l e con n ecti o n 24 kV, 25 k A

M ax. nu mb er o f cab l es p er p hase
I n [A] W i d th [mm] I th [k A] A [m m] B [mm] C [mm]
singl e core t riple core
1000
800
1250
3 3 497 608 180
1000
1250 25
1600 1000
2000 6 6 432 645 100
2500

78
F i g u re 137: Di men si o n o f pow er cab l e co nn ecti o n o f Un igear 24 kV, 31. 5 k A p an el s.
D T ypical pa ne l dept h 1 700 mm ( F or short -t ime curr ent up t o 25 k A a 1560 mm de pt h v ersion is av ailabl e.
But dimensi on must be v erif ied accordi ng t o t he rel ev ant order docu me nt at io n)

1 Cabl e con nect io n ba r

3 Cabl e cla mp

Di men si o n s o f pow er cab l e co n n ecti o n s 24 kV, 31. 5 k A

M ax. nu mb er o f cab l es p er p hase
I n [A] W i d th [mm] I th [k A] A [m m] B [mm] C [mm]
si n g l e co re tri p l e co re
IF 800 6 6 465 700 100
Up t o 1250 31. 5
IF M 8 00 2 2 460 740 118
IF 1000 5 5 425 770 120
Up t o 3150 31. 5
IF M 1 000 6 6 415 690 100

79
F i g u re 138: Di men si o n o f cab l e co n n ecti on in p an el s o f Un i g ear sw i tch g ear w i th 12 / 17. 5 kV sw i tch d i sco nn ecto r.
D T ypical pan el dept h is 134 0 (1 390) mm. T he di mensi on must be v erif ied accor din g t o t h e rel ev ant order docu ment at io n.

1 Cabl e con nect io n bar

2 Reduc er ring
3 Cabl e cla mp

F i g u re 139: Di men si o n o f cab l e co n n ecti on in p an el s o f Un i g ear sw i tch g ear w i th 24 kV sw i tch d i sco nn ecto r.
D T ypical pa ne l dept h is 1 700 mm. T he dime nsio n must be v erif ied accor din g t o t he relev ant or der docu ment at i on.

1 Cabl e con nect io n bar

2 Reduc er ring
3 Cabl e cla mp

80
6.10.2 Control cables
The control cables are conveyed into the panel
through the control wiring duct 23 (Figure 3) on the
left hand panel side. Mounting procedure:
Insert the cables into the control wiring duct on the
lefthand side. The duct is covered by covers 2, 4
(Figure 73).
Fasten the control cables at the top end of the
duct, strip the insulation and convey cable control
cores into the low voltage compartment, after the
terminal strip frame has been swung up (Figure
140).
Connect control cables to the terminal strip
according to the circuit diagram.
Make the control wiring connections to adjacent
panels using bushing.
F i g u re 140: L i ft -u p termi n al frame sw un g u p fo r co n n ecti on
w o rks.
F i g u re 141: F i xed termi n al frame.
6.11 Earthing the switchgear
Connect main earthing bar 6 with connections 2
provided in every panel (Figure 133).
Ensure protection for the wiring connection of the floor
frame or the erected raised false floor.
Connect the earthing conductor from the earth
electrode, preferably via a removable bolted
connection for testing purposes, to the main earthing
bar 6 of the switchgear.
6.12 Installation of
interconnecting bundles
The interconnecting bundles are supplied rolled up in
the low voltage compartment or in the accessories.
They are marked and fitted with ferrules or
connectors at both ends. Openings are provided in the
side walls of the low voltage compartmen t for these
lines to be looped through from panel to panel.
6.13 Final erection work
Check painted areas of the switchgear for possible
damage, touching up where required
Check bolt connections and tighten where
required, in particular all those carried out during
on-site erection of the busbars and earthing
system
After the lifting eyebolts have been removed, the
Ith limiter auxiliary switch (if delivered) must be
mounted and adjusted:
- The auxiliary switch holder is fixed by screws in
the panel
- The auxiliary switch holder must be positioned
horizontally
- The control pin of the auxiliary switch must be
moved to the centre of the hole in the pressure
relief flap
- Adjust the auxiliary switch
- If the auxiliary switch is mounted and adjusted
according to the above instructions, checking
during regular inspections is not necessary
Clean the switchgear thoroughly
Remove all foreign bodies from the panels
Correctly replace all coverings, etc. removed
during erection and connection
In the enclosure, any remaining openings must be
closed if they are no longer needed
Check the isolating contacts and interlocking
mechanisms for smooth motion, and grease again
with SYN-setral-EK 339 where necessary
W ithdrawable circuit -breaker parts must be
inserted and the control wirings connected
Panels doors must be properly closed
81
7. Operation of the switchgear
Note on safety at w ork
All relative work and operating procedures must be
carefully carried out by trained specialists familiar
with the installation, taking into account all the
relative safety regulations according to the IEC and
other relevant professional bodies, as well as any
local and work regulations and instructions.

W ARNING:
Do not walk on the top surfaces of the switchgear
panels as they contain rupture points for pressure
relief w hich could be damaged!
7.1 Switching operations
F i g u re 142: Co n tro l w i rin g p lu g co nn ecto r b l o cked to
p reven t d i sco n n ecti o n w i th th e w i thd raw abl e p art i n th e
servi c e p o si ti o n.
1 Int erl ock
2 Cont rol w ir in g plu g
3 Cont rol w irin g sock et

W ARNING
Carry out sw itchin g operations w ith the front doors
closed!

7.1.1 Withdrawable apparatus

Manual insertion from the test / disconnected position
to the service position:
Connect control wiring plug 2 (Figure 142).
Close the front door.
Ensure that the apparatus is in the OFF position.
Fit hand crank 1 (Figure 144) on square spigot 3
(Figure 16) of the spindle mechanism 26 (Figure
3), after opening the aperture for them by turning
slide (Figure 143).
Turn the crank clockwise (approx. 20 turns at 12 -
17.5 kV and 30 at 24 kV) until the stop is reached
and the withdrawable part is in the service
position.
Observe the position indicator.
Remove hand crank.

It must be noted that the spring loaded pin head 1

(Figure 16) will lie completely on the rear side of the
panel door when the hand crank is moved from square
spigot of spindle mechanism. This ensures that the
rear part of the pin head has been shifted onto the
hexagonal cap of the spindle and prevents
unintentional wrenching of the spindle during panel
service. W renching may lead to the circuitbreaker F i g u re 143: Befo re i n serti n g th e h an d cran k, i t i s
blocking. n ecess ar y to o p en th e ap eratu re fo r i t - tu rn th e sl i d e b y
u si n g th e key.
Note:
The withdrawable part must not be stopped in an y
intermediate position in the travel range between the
service and test / disconnected position!

