UniGear type ZS1

Medium voltage, arc-proof, air-insulated,

metal-clad switchgear
1
 1
UniGear type ZS1 3

2
UniGear 550 47

3
Double Level UniGear 55

4
Double Busbar System UniGear 63

5
UniGear type ZVC 73

6
Marine Applications 81

1
2
 1
UniGear type ZS1

Page Chap.

Description 4 1.1

Air-insulated 6 1.2

Loss of sevice continuity 8 1.3

Safe 10 1.4

Type-tested 12 1.5

Arc-proof 14 1.6

Vacuum circuit-breaker 16 1.7

Gas circuit-breaker 20 1.8

Vacuum contactor 22 1.9

Service trucks 24 1.10

Switch-disconnector 26 1.11

Instrument transformers 28 1.12

Measurement sensors 30 1.13

Distribution and automation 32 1.14

Automatic transfer systems 40 1.15

Typical units and technical data 42 1.16

3
 Description

Characteristics
• Metal-clad, air-insulated switch-

UniGear
gear.
• Suitable for medium voltage
distribution.
• Guaranteed arc-proof units.
• Factory-tested for indoor installa-
tions.

The Refinement
• Tested in accordance with the
main international Standards.
• Wide range of functional units
available for all installation
solutions.
• Compartments segregated by

Switchge
metallic partitions.
• Modular structure, easily built-up.
• Highly effective use of space.
• Extremely compact contactor unit
in MV
with fuses.
• Fitted with double-level units.
• Start-up, maintenance and
service operations can be carried
out from the front.
• Apparatus handling with the door
closed.
• Units can be installed against the
wall.
• Limited and simple maintenance
activities.
• Complete with mechanical safety
interlocks.
• Earthing switch with full making
capacity.
• Studied to guarantee maximum
service continuity.
• Complete apparatus range: gas
and vacuum circuit-breakers, con-
tactors and switch-disconnectors.
• Conventional or integrated
protection and measurement
systems.
• Fitted with conventional
instrument transformers or new
generation sensors.

4
 1.1

Applications

Utilities and Power Plants

• Power generation stations
• Transformer stations
• Switching stations
• Main and auxiliary switchgear.

Industry
• Pulp and Paper
• Cement
• Textiles
• Chemicals
• Food

ear
• Automotive
• Petrochemical
• Quarrying
• Oil and gas pipelines
• Metallurgy
• Rolling mills
• Mines.

Marine applications
• Rigs
• Drilling platforms
• Off-shore oil rigs
• Tender ships
• Passenger ships
• Container ships
• Tankers
• Cable ships
• Ferries.

Transport
• Airports
• Ports
• Railways
• Underground transport.

Services
• Supermarkets
• Shopping malls
• Hospitals
• Large infrastructures and civil
works.

5
 Air-insulated
From generating stations down to installation
distribution substations, ABB provides the most
reliable and top quality solution for supplying
products, systems and services.
As sole partner, ABB is the largest and most
complete supplier in the world of switchgear and
systems for electric power transmission and
distribution. ABB substations, cables,
transformers, control systems and switchgear are
used by our customers for efficient use of electric
power.
As a leading company in research, development
and innovation, ABB is able to provide the most
complete and suitable solutions for satisfying
present needs and future requirements of
producers, distributors and users of electric power.
The medium voltage switchgear is one of the most
important links in the electric distribution chain
and ABB has developed the UniGear switchgear
with the aim of satisfying all requirements.
UniGear is a combination of consolidated
solutions and innovative components, both of
which are fruit of ABB technology.
UniGear is medium voltage metal-clad switchgear
with a metal enclosure, suitable for indoor
installations.
Metal partitions segregate the compartments from
each other and the live parts are air-insulated.
6
The switchgear is modular and is built up by
placing standardised units side by side in a
coordinated way. The switchgear is simple to
configure and selection of the apparatus and
instruments does not imply dedicated solutions.
The functional units of the switchgear are
guaranteed arc proof in accordance with the IEC
62271-200 Standards, appendix AA, class A
accessibility, criteria 1 to 5. All the start-up,
maintenance and service operations can be
carried out from the front. The switchgear and the
earthing switches are operated from the front with
the door closed. The switchgear can be wall-
mounted. The range of apparatus for UniGear
switchgear is the most complete available on the
market, being able to count on vacuum and gas
circuit-breakers and vacuum contactors with fuses.
All this apparatus is interchangeable inside the
same switchgear unit. This makes use of a single
switchgear-user interface possible, with the same
service and maintenance procedure and
operations. The fixed version switch-disconnector
units complete the range of apparatus. The
switchgear can be fitted with conventional
(transformers and releases) or innovative (sensors
and multi-purpose unit) measurement and
protection components.
Apart from the traditional functional units, the
UniGear switchgear is fitted with double-level
solutions, compact units equipped with contactors
with fuses and double busbar systems. The use of
these units allows extremely efficient use of space.
Standards
The switchboard and main apparatus contained in
it comply with the following Standards:
• IEC 60694 for general purposes.
• IEC 62271-200 for the switchgear.
• IEC 62271-102 for the earthing switch.
• IEC 60071-2 for the insulation coordination.
• IEC 62271-100 for the circuit-breakers.
• IEC 60470 for the contactor.
• IEC 60265-1 for the switch-disconnector.
Normal service conditions
The rated characteristics of the switchboard are
guaranteed under the following ambient conditions:
• Minimum ambient temperature: – 5 °C
• Maximum ambient temperature: + 40 °C
• Maximum relative humidity: 95%
• Maximum altitude: 1000 m a.s.l.
• Presence of normal, non-corrosive and uncon-
taminated atmosphere.
 1.2

Electrical characteristics

Rated voltage kV 7.2 12 17.5 24

Rated insulation voltage kV 7.2 12 17.5 24
Rated power frequency withstand voltage kV 1min 20 28 38 50
Rated lightning impulse withstand voltage kV 60 75 95 125
Rated frequency Hz 50-60 50-60 50-60 50-60
Rated short-time withstand current kA 3s …50 …50 …40 …25
Peak current kA …125 …125 …100 …63
Internal arc withstand current kA 1s …40 …40 …40 …25
kA 0.5s …50 …50 – –
Main busbar rated current A …4000 …4000 …4000 …2500
Branch connection rated current A 630 630 630 630
1250 1250 1250 1250
1600 1600 1600 1600
2000 2000 2000 2000
2500 2500 2500 2300
3150 3150 3150 –
Branch connection rated current A 3600 3600 3600 2500
with forced ventilation 4000 4000 4000 –

Degrees of protection
The degrees of protection of the
switchboards conform with IEC
60529 Standards.
UniGear switchboards are normally
supplied with the following standard
degrees of protection:
• IP4X on the external housing.
• IP2X inside the units.
On request, the external housing can
be supplied with different degrees of
protection up to a maximum of IP53.
The electrical characteristics of the
switchboard can vary for ambient
conditions other than those de-
scribed and for higher degrees of
protection than the standard ones.

Colour of the external surfaces

RAL7035.