82

F i g u re 144: M o vemen t o f th e w ith d raw ab l e p art b etw een
th e test / d i sco nn ected p o si tio n an d th e servi ce p o si ti o n,
cl o ckw i se up to th e sto p to the servi ce p o si ti o n and an ti -
cl o ckw i se fo r th e test / di sco n n ected p o si tio n .
1 Hand cra nk
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 w ithdrawal of circuit -breakers (and
other w ithdraw able parts) must be gradual, in
order to avoid any shocks w hich could deform the
mechanical interlock. If the operations are
prevented, do not force the interlocks and check
that the operating sequence is cor rect. The force
normally applied to the insertion / withdrawing
lever is 260 N. In any case, the maximum applied
force must never exceed 400 N. Please also refer to
the technical documentation of the circuit -breakers
for installation operations.
Caution:
The insertion and withdraw al must always be
carried out w ith the apparatus open! Do not use
force to move w ithdrawable parts with locking
magnet Y0 or RL2 in the event of an auxiliary
voltage drop. If this occurs, they are locked along
the w hole travel range betw een the service and
test positions. To remove the interlock, consult the
technical documentation of the circuit-breakers.
Motorized movement of the withdrawable part:
Briefly operate the electrical control for insertion
or withdrawal (the withdrawable part then
automatically moves into the opposite position).
Observe the position indicator.
Note:
W hen the drive motor is faulty, the withdrawable part
can be moved using the emergency manual operation.
If the drive motor fai ls 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 1 (Figure 144) on spindle mechanism
26 (Figure 3), in a similar way to operation of a
withdrawable circuit-breaker with manual systems.
-Switch off the auxiliary power (m.c.b.), since the
motor would otherwise be braked electrically.
-Turn hand crank in the req uired direction. W hen 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 damaged!
Caution
In emergency manual operation of a motorized
withdrawable circuit -breaker part, the interlock
with the earthing switch is not effective!
W ithdrawal from the test / disconnected position onto
the service truck:
Open the door of the circuit-breaker compartment.
Release control wiring plug 2 (Figure 142) and
place it in the storage position on the withdrawable
part.
Position service truck 4 (Figure 146) with guide pin
1 (Figure 147) of the adjustable bench top at the
correct height facing the panel front, and allow
catch pin 2 to engage.
Move sliding handles 2 ( (Figure 145) inwards
against the springs to release withdrawable part 1,
draw the withdrawable part out onto the service
truck and secure it in the catches on the truck.
Press release lever 1 (Figure 146) (at the front
underneath the bench top) and release the service
truck from the switchgear panel.
Secure the position of the shutters with padlock.
Insertion from the service truck into the test /
disconnected position:
Carry out the procedure described above for
withdrawal in reverse order.
83
F i g u re 145: Servi ce tru ck en g ag ed w i th th e sw itch g ear F i g u re 146: W i th d raw ab l e p art stan d i n g o n servi ce tru ck
p an el . Wi th d raw ab l e p art rel eased fo r w i th d raw al w i th th e an d secu red i n th e catch es.
h an d l es sl i d i nw ard s.
1 Rele ase lev er f or cat ch pin
1 W it hdrawable p art 2 Cat ch (conn ect ed t o sli din g ha ndle)
2 Slidi ng h and le 3 Heig ht adj ust er
3 Serv ice t ruck 4 Serv ice t ruck

F i g u re 147: Po si tio n in g th e se rvi ce tru c k w i th th e g u id e F i g u re 148: Sh u tters secu red w i th p ad lo ck to p reven t

p i n s on th e ad ju stab l e h eig h t b en ch top at th e co rrect u n au th o ri zed o p erati o n.
h ei g h t fo r ap p ro ach to th e sw i tch g ear p an el , an d en g ag in g
th e catch . 1 Lock ing of low er shut t er
2 Lock ing of upp er shut t er
1 G uide pi n
2 Cat ch pin

84
7.1.2 Circuit-breaker - type VD4 and VD4G
Charging the stored energy spring system:
Charging of the circuit-breaker is carried out
automatically by the charging motor. If the
charging motor should fail, the charging procedure
can be carried out or completed manually.
If mechanical charging is necessary open the door
with the withdrawable part in the test position,
insert charging lever 3 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.
W hen the charged condition is reached, the
charging mechanism is automatically disengaged,
and any further strokes of the lever have no effect
(Figure 149). Pumping is effective if the lever is
moved over an angle of 90.

Opening and closing the circuit-breaker:

Opening and closing operations with the
withdrawable part in th e service position should
only be performed with the door closed.
Operate the local or remote electrical control.
Observe the switch position indicator. The
switching operation counter 4 for the circuit -
breaker automatically increases by one unit with
each operating cycle. An additional control F i g u re 149: M an u al o p erati on o f w i thd raw abl e p art w i th
mechanism fitted in the door of the circuit -breaker VD4 ci rcu i t - b reak er.
compartment enables me chanical operation of the
1 Mec han ical sw it ch pos it ion i ndi cat or
circuit-breaker with the door closed and with the 2 Charg ing co nd it i on i ndic at or
withdrawable part in either position. 3 Charg ing l ev er
Press the relevant mechanical pushbutton, having 4 Mec han ical oper at ing c ycl e cou nt er
previously turned knob 2 (Figure 11) anti-clockwise
to the stop if the withdrawable part is in the
service position.
Observe the switch position indicator. For further
details regarding operations and maintenance of
VD4 circuit-breakers, see instruction manuals BA
460-06, BA 414-06

The new VD4G-50 is the upgraded ve rsion of VD4

vacuum circuit-breaker for generator (GCB)
applications.
The VD4G-50 is suitable for the small power plants as
well as for industrial, oil and gas applications in which
generators are connected to the MV distribution of the
plant. Operation of VD4G-50 is identical to standard
VD4 circuit breaker.
VD4G-50 must be used only in the dedicated panel
version.

85
7.1.3 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 5 (Figure 150)
lights up.
Carry out the closing and opening test of the
circuit-breaker by pressing pushbuttons 6 and 7
(Figure 150).
Closing: By remote control via closing contacts or
locally by pressing ON pushbutton 6.
Opening: By remote control via closing contacts or
locally by pressing OFF push button 7.
Opening on failure of the auxiliary power supply:
Electrical opening is still possible within the first
200 s. After a period of 200 s, emergency manual
opening is necessary to insert emergency manual
operating lever 1 (Figure 151) onto the spigot of
the emergency shaft 3 (Figure 150) 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 1 (Figure 150) increases
by one full digit. On termination of a switching
operation, the position indicator 2 in the window of
the front plate displays the related switch position.
Anti-pumping system: The circuit -breaker
controller ensures that circuit-breaker closing is
locked when an opening command is active. W hen
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 manual BA 433/E.

F i g u re 150: W i th d raw ab l e p art w i th VM 1 typ e ci rcu i t - F i g u re 151: Emerg en c y man u al sw i tch - o ff.
b reake r - o p erati n g mech an i sm si d e.
1 Recess f or e merg enc y ma nua l open in g lev er
1 Mec han ical oper at ing c ycl e cou nt er 2 Emer genc y ma nu al op eni ng lev er
2 Mec han ical sw it ch pos it ion i ndi cat or
3 Cat ch f or emerge nc y man ual o perat in g lev er
4 F ront cov er plat e
5 Read y d ispl a y
6 O N pushbut t o n
7 O F F pushbut t on

86
7.1.4 Circuit-breaker - type HD4
Manual operation for spring charging:
To manually charge the closing springs, fully insert
charging lever into seat 3 (Figure 152) and turn it until
the yellow indicator 2 appears.
Electrical operation for spring charging:
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 recharge s the springs
after each closing operation until the yellow indicator
2 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 4 (Figure 153). W hen there is a shunt
F i g u re 152: HD4 typ e ci r cu i t - b reake r - si d e vi ew .
1 Cont rol w irin g plu g
2 Signa lin g dev ice
3 Shaf t f or man ual cl osin g sprin g chargin g
4 W it hdrawable ass e mb l y
closing release, the operation can also be carried out
by means of a control circuit. The indicator 2 shows
that closing has been accomplished.
Circuit-breaker opening:
For manual opening, press pushbutton 1 (Figure 153).
W hen there is a shunt opening release, the operation
can also be carried out with remote control by means
of a control circuit. The indicator 2 shows that opening
has been accomplished. An additional control
mechanism fitted in the door of the circuit -breaker
compartment enables mechanical operation of the
circuit-breaker with the door closed and with the
withdrawable part in either position.
Press the relevant mechanical pushbutton, having
previously turned knob 2 (Figure 11) 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
647016.
F i g u re 153: O p erati n g an d sig n al l in g p arts o f HD4 ci rcu i t -
b reake r.
1 O penin g pus hbut t on
2 O perat ion c ount er
3 Circuit - br eak er open/ cl ose d ind icat or
4 Closi ng pus hb ut t on
87
7.1.3 Withdrawable metering parts
Handling of the withdrawable metering part in the
metering panel is as described in (chapter 7.1),
without, however, the switching operations and
interlocking functions. W ithdrawable metering parts in
incoming and outgoing feeder panels are moved into
the cable compartment using a ramp. They reach their
service position immediately and engage in the panel
earthing by 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.
F i g u re 154: W i th d raw ab l e p art w i th meteri n g p an el .
1 Cast resin t ube (w it h f use cart ridge)
2 Volt age t ra nsf ormer
F i g u re 155: M i ni ci rcu i t b reakers o f tran sfo rm er se co n d ar y
ci rcu i ts.
88
7.1.6 Vacuum contactor - VSC
The VSC vacuum contactor is ideal for controlling AC
installations requiring a high number of operations.
The contactors basically consist of a moulded resin
monoblock, housing the vacuum interrupters, moving
apparatus, control electromagnet, multivoltage control
feeder and auxiliary accessories. The monoblock is
also the support for assembly of the fuse -holder
frame. Closing of the main contacts is carried out by
the control electromagnet. Opening is carried out by a
special opposing spring. The contactor can be
equipped with electrical or mechanical 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 standard s. For details, please refer to
manual 6497011.
F i g u re 156: VSC typ e va cu u m co n tacto r - fro n t vi ew .
1 Signa lli ng d ev ice O N/ O F F
2 O perat ing c ycl e cou nt er
F i g u re 157: VSC typ e va cu u m co n tacto r - p o l e sid e.
1 MV f uses
7.1.7 Earthing sw itch - type EK6 and ST-E
The earthing switch has a snap closing mechanis m
which is independent of the rotation of the drive shaft.
An earthing switch 15 (Figure 3) allocated to a circuit-
breaker is only enabled for switching when
withdrawable part 1 (Figure 145) is in the test /
disconnected position or removed from the switchgear
panel. Only turn earthing switches on when the doors
are closed.
Manual opening and closing:
Press slide 2 (Figure 158) downwards onto the
operating lever recess socket. (W hen the switch is
closed, it is already in this position! )
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 disengage the coupling to the motor
operator, first turn the lever further in the pre -
selected direction up to the relative stop
(turning through a small angle). On the next
operation w ith the motor operator after its
function has been restored, the coupling
automatically re-engages.

Caution:
If the operation is prevented, do not force the
interlock and check that the operation sequence is
correct. Fit operating lever 1 (Figure 159) onto
hexagonal shaft 2 (Figure 158),w hich is now
released for operation.
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.

Note:
Position operating lever 1 (Figure 159) to point up or
down on the hexagonal shaft 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 until
the stop is reached to close the earthing switch, or
anti-clockwise until the stop is reached to open the
earthing switch
Observe the mechanical/electrical switch position
indicator
Remove operating lever 1. Slide 2 (Figure 158)
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

Opening and closing with motor operator (EK6 only):

The earthing switch can also be fitted with a motor
operator. Briefly operate the electrical control for
opening or closing. The earthing switch is then
switched automatically into the opposite position.

Emergency manual operation:

If a fault should occur in the motor operator, the
earthing switch can be switched to emergency manual
operation with lever 1, in a similar way to manually
operated earthing switches.
F i g u re 158: Prep arati o n fo r op erati o n o f b ran ch earth i n g
sw i tch - p ress th e sl i d e d ow nw ard s.
1 Hexag on al shaf t of ES operat in g mec han is m
2 Slide

89
F i g u re 159: Prep arati o n fo r op erati o n o f b ran ch earth i n g F i g u re 160: Sh u tter li fti ng tru ck i n ci rcu i t - b reaker
sw i tch - op erati n g l ever p rep ared fo r sw i tchi n g o n/ o ff. co mp artmen t.
1 O perat ing l ev er 1 Shut t er lif t ing t ruck
2 Isol at ed o perat i on rod

7.1.8 Busbar earthing sw itch

To earth the busbars, EK6 earthing switches are also
used. Their operating mechanism is identical to that of
the branch earthing switches. The conditions for panel
to panel interlocking of the busbar earthing switches
(chapter 4.4).

7.1.9 Shutter lifting truck

Shutter lifting truck (optional accessories) can be
used for access to spouts after removing the circuit -
breaker from the circuit-breaker compartment:
Place the shutter lifitng truck 1 (Figure 160) into
the rails for the circuit -breaker truck in circuit -
breaker compartment
Push the shutter lifting truck in using the isolated
operation rod 2 (Figure 160) and open the shutters
for access to spo uts
Rotate the operation rod to lock the truck and pull
the truck out when finished Actuating bars must be
bolted in the top position (for operation of the
bottom shutters) or in the bottom position (for
operation of the top shutters), as required.

Caution: F i g u re 161: O p eni n g sh u tters.

Never operate shutter lifting truck only by hand.

90
 fuses will be required, the curren t-carrying bars will be
inserted in holders instead of the MV fuses to maintain
the same location of the earthing switch.

Notice:
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.

Ran g e o f fu ses
Un [ kV ] I n mi n. [ A ] I n max. [ A ]
7. 2 6 200
12 6 125
17. 5 6 160
24 6 125

F i g u re 162: I so l ated o p erati on ro d .

7.1.10 NALF sw itch-disconnectors

The NALF switch -disconnectors, combining a switch-
disconnector with fuses and E type earthing switches F i g u re 163: Prep arati o n fo r th e o p erati o n o f earth i n g
are intended for indoor use in switchboards. The sw i tch i n p an el w i th th e sw i tch - d i sco n n ecto r op erati n g
switch-disconnectors can open and close loaded and l ever p rep a red fo r th e O N op erati o n .
unloaded inductive and capacitive circuits. In the open 1 Lock able o perat i ng ha ndl e pa dlock
position the device has a visible isolating distance. 2 Posit ion i nd icat or of eart hi ng s wit ch
The switch-disconnectors are used in combination with 3 O perat ing s haf t f or t he eart hing swit ch
power fuses as short -circuit protection. This
combination excludes two -phase power supply,
because the interruption of any fuse link causes the
opening of the switch-disconnector by its tripping
system.
The E type earthing switches are constructed with a
snap closing mechanism. They can close and carry
short-circuit currents.

Operating mechanism of the switch-disconnector for

use in UniGear switchgear:

Operating mechanism A with two springs.

The opening spring is always charged before the
closing of the switch-disconnector. This means, that
the closed switch -disconnector always has stored
energy in the opening spring and the opening follows
immediately with the manual lever, opening shunt F i g u re 164: Prep arati o n fo r th e o p erati o n o f earth i n g
release or fuse tripping mechanism. This mechanism sw i tch i n p an el w i th th e sw i tch - d i sco n n ecto r op erati n g
facilitates remote opening and in combination with the l ever p rep a red fo r th e O FF operati o n .
motor operating mechanism makes completely remote 1 O perat ing l ev er
control possible.

The E type earthing switch is always operated locally

by the operating lever 1 (Figure 164).

To secure the protection of connected MV equipment

the UniGear switchgear with switch -disconnector uses
CEF medium voltage fuses. The UniGear switchgear
with NALF switch-disconnector can be equipped with a
range of fuses according to the following table.