7
 Loss of service continuity
With IEC 62271-200, new aspects relative to new
definitions and classifications of MV switchgear
have been introduced. One of the most significant
changes introduced in this release is that
classification of switchgear into metal-clad,
compartmented and cubicle types has been
completely abandoned. Revision of switchgear
classification rules has been based on the user’s
point of view, in particular on aspects like service
and maintenance of the switchgear, according to
the requirements and expectations for good
substation management, from installation to
dismantling. In this context, Loss of Service
Continuity has been chosen as a fundamental
parameter for the user.
According to the updated rules, UniGear
switchgear can be defined as follows:
1. Interlock-controlled accessible compartment
compartment containing high-voltage parts,
intended to be opened for normal operation and/or
normal maintenance, in which access is controlled
by integral design of the switchgear and
controlgear.
2. Procedure based accessible compartment
compartment containing high-voltage parts,
intended to be opened for normal operation and/or
normal maintenance, in which access is controlled
by a suitable procedure combined with locking.
3. LSC2B
Busbar, feeder and apparatus compartments
physically and electrically segregated.
This is the category that defines the possibility of
keeping other compartments and/or functional
units energised when opening a main circuit
compartment.
4. Partition Class
Metal-enclosed switchgear and controlgear
providing continuous metallic partitions and/or
shutters (if applicable), intended to be earthed,
between opened accessible compartments and
live parts of the main circuit.
Metallic partitions and shutters or metallic parts of
them shall be connected to the earthing point of
the functional unit.
8
Compartments
Each unit consists of three power compartments:
apparatus [A], busbars [B] and feeder [C].
There are two versions available for closing the
apparatus and feeder compartment doors - with
screws or central handle.
Each unit is fitted with an auxiliary compartment
[D], where all the instruments and cabling are
housed.
Arc-proof switchgear is normally provided with a
duct [E] for evacuation of the gases produced by
an arc.
All the units are accessible from the front and the
maintenance and service operations can therefore
also be carried out with the switchgear wall
mounted.
The compartments are segregated from each
other by metallic partitions.
Main busbars
The busbar compartment contains the main
busbar system connected to the fixed upper
isolating contacts of the apparatus by means of
branch connections.
The main busbars are made of electrolytic copper.
Up to 2500 A, the system is made with flat bus-
bars; for currents between 3150 A and 4000 A, a
special copper section is used.
The busbars are normally covered with insulating
material. There is a single busbar compartment
along the whole length of the switchgear and this
can be fitted with segregations for dividing each
unit into compartments.
Branch connections
The feeder compartment contains the branch
system for connection of the power cables to the
fixed lower isolating contacts of the apparatus.
The branch connections are made of electrolytic
copper. They are made with flat busbars for the
whole range of currents and are normally covered
with insulating material.
Earthing switch
Each incoming/outgoing feeder compartment can
be fitted with an earthing switch for cable earthing.
The same device can also be used to earth the
busbar system (measurements and bus-tie units).
It can also be installed directly on the main busbar
system in a dedicated compartment (busbar
applications).
The earthing switch has short-circuit making
capacity.
 1.3

Control of the apparatus is from the front of the

switchgear with either manual or motor-operated
operation. E
The position of the earthing switch can be seen
from the front of the switchgear by means of an
indicator.

Earthing busbar
The earthing busbar is made of electrolytic copper. D
It runs longitudinally all round of the switchgear,
thereby guaranteeing maximum personnel and
installation safety.

Insulating bushings and shutters B

The insulating bushings contained in the appara-
tus compartment contain the fixed contacts for
connection of the apparatus with the busbar
compartment and feeder compartment respective-
ly. They are single-pole type and are made of
epoxy resin. The shutters are metallic and are A
activated automatically during movement of the
apparatus from the racked-out position to the
service position and vice versa.

Cables
Single and three-core cables up to a maximum of
twelve per phase can be used depending on the
rated voltage, the unit dimensions and the cable
cross section.
The switchgear can be wall-mounted in the station
because the cables are easily accessible from the C
front.

Gas exhaust duct

The gas exhaust duct is positioned above the
switchgear and runs along its whole length.
Each power compartment is fitted with a flap
positioned on the top of it. The pressure generated
by the fault makes it open, allowing the gas to
pass into the duct.
Evacuation from the room of the hot gases and conformity with the Standards, such as expansion
incandescent particles produced by the internal chambers, absorbent filters and longitudinal
arc must normally be carried out. The UniGear evacuation chimneys.
switchgear is fitted with a complete range of
solutions to deal with all requirements, either in Busbar applications
the case where evacuation is possible directly at
Each switchgear unit can be fitted with an acces-
the end of the switchgear, or when solutions from
sory busbar application:
the front or rear are requested.
• current or voltage transformers for busbar
Some installations, such as marine ones, do not
measurements
allow conveyance of the gases to the outside of
• busbar system earthing switch
the room and therefore dedicated solutions have
• top entry duct to make interconnections be-
been realised to guarantee personnel safety and
tween different pieces of switchgear.

9
 Safe

The UniGear switchgear is fitted with all the

interlocks and accessories needed to guarantee
the high level of safety and reliability both for the
installation and operators.

Interlocks
The safety interlocks can either be the standard
ones [1-2-3] or those available on request [4-5].
The former are foreseen by the Standards and are
therefore necessary to guarantee the correct
operation sequence. The latter can be supplied on
request and they must be foreseen by the installa-
tion service and maintenance procedures.
Their presence guarantees the highest level of
reliability even in the case of an accidental error
and allows what ABB defines as an “error-free” The operations for apparatus racking-in/out [13]
system of interlocks. and earthing switch opening/closing [14] can be
prevented by applying the padlocks to the inser-
tion slots of the relevant operating levers.
Keys The padlock can also be applied to the earthing
The use of key interlocks is very important in switch of busbar applications.
realising the interlocking logics between units of The metallic segregation shutters [15] can be
the same switchgear, or of other medium, low and locked by means of two independent padlocks in
high voltage switchgear. The logics are realised by both the open and closed positions.
means of distributors or by ringing the keys. The switchgear is preset for using padlocks with a
The apparatus truck [6] can be locked in the 4 to 8 mm diameter.
racked-out position and the relevant lock key can
only be removed with the apparatus in this posi-
tion. The earthing switch closing [7] and opening Locking magnets
[8] operations can be locked by means of keys. The locking magnets are used to make automatic
The latter can only be removed with the earthing interlock logics without human intervention.
switch in an opposed position to the lock to be The apparatus racking-in/out [16] and the earthing
made. These locks can also be applied to the switch opening/closing [17] operations can be
earthing switch of busbar applications. prevented. This magnet can also be applied to the
The apparatus racking-in/out operations [9] and earthing switch of busbar applications.
earthing switch opening/closing [10] can be The doors of the apparatus [18] and feeder [19]
prevented by means of key locks, which prevent compartments can be locked in the closed posi-
insertion of the relevant operating levers. The key tion. The magnets can be applied to both door
lock can also be applied to the earthing switch of closing versions - with screws or with central
busbar applications. The keys can always be handle.
removed. The magnets operate with active logics and
therefore the lack of auxiliary voltage makes the
lock become operative.
Padlocks
The apparatus [11] and feeder [12] compartment
doors can be locked in the closed position by
means of padlocks. These can be applied to both
door closing versions - with screws or central
handle.

10
 1.4

Standard safety interlocks (mandatory)

Lock Condition
1 A Apparatus racking-in/out Apparatus closed
B Apparatus closing Undefined truck position
2 A Apparatus racking-in Apparatus multi-contact plug unplugged
B Apparatus multi-contact plug unplugging Truck in service or undefined position
3 A Earthing switch closing Truck in service or undefined position
B Apparatus racking-in Earthing switch closed

Additional safety interlocks (on request)

Lock Condition
4 A Apparatus compartment door opening Truck in service or undefined position
B Apparatus racking-in Apparatus compartment door open
5 A Feeder compartment door opening Earthing switch open
B Earthing switch opening Feeder compartment door open

Keys
6 Apparatus racking-in lock
7 Earthing switch closing lock
8 Earthing switch opening lock
9 Insertion of the apparatus
raking-in/out crank lever
10 Insertion of the earthing switch
operating lever
Can only be removed with the truck in the racked-out position
Can only be removed with the earthing switch open
Can only be removed with the earthing closed
Can always be removed
Can always be removed

Padlocks
11 Apparatus compartment door opening
12 Feeder compartment door opening
13 Insertion of the apparatus raking-in/out crank lever
14 Insertion of the earthing switch operating lever
15 Shutters opening or closing

Locking magnets
16 Apparatus racking-in/out
17 Earthing switch opening and closing
18 Apparatus compartment door opening
19 Feeder compartment door opening

Accessory devices
20 Shutters fail-safe
21 Apparatus-switchgear
unit compatibility matrix
22 Circuit-breaker mechanical
operating mechanism
The device locks the shutters in the closed position when the apparatus is removed from
the compartment. The operator cannot open the shutters manually. The shutters can only
be operated by the apparatus truck or the service trucks.
The apparatus multi-contact plug and relative switchgear unit socket are equipped unit
compatibility matrix with a mechanical matrix, that disables apparatus racking-in into a
switchgear unit with an inappropriate rated current.
The apparatus compartment is equipped with a mechanical device, that enables circuit-
breaker closing and/or opening directly by means of the front operating mechanism
pushbuttons, keeping the door closed. The controls can be operated with the circuit-
breakers in the service and racked-out position.

11
 Type-tested
The UniGear switchgear has under-
gone all the tests required by the
international (IEC) Standards and
local Standards (for example, the
Chinese GB and Russian GOST
standards). Apart from this, the tests
required by the main shipping
registers (LR, DNV, RINA, BV and
GL) have been carried out for use of
the switchgear in marine installa-
tions.
As indicated in the regulations of
these standards, the tests were
carried out on the switchgear units
considered most sensitive to the
effects of the tests and therefore the
results were extended to the whole
range.
Arc withstand test. The tests simulate situations which occur very
rarely or even never in the installations. For
example, a short-circuit at the maximum current
level for which the installation has been designed
is rather unrealistic because of the presence of
current-limiting components (such as the cables)
and because the power available is normally lower
than the rated one.
Apart from this, each switchgear unit is subjected
to the routine tests in the factory before its deliv-
ery.
These tests are aimed at a functional check of the
switchgear based on the specific characteristics of
each installation.
Type tests:
• Short-time and peak withstand current.
• Temperature rise and main circuit impedance
measurements.
• Dielectric test on main and auxiliary circuits.
• Making and breaking capacity of the apparatus.
• Earthing switch making capacity.
• Mechanical operations.
Type tests required by the shipping regis-
ters:
• High ambient temperatures (45 °C).
• Inclination.
• Vibration.
12
Routine factory tests:
• Visual inspection and check.
• Mechanical sequence operations.
• Cabling check.
• Electrical sequence operations.
• Insulation test.
• Measurement of the resistance of the main
circuits.
Type tests:
• Short-time and peak withstand current
The test shows that the main power and the
earthing circuits resist the stresses caused by the
passage of the short-circuit current without any
damage. It should also be noted that both the
earthing system of the withdrawable apparatus
and the earthing busbar of the switchgear are
subjected to the test. The mechanical and electri-
cal properties of the main busbar system and of
the top and bottom branch connections remain
unchanged even in the case of a short-circuit.
• Temperature rise
The temperature rise test is carried out at the
rated current value of the switchgear unit and
shows that the temperature does not become
excessive inside of it. During the test, both the
switchgear and the apparatus it may be fitted with
are checked (circuit-breakers, contactors and
switch-disconnectors). Apparatus subject to testing
in free air is able to withstand higher rated cur-
rents than that inserted in a switchgear unit,
therefore the rated current of the apparatus
depends on the characteristics of the switchgear
and on the relevant ventilation system (natural or
forced).
• Dielectric
These tests check that the switchgear has suffi-
cient capability to withstand the lightning impulse
and the power frequency voltage. The power
frequency withstand voltage test is carried out as
a type test, but is also routine on every switchgear
unit manufactured.
 1.5

• Apparatus making and breaking capacity • Inclination

All the apparatus (circuit-breakers, contactors and The test is carried out by inclining the switchgear for
switch-disconnectors) are subjected to the rated a defined time up to 25° alternatively on all four
current and short-circuit current breaking tests. sides and operating the apparatus (circuit-breaker,
Furthermore, they are also subjected to the contactor and earthing switch).
opening and closing of capacitive and inductive The test proves that the switchgear is able to resist
loads, capacitor banks and cable lines. these extreme service conditions and that all the
apparatus it contains can be operated without any
problems and without being damaged.
• Earthing switch making capacity
The earthing switch of the UniGear switchgear can
be closed under short-circuit. In actual fact, the
earthing switch is normally interlocked to avoid
being operated on circuits which are still live.
However, should this happen for any one of
several reasons, safety of the personnel operating
the installation would be fully safeguarded.

• Mechanical operations
The mechanical life tests of all the operating parts
highlight the reliability of the apparatus.
General experience in the electro-technical sector
shows that mechanical faults are one of the most
common causes of a fault in an installation. Inclination test.
The switchgear and apparatus it contains are
tested by carrying out a high number of operations
- higher than those which are normally carried out • Vibration
in installations in service. Moreover, the switchgear The reliability and sturdiness of the UniGear
components are part of a quality program system switchgear has been definitively proven by the
and are regularly taken up from the production result of the withstand test to mechanical stresses
lines and subjected to mechanical life tests to due to vibration. The service conditions on ship-
verify that the quality is identical to that of the ping installations and marine platforms require the
components subjected to the type tests. switchgear to work in environments strongly
affected by vibrations, such as those caused by
the operating motors on board large cruise ships
or on the drilling plants of oil rigs.
The switchgear has
Type tests required by the shipping regis- undergone the vibration
ters: test with a frequency
band from 2 to 100 Hz
• High ambient temperatures and with the following
motion with:
The service conditions of the electrical apparatus – 1 mm amplitude in
in shipping installations are generally more severe the frequency range
than those in normal land applications. between 2 and 13.2
The temperature is certainly one of these factors Hz.
and for this reason the shipping register regula-
– 0.7 g acceleration
tions require the switchgear to be able to operate
amplitude in the
at higher ambient temperatures (45 °C, but even
frequency range
higher) than those foreseen in the IEC Standards
between 13.2 and
(40 °C). Vibration test.
100 Hz.