In cases that the switch -disconnector without MV

91
Closing and opening of NALF switch-disconnector.
The switch-disconnector can only be switched on if
the earthing switch is open.
Put operating lever 1 (Figure 164) in position
pointing up or down 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 sides.
Turn the lever clockwise throug h approx. 180 to
charge the opening spring.
Turn the lever anti -clockwise 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 7 (Figure 6).
Caution:
Until the latch of the opening or closing spring
actuates, the lever w ill be returned back into the
starting position through the spring action.
Proceed w ith caution during this operation to
prevent the slipping of lever from hand - RISK OF
INJURY.
Closing and opening of integrated E type earthing
switch.
The earthing switch can only be switched on if the
switch-disconnector is open and opening spring is
charged.
Put operating lever 1 (Figure 164) in position
pointing left or up on the grooved shaft of the
earthing switch 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 ap prox. 90 until
the stop is reached to close the earthing switch.
92
Turn the lever anti -clockwise through approx. 90
until the stop is reached to open the earthing
switch.
Observe switch positioning indicator 7 (Figure 6).
Closing and opening of NALF switch -disconnector with
the motor operating mechanism.
The switch-disconnector can also be equipped with
the UEMC 40 K3 motor operating mechanism.
Briefly operate the control buttons for closing or
opening. The switch-disconnector is then switched
automatically or the springs of the switch -
disconnector are charged.
Emergency manual operation
If a fault should occur in the motor operating
mechanism, the switch -disconnector can be switched
manually with the operating lever 1 (Figure 164)
directly on the shaft of the switch-disconnector.
Notice:
After the manual operation the motor operating
mechanism will not be synchronous with the
switch-disconnector, which means that it must be
manipulated twice to reach synchronization, e.g.
opening closing.
W e recommend using a protective circuit -breaker
in the supply circuit of the motor operating
mechanism. The opening time of mechanism A
operated with motor operating mechanism is
approx. 1s. If faster openi ng is required, it is
necessary to equip the mechanism A with an
opening coil.
Caution:
The operating lever may only be fitted temporarily
to carry out an emergency manual sw itching
operation RISK OF INJURY.
7.2 Test procedure
7.2.1 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 in the isolating tulips, after the
corresponding upper shutter or lower shutter has been
opened. Shutter opening can be carried out by means
of a module. If the panels are equipped with
capacitive voltage indication, this can be used to
check the off -circuit condition. In this case, proceed
according to the manufacturers instructions or the
indicators. (Optionally, switchgear can be equipped
with various types of indicators from differents
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!
F i g u re 165: W i th d raw ab l e p art d u ri n g i n serti o n i n to th e
servi c e p o si ti o n, sh u tters n o t yet fu l l y o p en .
1 T op shut t er
2 Cont act syst e m
3 Isol at ion t u lip
4 Cont act ar m, wit h insu lat i ng sle ev e
7.2.2 Current and voltage tests
The testing and earthing module is available for
carrying out current and voltage tests. It is also
suitable for supplying primary current to any current
transformers which may be fitted during
measurements in the protection circuit and, for
example, for application of a test voltage during
insulating tests.
Isolate and secure the working area in accordance
with the IEC safety regulations.
For primary current supply, fix the connecting
cable of the est transformer to the contact pins.
For AC voltage tests, ball is required on the
contact pin. The bore in the ball is used for
connection of the voltage supply.
For current tests, for example of small connected
generators, the short-circuit bridge must be fixe d
onto the contact pins.
Note:
W ith voltage tests at power frequency withstand
voltage and/or impulse voltage, carry out the following
procedure:
Disconnect any voltage transformers and surge
arresters and cover them with an insulating plate.
F i g u re 166: Vi ew i n si d e th e ci rcu i t - b reaker co mp a rtmen t,
w ith d raw ab l e p art remo ved , sh u tters o p en .
1 Isol at ing t u lip
2 Isol at ing c ont act
3 Lower sh ut t er
93
7.2.3 Pow er cable test
The power cable test can be carried out by AC
voltage, DCv oltage or AC voltage applicable for very
low frequency (VLF)testing at 0,1Hz. For maximum
cable test voltage see table onthe next page.
Connect the cable test equipment to the test points
(contact pins in the CB compartement 2 (Figure
166)) and to the main earth busbar.
Swith OFF earthing switch. (see par. 7.1.7).
Carry out the cable test as required.

General
Voltage applied during cable testing can damage
voltage transformers,surge arrestors if fitted. It is Note:
therefore necessary todisconnect them from the circuit Pictures show the shutters lifting truck for panel 12 kV
before performing cable test.The below described 650mm. Shutters lifting truck for other configurations
procedure shall be used to carry outcable test on the may be slightly different but functionality is preserved.
power cables without disconnecting thecables from the
switchgear.

Caution:
All the operation s below must be carried out by
qualified and skilled personnel w ith in-depth
know ledge of the panel and apparatus.

Procedure described below must be followed to

accesscable test points
Switch OFF the circuit breaker.
Rack out the cir cuit breaker from service to test
position.
Open CB door.
W ithdraw the circuit breaker from the panel (see
par. 7.1.1).
De-energise the cable.
Switch ON the earthing switch (see par. 7.1.7).
Test the off -circuit condition (see par. 7.2.1).
Disconnect voltage transformers, surge arr estors
if fitted.
Insert modified shutters lifting truck inside the CB
compartement.
Push modified shutters lifting truck to service
position by insulating operating handle. The lower
(cable connection) shutter s hall open. Cable test
F i g u re 167: M o di fi ed shu tters l i fti ng tru ck i n serted i n CB
points (contact pins) shall be accessible. Shutters co mp artmen t.
lifting truck manipulation is described in par. 7.1.9.

F i g u re 168: Sh u tters l i fti n g tru ck w i th al l actu ati n g F i g u re 169: M o di fi ed shu tters l i f ti ng tru ck after
el emen ts. d emo u n ti ng of bo tto m actu atin g el emen ts.

94
Pow er cab l e test - M axi mu m ap p l i ed vo l tag e
Rat ed v olt age of t he swit ch gea r Ur [ k V] 12 17. 5 24
Rat ed po wer - f req ue nc y cabl e t est v olt age, max. durat i on 1 mi n Uct (AC) [ k V] 22. 4 30. 4 40
Rat ed DC ca ble t est v olt age, max. Durat ion 1 5 min Uct (DC) [ k V] 36 36 48
Rat ed AC cab le t est v olt age ap plica ble f or VLF t est ing at 0. 1 Hz, max. durat i on 6 0 min Uct ( A C -
[ k Vrms] 19. 2 26. 1 36
VLF )
N o t e : T he t e s t c i r c ui t i s d e s i gne d f o r a m a x i m um a p pl i e d v o l t a ge i n t h e t a bl e .

Caution:
The test circuit is designed for a maximum applied
voltage of table below .

To restore normal operating conditions:

De-energise cable connection. Switch-ON the
earthing switch.
Test the off -circuit condition (see in par. 7.2.1).
Disconnect the cable test equipment.
Connect voltage transformers, surge arr estors if
fitted.
Switch-OFF earthing switch.
Insert the circuit breaker into CB compartment.
Close CB door.
If needed rack-in the cir cuit breaker from test to
service position.
If needed switch-ON cir cuit breaker.

Caution:
After testing, the test connections may retain a
lethal electrical charge after the test equipment is
sw itched OFF. Discharge the test poin ts using a
safety ground (e.g. earthing sw itch to earthed ON
position) and ensure that the test connections are
dead before disconnecting the cable test
equipment. In all cases, ensure that the test points
are really dead.