13
 Arc-proof
When developing modern medium voltage switch-
gear, personnel safety must necessarily take first
place and this is why the UniGear switchgear has
been designed and tested to withstand an internal
arc due to a short-circuit current of the same level
as the maximum short-time withstand level.
The tests show that the metal housing of UniGear
switchgear is able to protect personnel operating
near the switchgear in the case of a fault which
evolves as far as striking an internal arc.
An internal arc is among the most unlikely of
faults, although it can theoretically be caused by
various factors, such as:
• Insulation defects due to quality deterioration of
the components. As an example, the causes can
be adverse environmental conditions and a
highly polluted atmosphere.
• Overvoltages of atmospheric origin or generated
by operation of a component.
• Incorrect operations due to not respecting the
procedures or to inadequate training of the
personnel in charge of the installation.
• Breakage or tampering of the safety interlocks.
• Overheating of the contact area, due to the
presence of corrosive agents or when the
connections are not sufficiently tightened.
• Entry of small animals in the switchgear.
• Material left behind inside the switchgear during
maintenance operations.
The characteristics of the UniGear switchgear
notably reduce the incidence of these causes in
generation of faults, but some of them cannot be
eliminated definitively.
The energy produced by the internal arc causes
the following phenomena:
• Increase in the internal pressure.
• Increase in temperature.
• Visual and acoustic effects.
• Mechanical stresses on the switchgear struc-
ture.
• Melting, decomposition and evaporation of
materials.
Unless suitably controlled, these can have very
serious consequences for the operators, such as
wounds (due to the shock wave, flying parts and
the doors opening) and burns (due to emission of
hot gases).
14
The test checks that the compartment doors
remain closed and that no components are
ejected from the switchgear even when subjected
to very high pressures, and that no flames or
incandescent gases come out, thereby ensuring
the physical integrity of the personnel operating
near the switchgear.
Moreover that no holes are produced in the
external freely accessible parts of the housing and
finally, that all the connections to the earthing
circuit remain efficacious, guaranteeing the safety
of personnel who may access to the switchgear
after the fault.
The IEC 62271-200 Standard describes the
methods to be used for carrying out the test and
the criteria which the switchgear must conform to.
The UniGear switchgear fully conforms to all the
criteria indicated:
1 The doors of the switchgear must remain
closed and no opening of the cover panels must
occur.
2 Any part of the switchgear which may be
hazardous for personnel must not be ejected.
3 No holes must appear in the external housing
of the switchgear in any parts accessible to
personnel.
4 The vertically and horizontally arranged fabric
indicators placed outside the switchgear must
not get burnt.
5 All the switchgear earthing connections must
remain effective.
In the case where classification IAC is proven by
the tests, the metal enclosed switchgear will be
designated as follows:
– General: classification IAC (initials for Internal
Arc Classified)
– Accessibility: A, B or C (switchgear accessible to
authorized personnel only (A), to all (B), not
accessible due to installation (C))
– Test values: test current in kiloamperes (kA),
and duration in seconds (s).
UniGear switchgear is classified IAC AFLR.
When installing the switchgear, some fundamental
points must be taken into consideration:
• Level of the fault current (16...50 kA).
• Duration of the fault (0.1...1s).
• Escape routes for the hot and toxic gases given
off by combustion of materials.
• Dimensions of the room, with special attention
to the height.

The parameters of each specific plant mean that
evacuation of the hot gases and incandescent
particles must be checked very carefully in order
to ensure and maintain personnel safety.
UniGear switchgear is fitted with a complete range
of solutions to deal with all requirements, when
evacuation is possible inside the room, but also
when this is not compatible with the plant charac-
teristics, as in the case of shipping installations.
UniGear switchgear offers complete passive type
protection against the effects of a fault due to an
internal arc by means of its structure for a time of
1s up to 40 kA and 0.5s at 50 kA.
ABB has also developed protection systems which
allow very important objectives to be achieved:
• Detection and extinction of the fault, normally in
less than 100ms.
• Limitation of the consequences of the fault on
the apparatus.
• Limitation of out of service.
For active protection against an internal arc,
devices consisting of various types of sensors can
be installed in the various compartments, which
detect the immediate outburst of the fault and
carry out selective opening of the circuit-breakers.
Arc duration and
damage caused
Steel
Copper
Cables
1.6
The limiting systems are based on sensors which
exploit the pressure or light generated by the fault.
The ITH and FRD devices (20 ms activation time)
belong to the former family, whereas the TVOC
and REA systems (3 ms activation time)
belong to the latter.
ITH
The sensors consist of microswitches positioned
on the top of the switchgear near the gas exhaust
flaps of the three power compartments (apparatus,
busbars and feeder). The shock wave makes the
flats open and operate the microswitchesm
connected to shunt opening releases of the circuit-
breakers.
FRD
This system consists of pressure sensors located
in the auxiliary compartment and connected to the
three power compartments by means of small
tubes. The sensors detect the rising front of the
pressure wave which develops on the outburst of
the arc and react by making the circuit-breakers
open. The sensors are protected against the
external environment and can be checked even
with the switchgear in service.
TVOC
This system consists of an electronic monitoring
device located in the auxiliary compartment which
the optic sensors are subject to. These are
distributed in the various power compartments and
are connected to the device by means of optic
fibres. When a certain established light level is
exceeded, the device opens the circuit-
breakers.To prevent the system from intervening
due to light occasionally generated by external
phenomena (flash of a camera, reflections of
external lights, etc.), current transformers can also
be connected. The protection module only sends
the opening command to the circuit-breaker if it
receives the light and short-circuit current signal
simultaneously.
REA
Please refer to page 38.
15
 Vacuum circuit-breaker
UniGear switchgear can be fitted with the widest
range of apparatus available on the market today
and of these the vacuum circuit-breaker now
occupies a position of prime importance in all
sectors of primary distribution.
Vacuum circuit-breakers cover the whole range of
switchgear parameters and therefore the whole
range of applications.
Dozens of years of experience gained in develop-
ing and using vacuum interrupters are today
reflected in the range of ABB circuit-breakers,
which stand out for their exceptional electrical and
mechanical characteristics, extremely long
and low maintenance life, compactness and the
use of highly innovative construction techniques.
ABB develops and produces a complete range of
interrupters for use in circuit-breakers and contac-
tors and for all medium voltage applications.
VD4
The VD4 medium voltage circuit-breaker interrupt-
ers use the vacuum to extinguish the electric arc
and as the insulating medium.
Thanks to the unequalled properties of vacuum
and the breaking technique used, current interrup-
tion takes place without arc chopping and without
overvoltages. Restoration of the dielectric proper-
ties following interruption is extremely rapid.
The VD4 circuit-breakers are used in electrical
distribution for control and protection of cables,
overhead lines, transformer and distribution
substations, motors, transformers, generators and
capacitor banks.
16
Poles
The VD4 medium voltage circuit-breakers use
vacuum interrupters embedded in resin poles.
Embedding the interrupter in the resin makes the
circuit-breaker poles particularly sturdy and
protects the interrupter itself against shocks,
deposits of dust and humidity.
The vacuum interrupter houses the contacts and
makes up the interruption chamber.
ABB circuit-breakers use the most advanced
vacuum breaking techniques: with radial magnetic
flow for circuit-breakers with medium-low perform-
ances and with axial magnetic flow for those with
high breaking capacity. Both techniques guarantee
even distribution of the arc roots over the whole
surface of the contacts, allowing top performances
at all current values.
The structure of a vacuum interrupter is relatively
simple. The housing is made up of a ceramic
insulator closed at the ends by stainless steel
covers.
The contacts are made of pure copper and
sintered chrome and are welded to the copper
terminals. A metallic bellows allows movement of
the moving contact-terminal group, at the same
time guaranteeing that the vacuum is maintained
in the interrupter.
The interrupter components are welded in an
environment under a very strong vacuum to
guarantee a vacuum of less than 10-5 Pa in the
interrupter.
The interrupter does not therefore contain any
ionisable material. In any case, on detachment of
the contacts, an electric arc is generated which
only consists of the melted and vaporised material
of the contact.A metallic shield is integrated inside
the interrupter to capture the metallic vapours
given off during interruption, as well as for control-
ling the electric field. The particular shape of the
contacts generates a magnetic field which forces
the arc to rotate and to involve a much wide
surface than that of a fixed contact arc. Apart from
limiting the thermal stress on the contacts, all this
makes contact erosion negligible and, above all,
allows the interruption process to be controlled
even with very high short-circuit currents. The
electric arc remains supported by the external
energy until the current passes through its natural
zero.
The ABB vacuum interrupters are zero current
interrupters and are free of any re-striking phe-
nomena.
 1.7

The rapid reduction of the current density and fast

condensation of the metallic vapours, simultane-
ously with the instant of zero current, allow the
maximum dielectric strength between the inter-
rupter contacts to be re-established within a few
thousandths of a second. Supervision of the
vacuum level is not necessary as the circuit-
breaker poles are sealed-for-life pressure systems
and do not require any maintenance.

Operating mechanism
The VD4 circuit-breaker is fitted with a mechanical
stored energy type operating mechanism.
Trip is free and therefore allows opening and
closing operations independent of the operator.
The operating mechanism spring system can be
recharged either manually or by means of a
geared motor.
The apparatus can be opened and closed by
means of the pushbuttons on the front of the
operating mechanism or by means of electric
releases (shunt closing, shunt opening and Apparatus-operator interface
undervoltage). The front part of the circuit-breaker represents the
The circuit-breakers are always fitted with an anti- interface of the apparatus with the user personnel.
pumping device to eliminate the possibility of It is fitted with the following accessories:
simultaneous opening and closing commands, • Opening pushbutton.
closing commands with springs discharged or with
• Closing pushbutton.
the main contacts not yet in their run-end position.
• Operation counter.
• Indicator of the circuit-breaker open and closed
Truck state.
• Indicator of the charged or discharged state of
The poles and operating mechanism are fixed
the operating mechanism springs.
onto a metal support and handling truck.
• Manual charging device of the operating mecha-
The truck is provided with a wheel system which
nism springs.
makes the operations for racking the apparatus
into and out of the switchgear unit possible with • Override selector of the undervoltage release
the door closed. The truck allows efficient earthing (optional).
of the circuit-breaker by means of the metallic
structure of the switchgear unit.
The vacuum circuit-breaker truck can be motor- Standards
operated. IEC 62271-100 for the circuit-breaker.
The racking-out and racking-in operations can be
carried out by means of electrical controls, either
locally by the operator or by a remote system.

17
 Vacuum circuit-breaker
Vmax
Vmax medium voltage circuit-breakers are the
synthesis of ABB technology in designing and
constructing vacuum interrupters and of the
excellence of design, engineering and production
of the circuit-breakers. They find their ideal
use in UniGear ZS1 type switchgear 550 mm wide
up to 17.5 kV, 1250 A and 31.5 kA.
Vmax circuit-breakers are used in electrical
distribution for control and protection of cables,
overhead lines, transformer and distribution
substations, motors, transformers, generators and
capacitor banks.
Insulating monobloc
The structure of Vmax is particularly innovative
since instead of have three distinct separate poles,
it has a single insulating monobloc where the
three vacuum interrupters are housed. The
monobloc and operating mechanism, of the
mechanical type with a spring for operating energy
storage, are fixed to a sturdy metallic frame. The
compact structure ensures the same sturdiness
and mechanical reliability as a traditional circuit-
breaker consisting of an operating
mechanism/pole base cover and three separate
poles. The low speed of the contacts together with
the reduced run and the mass container, limit the
energy required for the operation and therefore
guarantee extremely limited wear on the system.
This means the circuit-breaker requires limited
maintenance.
18
The interrupters of the Vmax medium voltage
circuit-breakers are the same as those used in the
VD4 and VM1 series. The Vmax series therefore
guarantees the same characteristics as the
vacuum series mentioned above, i.e. interruption
of the currents without arc chopping and overvolt-
ages and extremely rapid recovery of the dielectric
properties after the interruption.
Operating mechanism
The Vmax series is fitted with a mechanical
operating mechanism of simple conception and
use, derived from the same mechanical operating
mechanism which equips the VD4 series.
The stored energy operating mechanism with free
trip therefore allows opening and closing opera-
tions independent of the operator. The spring
system of the operating mechanism can be
recharged both manually and by means of a
geared motor. Opening and closing of the appara-
tus can take place both by means of the pushbut-
tons located on the front of the operating mecha-
nism, and by means of the electric releases (shunt
closing, shunt opening and undervoltage).
The circuit-breaker is always fitted with a mechani-
cal anti-pumping device to prevent repeated
sequences of opening and closing operations
following simultaneous and maintained opening
and closing commands (local and/or remote).
Truck
The poles and operating mechanism are fixed
onto a metal supporting and handling truck.
The truck is provided with a system of wheels
which makes the racking-in and racking-out
operations of the apparatus into the switchgear
unit with the door closed possible.
The truck allows efficacious earthing of the circuit-
breaker by means of the metallic structure of the
switchgear.
 1.7

Apparatus-operator interface VM1

The front part of the circuit-breaker represents the
interface of the apparatus with the user personnel.
It is provided with the following accessories:
• opening pushbutton
• closing pushbutton
• operation counter
• indicator of the open and closed state of the
circuit-breaker
• indicator of the charged and discharged state of
the operating mechanism springs
• manual device for charging the operating
mechanism springs
• selector for exclusion of the undervoltage
release (optional).

The conventional mechanical stored energy type

of operating mechanism of the VD4 circuit-
breakers can be replaced with an operating
mechanism with magnetic actuator, thereby giving
rise to the VM1 series of circuit-breakers.
All the characteristics of the circuit-breakers
described in this chapter remain unchanged
except for the operating mechanism.
The operating mechanism is based on a greatly
reduced number of components:
• Actuator with permanent magnets. The heart
of the operating mechanism consists of the
magnetic actuator which carries out the closing
and opening operations, and keeps the main
contacts in their positions taken up after the
operation. The magnet transmits the operating
mechanism to the interrupters by means of a
single transmission lever.
Standards • Electronic control device. All the functions
IEC 62271-100 for the circuit-breaker. (trip, operation, energy charging and watchdog)
are carried out from the integrated electronic
controller. The circuit-breaker is fitted with a
multivoltage direct and alternating current
feeder.
• Capacitors. The energy required to switch the
operating mechanism is obtained by means of
an incorporated capacitor bank. The stored
energy guarantees the complete O-C-O reclos-
ing sequence.reclosing sequence.
• Position sensors. The position of the circuit-
breaker contacts is detected by means of
electronic proximity sensors.

19
 Gas circuit-breaker
The single and double-level switchgear can be
fitted either with vacuum circuit-breakers or with
SF6 circuit-breakers.
The ABB vacuum and gas series of circuit-
breakers are mechanically interchangeable and
the same switchgear unit can therefore take either
type of apparatus. Only ABB can offer apparatus
belonging to the two techniques for the whole
range of applications, voltage levels (12-17.5-
24 kV), rated current (630...4000 A) and breaking
capacity (16...50 kA), giving the opportunity of
selecting those most suited to the installation
characteristics and to the feeders to be switched
and protected. The long and proven experience of
ABB shows that the two types of circuit-breakers
are equally valid and complementary and there-
fore allow optimised selection for their use.
HD4
The HD4 medium voltage circuit-breakers use
sulphur hexafluoride gas (SF6) to extinguish the
electric arc and as the insulating medium.
Thanks to the excellent properties of SF6 gas,
interruption of the currents takes place without arc
chopping and overvoltages. There is no restriking
phenomenon after interruption and the dielectric
properties following interruption are
recovered extremely rapidly.
There are circuit-breakers for all electric power
distribution applications. They can be particularly
recommended for the use on capacitor banks,
motors, transformers insulated in oil and in
installations where components which are
20
particularly sensitive to dielectric and dynamic
stresses are installed (for example, old cables or
transformers).
Poles
The HD4 circuit-breaker poles use the autopuffer
breaking system, combining the compression and
self-blast techniques in a single solution.
The autopuffer system is the most innovative
technique in the field of gas circuit-breakers and
originates from the high voltage apparatus.
The combination of the compression and self-blast
techniques allows the best performances to be
obtained at all current values. Both are always
present, but whereas the former operates optimal-
ly in switching low currents, the latter acts
effectively during operation on higher current
values. The autopuffer technique allows the use of
a smaller quantity of gas than that required by
circuit-breakers based on other techniques. For
the same reason, the gas pressure is also consid-
erably reduced. The autopuffer technique guaran-
tees the insulating withstand voltage and the
breaking capacity up to 30% of the rated one even
with zero relative pressure.
The whole range of HD4 circuit-breakers uses the
same gas pressure for all rated voltage levels (12-
17.5-24 kV). SF6 gas pressure level monitoring is
not necessary, since the circuit-breaker poles are
sealed-for-life pressure systems and are mainte-
nance-free. In any case, they are fitted with a
pressure control device for checking that the
characteristics
are not altered due to transport or incorrect
operations.
Operating mechanism
The HD4 circuit-breaker is fitted with a mechanical
stored energy operating mechanism. Trip is free
and therefore allows opening and closing opera-
tions independent of the operator. The operating
mechanism spring system can be recharged either
manually or by means of a geared motor. The
operating mechanism is of the same type for the
whole series and has a standardised range of
accessories and spare parts. All the accessory
components can easily be replaced by means of
plug-socket connectors.
Opening and the closing of the apparatus can be
carried out by means of the pushbuttons on the
front of the operating mechanism or by means of
electric releases (shunt closing, shunt opening
and undervoltage).