95
7.3 Service trucks
Instead of earthing, short-circuiting and testing with
module 9 (Figure 171) it is possible to use the service
trucks. These trucks are divided into four different
types:
Earthing truck w ithout making capacity
These trucks carry out the same function as the
earthing switches without making capacity. Therefore
they do not have any capacity to earth the live circuits
under fault conditions. They are used to ensure fixed
additional earthing, as required by the plant service
and maintenance procedures, as a further safety
measure for personnel. The use of these trucks
anticipates removal of the switching device from the
switchgear (circuit -breaker or contactor) and its
replacement with the truck. The panels preset for use
of earthing trucks are fitted with a key lock which, if
activated, prevents their racking -in. This truck is
available in two versions:
Main busbar system earthing.
Power cable earthing.
During the racking-in phase, the main busbar earthing
truck only lifts the top shutter and earths the contacts
connected to the top branches (and therefore to the
main busbar system) by the switchgear structure.
During the racking-in phase, the power cable earthing
truck only lifts the bottom shutter and earths the
contacts connected to the bottom branches (and
therefore to the power cables) by the switchgear
structure. These trucks can also be used in the bus-tie
panels. In this case, they earth the two sides of the
main busbar system.
F i g u re 170: Earth i n g tro l l ey w ith ou t sh o rt ci rcu i t sw i tch ing
cap ab i l i ty.
1 Cont act syst e m
2 Cont act ar ms
3 Act uat ing b ars
4 Eart hing co nt act
5 Eart hing mo du le wit h out short circuit swit chi ng
capab ilit y
Earthing truck w ith making capacity
These trucks carry out the same function as the
earthing switches with making capacity. They consist
of circuit-breakers only fitted with top (main busbar
earthing) or bottom (power cable earthing) terminals.
The contacts without terminals ar e short-circuited by
means of a copper bar and connected to earth by the
apparatus truck. They keep all the characteristics of
96
the circuit-breakers, such as full making capacity and
opening of the live circuits under fault conditions.
They are used to ensu re extremely effective earthing
on circuits stressed by a fault. They allow opening and
closing operations to be carried out rapidly with
remote electric control.
The use of these trucks anticipates removal of the
switching device from the switchgear (ci rcuit-breaker
or contactor) and its replacement with the truck. The
panels preset for use of earthing trucks are fitted with
a key lock which, if activated, prevents their racking -
in. This truck is available in two versions:
Main busbar system earthing.
Power cable earthing.
During the racking-in phase, the main busbar earthing
truck only lifts the top shutter and presets the contacts
connected to the top branches (and therefore the main
busbar system) for closing to earth by the control.
During the racking-in phase, the power cable earthing
truck only lifts the bottom shutter and presets the
contact connected to the bottom branches (and
therefore to the power cables) for closing to earth by
the control. These trucks can also be used in bus -tie
panels. In this case, they earth the two sides of the
main busbar system.
Pow er cable test truck
These trucks allow the insulation tests to be carried
out on the power cables without accessing the feeder
panel or disconnecting the cables from the switchgear.
The use of these trucks anticipates removal of the
switching device from the switchgear (circuit -breaker
or contactor) and its replacement with the truck.
During the racking-in phase, the truck only lifts the
bottom shutter and, by the connectors it is fi tted with,
allows connection of the test apparatus cables. This
truck can only be used in the incoming / outgoing
panels.
Isolation truck
The isolation truck allows the switchgear top and
bottom contacts to be connected directly. Connection
is made extremely safe by using the poles of the HD4
circuit-breakers to insulate the connection bars from
the external environment. In the incoming / outgoing
panels, it connects the main busbar system to the
power cables, whereas in the bus -tie panels, it
connects to the two sides of the busbar system.
This truck is used in the UniGear switchgear to make
incoming / outgoing panels without circuit -breakers in
radial networks, to make cable connections between
two switchgear panels placed in front of each other,
and for constructing interconnection panels and
creating bus-tie-riser panels with double insulation (in
this case, both the panels are made from bus -ties, the
first fitted with a circuit -breaker and the other with an
isolation truck).
Earthing and short-circuiting w ith earthing module
(Figure 171)
Isolate the area to be earthed and secure it
against reconnection.
Carefully follow all safety regulations.
Remove the withdrawable circuit -breaker part from
the relevant switchgear panel.
Secure the shutter in front of the live contact pins
by means of the padlock. Screw on the earthing
module 9 actuating bars 4 as follows: To the top
 position for opening of bottom shutter and to the
bottom position for opening of top shutter.
Further screw on the earthing module 9 insulating
plate 1 with three removable bushings as follows:
- Contact arms 3 in the bottom position for
earthing of cable output feeder.
- Contact arms 3 in the top position for earthing of
busbars.
Insert the earthing module 9 into the test /
disconnected position and then move it into the
service position with the hand crank (Figure 193).
Using a high voltage tester, check that the contact
pins 6 of the earthing module are definitely off -
circuit.
W ithdraw the earthing module back into the test /
disconnected position (chapter 7.1).
Mount a complete short circuit link 7 on the
earthing module 9. Connect one end of earthing
F i g u re 171: T esti n g an d earth i n g mo d ul e.
Act uat ing b ars, remov able
- t op posit io n f or bot t om sh ut t e
- bot t om pos it io n f or t op shut t er
Cont act ar ms, remov able
- bot t om pos it io n f or cable ar ea
- t op posit io n f or busbar ar ea
Insu lat in g p lat e w it h a lt ernat iv e mou nt ing posit i ons f or c abl e or
busbar e art hi ng (t urn t hrou gh 1 80 f or busb ar eart hi ng).
Cont act s yst e ms, repl acea b le f or dif f ere nt cont act pi n
dia met ers o n t he swit c hge ar. Ball h and les, re mov able, f o r
v olt age t est s.
Short - circuit i ng con nect i on - ca n be repl ace d wit h ba ll ha ndl es .
cable 10 under one of three screws M12, with
which short circuit link 7 is connected to contact
pins 6. Connect the second end of this cable to the
earthing terminal in the panel.
Insert the earthing module 9 with short -circuit link
7 mounted and earthing cable 10 returned from the
test / disconnected position into the service
position in the panel with hand crank. For safety
reasons, insert the module only with the circuit-
breaker compartment door closed and with door
catches locked.
Display earthing warning label on the switchgear
panel door.
Secure neighboring areas to prevent inadvertent
contact with live parts (e.g. feeder cables).
The procedure for removing earthing is the same, only
in reverse order.
1 Insu lat in g pl at e wit h 3 re mov ab le bush in ghs
2 Cont act syst e ms
3 Cont act ar ms (3 p cs. )
4 Act uat ing b ars (1 pair)
5 Bushin gs
6 Cont act pin
7 Short - circuit i ng con nect i on, co mp let e
8 Ball ha nd les (3 pcs. )
9 T est ing and eart hi ng mod ule wit h manu al mech anis m
10 Eart hing ca bl e
97
8. Commissioning
8.1 Preparatory work
In preparation for commissioning, the following work
must be carried out:
Check the general condition of the switchgear for
any damage or defects.
Visually inspect the switching devices,
withdrawable parts, iso lating contacts, insulating
parts, etc.
Check connection of the main earthing bar to the
installation earthing conductor (following the
appropriate safety regulations).
Check the paintwork for damage and, where
necessary, touch up as described in (chapter 9.5).
Remove all residues of materials, foreign bodies
and tools from the switchgear.
Clean the switchgear, rubbing down insulating F i g u re 172: W i th d raw ab l e p art w i th VD4 typ e h i g h cu rren t
parts with a soft, dry, clean, non -fraying cloth. ci rcu i t - b reaker, p o l e si d e.
Remove any greasy or sticky dirt as described in
1 T ransport caps (t o be remov ed on co mmisi oni ng)
(chapter 9.4).
2 Lif t ing e yebo lt (t o be remov ed on co mmissi oni ng)
Correctly remount all covers etc. removed during
assembly and testing procedures.
Transport caps on heavy duty vacuum circuit -
breakers if applicable - must be removed.
Lifting eyebolts on high current vacuum
circuitbreakers must be removed if still fitted.
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 de formation caused by
shocks received during transport and storage
-It is advisable to check the SF6 gas pressure
In switchgear panels with an additional ventilation
system for high current circuit -breakers (required
for ambient temperature higher than > 4 0 C
and/or higher frequency 60 Hz - according to
(chapter 2.3) and (Figure 172), (Figure 173), flap F i g u re 173: F i tti n g o f h o ri zon tal p arti ti on w ith add i ti o n al
hanging in partition must rest loosely against leaf ven ti l ati o n fo r h ig h cu rren t circu i t - b reake rs, req u i red d u e
spring (with the centrifu gal fan at a standstill, if to i n creased amb i en t temp era tu re (>40 C) an d / o r i n crease d
freq u en c y (60 Hz) ac co rd i n g to secti o n 2. 3. T h e in tern al
fitted). This is not standard. fl ap i s sh ow n i n th e ser vi ce p o si ti o n (o p en ). Sid e vi ew , b u t
w ith ou t th e w in d van e w i th mi cro - sw i tch req u i red w ith a
To check: fan . No t stan d ard .