The circuit-breakers are always fitted with an anti-
pumping device to eliminate the possibility of
simultaneous opening and closing commands,
closing commands with springs discharged or with
the main contacts not yet in their run-end position.
Truck
The poles and operating mechanism are fixed
onto a metal support and handling truck.
The truck is provided with a wheel system which
makes the operations for racking the apparatus
out of and into the switchgear unit possible with
the door closed. The truck allows effective earthing
of the circuit-breaker by means of the metallic
structure of the switchgear unit.
Apparatus-operator interface
The front part of the circuit-breaker represents the
interface of the apparatus with the user personnel.
It is fitted with the following accessories:
• Opening pushbutton.
• Closing pushbutton.
• Operation counter.
• Indicator of the circuit-breaker open and closed
state.
• Indicator of the charged and discharged state of
the operating mechanism springs.
1.8
• Manual charging device of the operating mecha-
nism springs.
• Override selector of the undervoltage release
(optional).
• LED gas pressure indicator (optional).
Standards
IEC 62271-100 for the circuit-breaker.
IEC 60376 for the SF6 gas.
HD4-HXA
The range of HD4 circuit-breakers is enriched by
the HXA version.
This series of circuit-breakers keeps all the
characteristics described in this chapter, but
stands out for its ability to switch loads with strong
unidirectional components.
For breaking capacities of 40 kA or lower, they are
able to switch loads with unidirectional compo-
nents IDC = 100%, up to service voltage 13.8 kV;
at 50 kA the unidirectional component percentage
IDC is reduced to 50%.
They can be used in all installations affected by
strong unidirectional components, but their natural
field of application is found in switching and
protecting transformers of the auxiliary circuits in
power generating stations.
They comply with the IEC 62271-100 Standards.
21
 Vacuum contactor
V-Contact medium voltage contac-
tors are apparatus suitable for
operating in alternating current and
are usually used to control feeders
which require a high number of
operations per hour.
They are suitable for operating and
protecting motors, transformers and
power factor correction banks. Fitted
with appropriate fuses, they can be
used in circuits with fault levels up to
1000 MVA.
The electrical life of V-Contact
contactors is defined as being in
category AC3 with 100,000 opera-
tions (closing-opening), 400 A
interrupted current.
The contactors consist of a monobloc of resin
containing the following components:
• vacuum interrupters
• moving equipment
• control electromagnet
• multivoltage feeder
• accessories and auxiliary contacts.
The V-Contact contactors are provided in the
following versions:
• V7 for voltages up to 7.2 kV.
• V12 for voltages up to 12 kV.
Both versions are available with the operating
mechanism with electrical or mechanical latching.
The V-Contact contactors are mechanically
interchangeable with the whole series of ABB
circuit-breakers and the same switchgear unit can
therefore take both types of apparatus without
distinction.
The same basic components of the V-Contact
contactor are also used to realise the UniGear
type ZVC compact apparatus. For the specific
characteristics and the relevant applications refer
to chapter 3.
Operating mechanism with
electrical latching
Closing of the main contacts is obtained by means
of a control electromagnet. Opening is carried out
thanks to the action of a counter spring.
22
The contactor remains in the closed position as
long as the electromagnet remains energised and
opens automatically when the auxiliary voltage is
cut off.
Operating mechanism with mechanical
latching
This is a mechanical device which, on closing of
the contactor, latches up the moving equipment
and keeps the contactor closed with the coils of
the operating mechanism de-energised.
The mechanical latching device includes the shunt
opening release for instantaneous service, the
opening pushbutton and the release device in
case of fuse tripping.
Fuses
The contactor is fitted with medium voltage fuses
for protection of the operated feeders.
Coordination between the contactor, fuses and
protection unit is guaranteed in accordance with
the IEC 60470 Standards for apparatus in class C.
The fuse-holder frame is usually preset for instal-
lation of a set of three fuses per phase with
average dimensions and type of striker, according
to the following Standards:
• DIN 43625.
• BS 2692.
The following fuses can be applied:
• DIN type with a length of 192, 292 and 442 mm
• BS type with a length of 235, 305, 410, 454 and
553 mm.
The fuse-holder frames are fitted with a device for
automatic opening when even just one fuse blows.
This same device does not allow contactor closing
when even a single fuse is missing.
The ABB range of fuses for transformer protection
is called CEF, whereas CEM is the one for motors
and capacitors.
Voltage transformer
The contactor can be fitted with a two-pole voltage
transformer complete with the relevant protection
fuses. The voltage transformer is used to supply
the coils of the contactor operating mechanism.
Apart from power supply of the contactor, ito can
also supply other components of the switchgear
unit (lamps, signalling devices, auxiliary relays,
etc.) up to a maximum power of 50 VA.
 1.9

Electrical characteristics

Rated voltage kV 3.6 7.2 12

Rated insulation voltage kV 3.6 7.2 12
Rated power frequency withstand voltage kV 1min 16 20 28
Rated lightning impulse withstand voltage kV 40 60 75
Rated frequency Hz 50-60 50-60 50-60
Rated short-time withstand current kA(1) ...50 …50 …50
Peak current kA …125 …125 …125
Internal arc withstand current (2) kA 1s …40 …40 …40
kA 0.5 s …50 …50 …50
Maximum rated current of the contactor A 400 400 400

Maximum performances of the contactor with fuses

Motors kW 1500 3000 5000

Transformers kVA 2000 4000 5000
Capacitors kVAR 1500 3000 4800

Maximum load currents of the fuses

Feeder Transformers Motors Capacitors

Rated Fuse Maximum Fuse Maximum Fuse Maximum
voltage load load load
3.6 kV 200A 160A 315A 250A 450A 360A
7.2 kV 200A 160A 315A 250A 355A 285A
12 kV 200A 160A 200A 160A 200A 160A

Standards
IEC 60470 and IEC 60632-1 for the contactor.
IEC 60282-1 for the fuses.

(1) Limited by the fuses.

Fuse according to DIN Standards
(2) The internal arc with-
Fuse according to BS Standards
stand values are guar-
anteed in the compart-
ments on the supply
side of the fuses
(busbars and appara-
tus) by the structure of
the switchgear and on
the load side (feeder) by
the limiting properties of
the fuses.

23
 Service trucks
The UniGear range is equipped with all the service
trucks needed to complete the switchgear and
required for service operations and during mainte-
nance work.
The trucks are divided into four different types:
• Earthing without making capacity.
• Earthing with making capacity.
• Cable test.
• Isolation.
Earthing truck without making capacity (*)
These trucks carry out the same function as the
earthing switches without making capacity.
They therefore have no capacity to earth live
circuits in fault conditions.
They are used to ensure an additional fixed earth,
as is required by some installation service and
maintenance procedures, as a further guarantee
for personnel.
The use of these trucks foresees removal of the
apparatus from the switchgear (circuit-breaker or
contactor) and its replacement with the truck.
The units preset for use of the earthing trucks
must be provided with a key lock which, when
activated, prevents their racking-in.
This truck is available in two versions:
(*) Derived from HD4 • Earthing of the main busbar system.
series. • Earthing of the power cables.
24
The earthing truck of the main busbars, during the
racking-in phase, only lifts the top shutter and
earths the contacts connected to the top branch
connections (and therefore to the main busbar
system) by means of the switchgear structure.
The earthing truck of the power cables, during the
racking-in phase, only activates the bottom shutter
and earths the contacts connected to the bottom
branch connections (and therefore to the power
cables) by means of the switchgear
structure.
These trucks can also be used in the bus-tie unit.
In this case, they earth one of the two sides of the
main busbar system.
Earthing truck with making capacity (*)
These trucks carry out the same function as the
earthing switches with making capacity.
They consist of circuit-breakers provided with top
(earthing of the main busbars) or bottom (earthing
of the power cables) terminals only. The contacts
without terminals are short-circuited by means of a
copper bar and connected to earth by
means of the apparatus truck.
They keep all the characteristics of the circuit-
breakers, such as full making and breaking
capacity on live circuits under fault conditions.
They are used to ensure extremely effective
earthing on circuits stressed by a fault. They allow
opening and closing operations to be carried out
rapidly with electric remote control.
The use of these trucks foresees removal of the
apparatus from the switchgear (circuit-breaker or
contactor) and its replacement with the truck.
The units preset for use of the earthing trucks
must be provided with a key lock which, when
activated, prevents its being racked-in.
This truck is available in two versions:
• Earthing of the main busbar system.
• Earthing of the power cables.
The earthing truck of the main busbars, during the
racking-in phase, only lifts the top shutter and
presets the contacts connected to the top branch
connections (and therefore to the main busbar
system) for closing to earth by means of operating
mechanism.

The earthing truck of the power cables, during the
racking-in phase, only activates the bottom shutter
and presets the contacts connected to the bottom
branch connections (and therefore to the power
cables) for closing to earth by means of operating
mechanism.
These trucks can also be used in the bus-tie unit.
In this case, they earth one of the two sides of the
main busbar system.
Power cable test truck
These trucks allow the insulation tests on the
power cables to be carried out without accessing
the feeder compartment or disconnecting the
cables from the switchgear.
The use of these trucks foresees removal of the
apparatus from the switchgear (circuit-breaker or
contactor) and its replacement with the truck.
The truck, during the racking-in phase, only
activates the bottom shutter and, by means of the
connectors it is fitted with, allows connection of the
test apparatus cables.
This truck can only be used in the incoming/
outgoing feeders with the door open.
Main busbar system earthing
truck, without making capacity.
Main busbar system earthing
truck, with making capacity.
1.10
Isolating truck (*)
The isolating truck allows the top switchgear
contacts to be connected directly to the bottom
ones. Connection is made extremely safe by using
the poles of the circuit-breakers to insulate the
connection busbars from the external environment.
In the incoming/outgoing feeder units it connects
the main busbar system to the power cables,
whereas in the bus-tie, to the two sides of the
busbar system.
This truck has its application in UniGear switch-
gear for making incoming/outgoing feeders without
a circuit-breaker in radial networks, for making
cable connections between two pieces of switch-
gear placed in front of each other, in making
interconnection units and in creating the bus-tie
riser configuration with double insulation (in this
case, both the units are made up of bus-ties, the
former fitted with a circuit-breaker and the latter
with an isolating truck).
The units preset for use of the isolating trucks
must be fitted with a key lock which, when activat-
ed, prevents its being racked-in.
(*) Derived from HD4
series.
Cable test truck.
Power cable earthing truck,
without making capacity.
Power cable earthing truck, Isolating truck.
with making capacity.
25
 Switch-disconnector
The DF units are fitted with NAL type
switch-disconnectors.
These units are used to switch and
protect feeders and transformers or
the auxiliary services transformers in
electrical power stations.
The NAL switch-disconnectors are
medium voltage air-insulated appara-
tus consisting of a fixed support to
which the post
insulators are applied (top and
bottom), the system of contacts
(fixed and moving) and latching
pliers (of the fuses or of the insulat-
ing bars).
The switch-disconnector is fitted with
two systems of moving blade con-
tacts, the main one (passed through
by the load current with the switch in
the closed position) and the arc-
breaking one (passed through by the
current during the opening and
closing operations). This solutions
means the main contacts are not stressed and
therefore keep the electrical characteristics of the
apparatus unchanged.
During switch-disconnector opening there is
compression of the air by means of the pistons
contained in the top insulator cylinders. At the
moment of separation of the contacts, thanks to
generation of a blast of compressed air which
comes out through special nozzles, the arc is
cooled and de-ionised. This leads to a gradual
increase in the arc resistance which determines its
extinction. The movement of the pistons is syn-
chronised with that of the arc-breaking contacts of
the switch-disconnector so as to guarantee the
highest inflow of air at the moment of separation of
the contacts and thereby obtain certain arc
extinction.
The unit can be fitted with insulating bars (NAL
switch-disconnector unit) or with medium voltage
fuses (NALF switch-disconnector unit with fuses).
The NALF switch-disconnector is fitted with an
automatic release mechanism for fuse tripping and
uses fuses in accordance with DIN 43625 Stand-
ards. The ABB range of fuses for transformer
protection is called CEF. Each unit is fitted with an
earthing switch with making capacity for earthing
the cables.
26
Switch-disconnector control, like that of the
earthing switch, comes from the front of the
switchgear by means of manual operation.
The position of both pieces of apparatus can be
seen directly from the front of the switchgear
through an inspection window.
The unit can be fitted with a set of three current
transformers or with measurement sensors.
The DF unit consists of two power compartments:
busbars and feeder. The latter contains both the
switch-disconnector and the connection terminals
of the power cables.
Segregation between the power compartments
takes place automatically with earthing switch
closure. An insulating shutter creates complete
separation between the fixed contacts of the
switch-disconnector, making the top ones inacces-
sible to the operators. This makes maintenance
operations on the cables and fuses possible,
keeping the remainder of the switchgear in
service.
The switch-disconnector, earthing switch and
access door to the feeder compartment are
interlocked with each other to guarantee maximum
safety for the personnel and correct operation.
Each unit is fitted with an auxiliary compartment,
where the instruments and cabling are housed.
All the units are accessible from the front and
maintenance and service operations can therefore
be carried out even with the switchgear wall-
mounted.
Standards
IEC 60265-1 for the switch-disconnector.
IEC 60282-1 for the fuses.
 1.11

Electrical characteristics

Rated voltage kV 12 17.5 24

Rated insulation voltage kV 17.5 17.5 24
Rated power frequency withstand voltage kV 1 m 38 38 50
Rated lightning impulse withstand voltage kV 95 95 125
Rated frequency Hz 50-60 50-60 50-60

NALF switch-disconnector unit with fuses

Rated short-time withstand current kA (1) …25 …25 …20

Peak current kA …100 …100 …63
Maximum rated current of the fuses A 63 63 63
Internal arc withstand current (2) kA 1 s …40 …40 …25

Selection table of the fuses for protection transformers

Rated power of the transformer (kVA)

kV 25 40 50 63 80 100 125 160 200 250 315 400 500 630 800 1000 1250 1600
Rated normal current of the fuse (A)
3 10 16 25 25 40 40 63 63 100 100 100 100
5 6 10 16 16 25 25 40 40 63 63 100 100 100 100
6 6 6 10 10 16 16 25 25 25 40 40 63 63 100 100
10 6 6 10 10 16 16 25 25 25 40 40 63 63 100 100
12 6 6 6 10 10 16 16 25 25 40 40 40 63 63 100 100 100
15 6 6 6 10 10 16 16 25 25 25 40 40 40 63 63 100 100
17 6 6 6 6 6 10 16 16 25 25 25 40 40 63 63 63 100 100
20 6 6 6 6 6 10 16 16 16 25 25 40 40 40 63 63
24 6 6 6 6 6 6 10 16 16 16 25 25 40 40 40 63 63

(1) Limited by the fuses.