Insert a suitable screwdriver through opening 4 1 Hori zo nt al part it i on

2 Leaf sprin g
(Figure 173) in horizontal partition 1 and into
3 Brack et
bracket 3 on flap 5. 4 Insp ect io n apert ur e
Swing flap 5 upwards and allow it to rest loosely 5 F lap
again on leaf spring 2. 6 Cent rif ug al f an
If the flap is in the locked position, use the
screwdriver to press leaf spring 2 downwards by
approx. 5 mm to release the lock before swinging
the flap.
If any centrifugal fans cont rolled in relation to
primary current are fitted, also check that these
function correctly.

On motorized withdrawable parts, check the direction

of rotation of the travel motor. For any other matters
regarding operation of the withdrawable circuit-
breaker part and testing facilities for the withdrawable
part.

98
F i g u re 174: Ho ri zo n tal p arti tio n w ith add i tio n al ven til ati o n
faci l i ti es. Ch ecki n g un i mp ed ed mo vemen t o f th e in tern al
fl ap .
1 Insp ect io n ope nin g

8.2 Measurements and tests

Tests at site are mandatory prior to energization of
the switchgear.
The main purpose of site tests in general is to make
sure the switchgear is ready for energization, not to
repeat the factory testing and confirm the factory
results. For manufacturers recommendation of test
scope and method please contact ABBs Service
Department. After performing the tests, make sure
that all normal service conditions are restored.

W ARNING
The check is only successful if all the above
tests have been passed successfully.
If the inspection gives negative results,do not
put the apparatus into service but, if necessary,
contact ABBs Customer Service Department.
Only energise the sw itchgear w ith all the
withdrawable parts in the test position and with
the circuit-breaker open.

99
9. Maintenance
9.1 Maintenance strategies
Preventive maintenance is maintenance carried out
at predetermined intervals or according to prescribed
criteria, aimed at reducing the failure risk or
performance degradation of the equipment. This
method is based on scheduled activities performed on
the out-of-service equipment including: visual checks,
apparatus cleaning, mechanical components
lubrication, worn parts replacement and routine tests.
Risk-based maintenance is maintenance carried out
by integrating analysis, measurement and periodic
test activities with standard preventive maintenance.
The gathered information is viewed in the context of
the environmental, operation and process conditi on of
the equipment in the system. The aim is to perform
the asset condition and risk assessment and define
the appropriate maintenance tasks. Please refer to
next chapters for details of preventive and risk -based
maintenance programs.
W ARNING - Alw ays follow 7 safety steps:
Clearly identify the w ork location
Disconnect and secure against reconnection
Protect against any other live parts
Take special precautions w hen close to bare
conductors
Check the installation is dead
Carry out earthing and sho rt circuiting
Issue a permit to w ork
100
9.2 Preventive maintenance
Maintenance serves to preserve trouble -free operation
and achieve the longest possible working life of the
switchgear. It comprises the following closely re lated
activities:
Inspection: Determination of the actual condition.
Servicing: Measures to preserve the specified
condition.
Repair: Measures to restore the specified condition.
Note:
W hen 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 over -riding 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 depend,
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 operatin g instructions must also be
followed, together with this instruction manual in the
individual cases concerned:
Vacuum circuit-breaker: type VD4 (1VCP000001).
Vacuum circuit-breaker: type VD4 - high current.
Vacuum circuit-breaker with magnetic actuator:
type VM1.
Gas circuit-breaker: type HD4.
Vacuum contactor: type VSC.
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 panels
with NALFE earthing switch).
Intervals for inspection, servicing and repairs number of rated and short -circuit current switching
Time intervals for maintenance work to be carried out operations, ambient temperature, pollution etc. W e
always depend on the operating conditions of the recommend carrying out the maintenance work at the
switchgear, and mainly on the mode of operation, the following intervals:

Act iv it y See sect io n T ime int erv al in years Accordin g t o nu mb er of swit chi ng op erat io ns
Insp ect io n 9. 3 4(1) As require d ( 3 )
Serv icing 9. 4 4(2) As require d ( 3 )
Repa ir 9. 5 As require d As require d
( 1 ) I n m o r e d e m a nd i n g s e r v i c e c o n d i t i o ns , w e r e c o m m e nd r e d uc i n g t h i s i nt e r v a l s u i t a b l y a l s o s e e s e c t i o ns 1 a nd 2 .
( 2 ) A c c o r d i n g t o t he r e s u l t s o f t he i ns pe c t i o n.
( 3 ) S e e t he i ns t r uc t i o n m a n ua l s o f t he s w i t c hi n g d e v i c e .

9.3 Inspection
Inspection is primarily to carry out a visual check for Basic checking with temporary operation of the
grime, corrosion and moisture: centrifugal fan with an external power supply of
230 V AC.
Effects of high temperature on the main circuits.
In both cases, check for unimpeded normal running
Traces of partial discharge on the insulating of the fan and listen for any unusual bearing noise.
material parts. Remove any dirt on the fan rotor.
Traces of leakage current on the insulating Check unimpeded operation of the wind vane and
material parts. microswitch by starting the fan several times.
Surfaces of the contact systems. The wiring to removable horizontal partition 29
(Figure 3) can be disconnected behind the right -
However, inspection must also include correct hand side duct cover. Follow the circuit diagram
mechanical / electrical operation of the following and carefully reconnect the wiring again on
parts: switching devices, actuating, interlocking, completion.
protection and signalling devices.

Special conditions
On panels with additional ventilation devices due to
Caution:
increased ambient temperature (chapter 2.3).
With regard to the sw itching devices, their
Check flap 27 (Figure 3) for correct operation, also separate Instruction manuals should be followed.
(Figure 173).
The centrifugal fan (if fitted) does not require any
special maintenance. Its working life depending
on the service conditions, and one significant Visual inspection of busbar compartment
parameter being the room temperature - is approx.
By gaining access from the circuit -breaker
between 20,000 and 30,000 operating hours.
compartment, remove bulkhead 3 (Figure 178),
unscrewing 7 x M8 screws.
Checking readiness for operation can be carried out
After removal of the bulkhead from the circuit -
as follows:
breaker compartment, the main busbars are
Load-dependent functional test with controllable visible.
primary current supply of the relative instrument Visually check that the top monoblocks 4 (Figure
transformer. On current rise: 178), where the tulip isolating contact is housed,
-to approx. 70 % of the rated instrument are fully intact and do not show any sign of
transformer current, the fan must start. damage.
-to 80 % of the rated instrument transformer Visually check that the insulating covering of the
current, the fan must have reached the required main busbars and the insulating joining cover of
minimum air flow. Corresponding monitoring the busbars are fully intact and do not show an y
(signalling) by the wind vane with microswitch. sign of damage.

101
Cleaning and checking the auxiliary connections
Open the miniature circuit -breakers 1 (Figure 175)
positioned inside the low voltage compartment to
remove the auxiliary power supply to the panel.
Carry out a visual inspection on all the cabling,
terminal boxes 2 and check for any presence of
dirt.
Manually check correct insertion of the cabling in
the terminal box.
F i g u re 177: T esti n g i n terl o ck co n d i ti o n s.
1 Door int er lock s
2 F ail saf e
1.
F i g u re 175: Au xi l i ar y co n n ec ti o n s.
1 Circuit bre ak er
2 T erminals
Testing interlock conditions
Carry out a visual inspection of the mechanical parts
of the interlocks (key locks 1 , door interlocks 1 , fail
safe 2) and check for any presence of humidity and
signs of corrosion on the moving parts.
Use no force! Also see the note in (chapter 7.1)!
2.
3.
F i g u re 176: T esti n g i n terl o ck co n d i ti o n s.
1 Key l ock s
102
The withdrawable par t must only be movable from
the test / disconnected position into the service
position when the circuit-breaker is open and the
earthing switch is open. Check the following
conditions individually:
W ith the circuit-breaker closed, insertion of the
withdrawable part towards the service position
must be locked after only half a turn of the crank in
the clockwise direction, and it must not be possible
to switch on the travel motor on motor -operated
withdrawable parts.
W ith the earthing switch closed, insertion of the
withdrawable part towards the service position
must be locked after only two clockwise turns of
the crank, and it must not be possible to switch on
the travel motor on motor-operated parts.
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:
W ith 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.
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 2 (Figure 142)
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 a uxiliar y
switch (Figure 16) 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 (Figure 16) in the withdrawable assembly.
 7.
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. W ithdrawable 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.
Disengage locking magnet Y0 by pulling the
magnet armature.
W hile doing so, turn crank (Figure 193) 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 2 (Figure
142) as well as later insertion must be locked in
the withdrawable part service position. Check this
condition
Operation of the earthing switch must only be
possible when withdrawable part 1 (Figure 145) is
in the test / disconnected position or the removed
position (subject to any additional electro-magnetic
interlocks in individual cases).
Check this condition:
W ith the withdrawable part in the test /
disconnected position, it must be possible to press
slide 2 (Figure 158), in front of the earthing switch
operating shaft 1, downwards to the opening
position. The earthing switch can then be
operated.
W ith the slide pressed down, it must also be
impossible to start the travel motor on moto r-
driven withdrawable parts.
If the slide is pressed down slightly when the
travel motor is running, the motor must then
automatically switch off immediately. The selected
travel direction is continued by pressing the button
It is only possible to press sl ide 2 (Figure 158)
down fully with a running travel motor when the
latter is in the start-up phase.
W hen the withdrawable part is moved inwards
towards the service position, pressing down of
slide 2 (Figure 158) must be locked after only one
and a half clockwise turns on the crank.
103
9.4 Servicing
W hen, during an inspection as per (chapter 9.3), the 9.4.2 Maintenance in cable compartment
need to carry out cleaning operations is noted, Checking tightening of the cable busbar connections
proceed as follows:
Open the cable compartment door; the cable
Clean the surfaces: busbar connections are visible.
Remove any dry dust deposits which are not Using a dynamometric spanner, check tightness of
strongly adherent using a soft dry cloth. all the screws. Refer to the table on page 51 for
Remove any more adhering dirt with ETHANOL F the tightening values.
25 M.
Clean the insulating surfaces and the conductive Note
components with ETHANOL F 25 M. The cable compartment door cannot be opened if the
After cleaning, rinse with clean water and dry earthing switch is open.
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 service
department.

9.4.1 Maintenance in busbar compartment

Checking of the tightening main busbars
By accessing thro ugh the circuit-breaker
compartment, remove the bulkhead 3 (Figure 178)
unscrewing 7 x M8 screws.
After the removal of the bulkhead from the circuit -
breaker compartment, the main busbars are
visible.
Using a dynamometric spanner, check tightness of
all the screws. Refer to the (chapter 6.3) for the
tightening values.

F i g u re 179: I n tern al vi ew o f th e cab l e co n n ecti o n

co mp artmen t , w i th a maxi mu m n u mb er o f si x cab l es i n
p aral l el .
1 Eart hing sw it ch pos it ion i ndic at or
2 Cabl e bus bar con nect io n
3 F airlea d
4 Slot t ed bot t o m pl at e

F i g u re 178: Vi ew o f th e b u sbar co mp artm en t, sh ow n

w ith ou t in su l ati ng co vers.
1 Busbars
2 Branch con duct or
3 Bulk head, re mov abl e
4 T ulip isolat in g cont act

104
Earthing sw itches type EK6; ST-E
Cleaning the kinematics to prevent faults on the Cleaning and checking of the voltage transformers and
signalling contacts anti-ferroresonance circuit.
Fixed version voltage transformers:
Carry out a visual inspection of the kinematics and
check for any presence of dirt, humidity and signs Open the cable compartment door.
of corrosion on the moving parts. Remove the circuit -breaker plate (Figure 182) to
Manually check correct changeover of the earthing get larger access.
switch signalling contacts (Figure 181). Visually check the voltage transformer
Remove any deposits of dust using a dry cloth that connections.
does not leave any deposits on the treated Using a dynamometric spanner check tightness of
surfaces (do not use woollen cloths). all the screws. Refer to the table in (chapter 6.3)
If necessary, grease the mechanical moving parts for the tightening values.
by applying a thin layer of mechanical g rease for Carry out a visual inspection of the transformers
moving parts. and check for any presence of dirt.
Carry out a visual inspection on the toothed wheel Remove any deposits of dust using a dry cloth that
and pinion 2 (Figure 180) and check any presence does not leave any deposits on the treated
of dirt, humidity and signs of corrosion on the surfaces (do not use woollen cloths).
moving parts.
Voltage transformers in removable version:
Open the cable compartment door.
Manually withdraw the VT truck.
Carry out a visual inspection of the transformers
and check for any presence of dirt.
Remove any deposits of dust using a dry cloth that
does not leave any deposits on the treated
surfaces (do not u se woollen cloths).

Voltage transformers in withdrawable version:

Open the cable compartment door.
Manually withdraw the VT truck.
Carry out a visual inspection of the transformers
and check for any presence of dirt.
Remove any deposits of dust using a dry cloth that
does not leave any deposits on the treated
F i g u re 180: M an u al earth i ng sw i tch o p erati n g mech an i sm. surfaces (do not use woollen cloths).
1 Driv e shaf t
2 Auxili ar y cont act

F i g u re 182: Remo vab l e ci rcu i t - b reaker p l ate.

F i g u re 181: Ch an g eo ver o f the earth i n g sw i tch sig n al li n g

co n tacts.

Instrument transformers
Cleaning and checking of the current transformers.
Open the cable compartment door.
Remove the circuit-breaker plate (Figure 182) to
get larger access.
Visually check the connections of the current
transformers.
Using a dynamometric spanner, check the
tightness of all the screws. Refer to the table in
(chapter 6.3) for the tightening values.

105
Cleaning and checking the anti-ferroresonance circuit.
Open the miniature circuit -breakers 1 (Figure 175)
positioned inside the low voltage compartment to
remove the auxiliary power supply to the panel.
Carry out a visual inspection on the anti -
ferroresonance resistors and check for any
presence of dirt.
Manually check correct insertion of the cabling.
9.4.3 Maintenance in circuit -breaker compartment
Lubrication of the isolating contacts:
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 mechanical moving parts
by applying a thin layer of mechanic al grease for
moving parts.

F i g u re 183: An ti - ferro re so n an ce resi sto r.

Cleaning and checking of the fuses.

W ith the VT truck withdrawn, manually hook up the
fuses contained in the resin tube of the voltage
transformers.
Carry out a visual inspection on the fuses and
check for any presence of dirt.
Remove any deposits of dust using a dry cloth that
does not leav e any deposits on the treated
surfaces (do not use woollen cloths).

F i g u re 184: W i th d raw ab l e p art w i th measu remen t p an el .

1 Resin t ub e (wit h f use)
2 F use
3 Volt age t ra nsf ormer

106
9.5 Repairs
9.5.1 Repair on sw itchgear assemblies
9.5.1.1 Repair of surface damage:
Carry out repair work immediately after a defect
has been discovered.
Completel y 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 apply 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 high qualit y
galvanized steel 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).
Replacement of the contact pins when the surface is
damaged. After any required replacement of contact
pins, the latter should be retightened using the socket
head bolts - see table (chapter 6.3).
F i g u re 186: Vi ew o f in si d e circu i t - b reake r co mp artm en t,
w ith d raw ab l e p art remo ved , sh u tters o p en .
1 Isol at ing t u lip
2 Isol at ing c ont act
3 Lower sh ut t er
9.5.1.2 Repair on earthing switch signaling contact
The auxiliary switches of the interchangeable groups
are adjusted at the factory. W hen 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 4 (Figure 187) for earthing
switch ON must be operated in the range of
movement of the lever 5 - 10 before the end
position.
Auxiliary limit switch 1 for earthing switch OFF
must be:
- operated on earthing switches with manual
mechanisms during the opening movement of slide
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.
- operated on earthing switches with motor
operator (no slide 2 fitted) immediately after the
toggle spring mechanism has passed the dead
centre position during rotation to the OFF position.
In cases where there has been an internal arc is
necessary to repair and clean the whole
substation.
F i g u re 187: M an u al earth i ng sw i tch o p erati n g mech an i sm
w ith au xil i ary co n tacts, si d e p ro tecti o n remo ved .
1 Q 8S1 auxil iar y co nt act eart hi ng swit ch O F F
2 Slidi ng clos ure
3 Ca m plat e, a djust a ble
4 Q 8S2 auxil iar y co nt act eart hi ng swit ch O N
107
F i g u re 188: Earth i n g sw i tch mo to r o p erato r w i th au xi l i ary
co n tacts i n stal l ed , p ro tecti ons remo ved .
1 Lock ing disk
2 Ca m
3 Q 8S2 auxil iar y co nt act eart hi ng swit ch O F F
4 Q 8S1 auxil iar y co nt act eart hi ng swit ch O N

9.5.2 Repairs on w ithdrawable parts

W hen functional tests are carried out on withdrawable
parts, compliance with the conditions listed below
should also be checked. 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 HD4
Vacuum contactor: type VSC
Operating mechanisms of the circuit-breakers with
high voltage - catalogue

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.
W here 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.

108
9.6 Risk-Based maintenance
ABB supports UniGear users with optimized and cost
effective strategies to ensure that the correct actions
are implemented at the right time. Asset managers are
fully supported in moving from conventional
approaches (Corrective maintenance and Preventive
maintenance) to advanced strategies (Risk -based
maintenance and Condition -based maintenance).
In this way, the service activity is no longer driven by
predefined timeframes, observations and past
experiences, but takes into account the actual
condition of the equipment, the required reliability
level and the expetation for life time extension.
This assessment is performed by trained technicians
as part of risk-based maintenance programs or is
carried out automatically by on-line monitoring
systems for condition-based maintenance solutions.
Please refer to brochure 1VCP000427 - Maintenance
by ABB for more details on Risk -Based maintenance.

9.7 Spare parts, auxillary

materials and lubricants
Spare parts
A spare parts list is available on request for
procurement of spare parts. It basically includes
moving parts and parts subject to wear. W hen parts
are required, the serial number of the relevant
switchgear or switching device should always be
quoted.

Auxiliary materials, lubricants

Lubricant - SYN-setral-EK 339
DOW CORNING TORAY DC4 silicone grease
Halogen-free cleansers (optional) - ETHANOL F 25
M (for general cleaning)
Touch-up paint (optional) - Standard colour RAL
7035.

109
9.8 Operating accessories

F i g u re 189: Ch arg i n g l ever (fo r HD4 F i g u re 190: Do u bl e b i t key (t o u se th e F i g u re 191: M an u al emerg en c y

typ e ci r cu i t - b reak er) cen tral l o cki n g d evi c e an d the screw o p erati n g l ever (to remo ve vo l tag e to
typ e d o o r l o ck) VM 1 typ e ci rcu i t - b reake r)

F i g u re 192: O p erati n g l ever (fo r F i g u re 193: Cran k h an d l e (to mo ve th e F i g u re 194: O p erati n g l ever (fo r
earth i n g sw i tch ) w ith d raw ab l e p art i n si d e th e p an el ) sw i tch -d i sco n n ecto r)

110
10. Product quality and environmental
protection
The UniGear panels are produced in compliance with The duty of company is to facilitate subsequent
the requirements of international standards for the recycling or disposal at the end of product life.
quality management system and environmental
management system. In these fields, the level of During disposal of the product, it is always necessary
excellence achieved is documented by quality to act in accordance with local legal requirements in
certificates according to ISO 9001 and by the EMS force.
according to ISO 14 001.
The following methods of disposal are possible:
End of life of product Disposal can either be carried out thermally in an
ABB is committed to complying with the relevant legal incineration plant or by storing on a waste site.
and other requirements for environmental protection
according to the ISO 14 001 standard.

Raw materi al Reco mm en d ed meth o d o f d i sp o sal

Met a l mat eria l (F e, Cu, Al, Ag, Z n, W , ot hers) Separat i oi n and rec yc lin g
T hermopl ast Rec ycli ng or disp osa l
Epox y resin Separat i on of met al a nd t he d is posal of rest
Rubb er Dispos al
O il as diel ect ric (t ransf or mer oi l) Drain ing f or eq ui p ment an d f urt her rec ycli lng or d isp osal
SF 6 gas Dischar gin g f rom e qu ip me nt an d f urt her recyc lin g or disi pos al
Pack ing mat erial - wo od Rec ycli ng or dis pos al
Pack ing mat erial - f oil Rec ycli ng or dis pos al

111
1 V L M 0 0 0 3 6 3 - B , E N - In s t r u ct i on m a n u a l - 2 0 1 6 . 1 1 ( Un i g e a r Z S1 ) ( g s )

Y o u r s a l e s c o n t a c t : w w w .a b b . c o m / c o n t a c t s
M o r e p r o d u c t i n f o rm a t i o n : w w w. a b b . c o m / p r o d u c t g u i d e

T h e d a t a a n d i llu s t r a t i o n s a r e n o t b i n d i n g . W e r e s e rv e t h e r i g h t to
m a k e c h a n g e s wi t h o u t n o t i c e i n t h e c o u r s e o f t e c h n i c a l
d e v e lo p m e n t o f t h e p r o d u c t.

Co p yr i g h t 2 0 1 6 A B B .
A ll r i g h t s r e s e rv e d .