(2) The internal arc withstand values are
guaranteed in the compartment on the
supply side of the fuses (busbars) by the
structure of the switchgear and on the
load side (feeder) by the limiting prop-
erties of the fuses.

27
 Instrument transformers

Current transformers
The current transformers are of the type insulated in resin and
are used to supply the measurement devices and protection
instruments. These transformers can have a wound core or a
bushing bar with one or more cores, with performances and
accuracy classes suitable for the installation requirements.
They conform to the IEC 60044-1 Standards.
Their dimensions are in accordance with the DIN 42600 Narrow
Type Standard, in the Medium and Long Size versions
up to 2500A, whereas they are of the toroidal type in the range
of currents from 3150 A to 4000 A.
The current transformers can also be provided with a capacitive
socket for connection to voltage signalling devices.
The current transformers are normally mounted on the load side
of the apparatus compartment for measurement of the
phase currents of the switchgear unit. Mounting on the supply
TPU 1250 A.
side of the apparatus compartment is also possible (busbar
applications) for measuring the busbar currents or for realising
particular protection schemes. The ABB range of current
transformers is called TPU.

Toroidal current transformers

The toroidal transformers are of the type insulated in resin and
are used to supply measurement and protection devices.
These transformers can either be with a closed or openable
core.
They can be used both for measuring phase currents or for
detecting the earth fault current.
They conform with the IEC 60044-1 Standards.

TPU 2500 A.

Toroidal current transformer. TPU 3150 A.

28
 1.12

Voltage transformers
The voltage transformers are of the type insulated in resin and
are used to supply measurement and protection devices. They
are available for fixed assembly or for installation on removable
and withdrawable trucks.
They conform with the IEC 60044-2 Standards.
Their dimensions are in accordance with the DIN 42600 Narrow
type Standard.
These transformers can have one or two poles, with perform-
ances and precision classes suited to the functional require-
ments of the instruments connected to them.
When they are installed on removable or withdrawable trucks
they are fitted with medium voltage protection fuses.
The withdrawable trucks also allow replacement of the fuses Single pole VTs - type TJC.
with the switchgear in service. Truck racking-out with the door
closed automatically operates closure of a metallic segregation
shutter between the live parts of the switchgear and the instru-
ment compartment.
Fixed voltage transformers can be installed directly on the main
busbar system in a dedicated compartment (busbar
applications).
The ABB range of voltage transformers is called TJC, TDC,TJP.

Double-pole VTs - type TDC.

VT truck with fuses. Single-pole VTs with fuse - type TJP.

29
 Measurement sensors
Introduction of digital technologies in electrical
measurement and protection instruments has
greatly changed the performances required of
transformers.
The analogue input levels of the instruments have
been significantly reduced when compared with
those of conventional systems.
For this reason, ABB has introduced a new range
of sensors which optimally covers the characteris-
tics of the new generation instruments.
The UniGear switchgear can be fitted with KEVCD
type sensors up to 2500 A.
Their dimensions are in accordance with the DIN
42600 Narrow Type Standard, in the Medium size
version.
The current and voltage sensors or just the current
sensor can be incorporated at the same time in
the same resin body.
The capacitive divider for connection to the
voltage signalling devices is also inserted.
30
Characteristics of the sensors
• Linear response over the whole measurement
field.
• Excellent frequency response.
• No hysteresis phenomenon.
• High degree of immunity to electromagnetic
disturbance.
• A single instrument for protection and measure-
ment devices.
• Cl.1 overall class of measurement (sensors and
multi-purpose unit).
• Any short-circuits or interruptions of the second-
ary circuit do not cause any damage.
• The output signal remains very low even in
primary fault situations.
• Test terminal blocks are not required.
• Connection between the sensor and the meas-
urement and protection instrument is made with
shielded cables and connectors.
Benefits provided by the sensors
• Improvement of installation selectivity.
• More efficient fault location.
• Perfecting of fault analysis.
• Simplification of engineering tasks.
• More rapid and less costly switchgear modifica-
tions and upgrading.
• Simple and safe maintenance operations.
• Reduction in faults in the measurement and
protection apparatus.
• Greater safety for operators thanks to the
absence of high induced currents or voltages in
the secondary circuit.
• Optimisation of maintenance programmes.
• Reduction in control and testing times.
• Reduction in the number of spare parts.

Current sensor
The current sensor consists of a Rogowski coil
without the ferromagnetic core.
The coil is formed by a uniform winding over a
closed non-magnetic core of constant cross
section. The induced voltage in the secondary
circuit is directly proportional to the variation in the
let-through current. The multi-purpose devices
integrate the signal to obtain the current value.
They conform to the IEC 60044-8 Standards.
Rogowski coil
The output signal (Uout) is a voltage (150 mV at
50Hz and 180mV at 60Hz) proportional to the
variation in the current time (Ip); the current
measurement is obtained by integrating the signal.
dip
Uout = M
dt
Characteristics of the current sensors
• No saturation phenomenon.
• Precise measurement of the fault currents as
well.
• The sensor winding can remain open even with
the switchgear in service.
• Just two coils cover the range from 0 to 2500 A.
1.13
Voltage sensor
The voltage sensor consists of a resistive divider
through which the signal is taken up.
The resistive element consists of a bar made of
ceramic material.
The output signal is a voltage directly proportional
to the primary voltage. The multi-purpose device
reproduces the measurement by means of the
partition ratio.
They conform to the IEC 60044-7 Standards.
Resistive divider
The output signal (Uout) is a voltage directly
proportional to the primary voltage (Up). The
partition ratio is 10000/1.
R2
Uout = Up
R1 + R2
Characteristics of the voltage sensors
• No ferroresonance phenomenon.
• The divider is unaffected by the effects of the
direct components.
• The sensor can remain connected even during
switchgear voltage tests at power frequency.
• A single divider covers the range from 0 to 24
rated kV.
31
 Distribution and automation
Introduction
ABB protection philosophy
With deliveries of protection releases to more than
70 countries, ABB fully understands the need for
diverse protection philosophies as a result of local
legislation, environmental requirements and
engineering practice. The main purpose of a
release protection system is to recognize any
abnormal power system conditions, or abnormally
operating system components. Based on the
information gathered, the protection system will
initiate corrective actions that return the system to
its normal operating state.Release protection does
not prevent network faults from arising, but it is
activated only when something abnormal has
occurred in the power system. However, careful
selection of protection functions and methods
improves the performanceand the reliability of the
protection system, thus minimizing the effects of
network faults and preventing the disturbance from
spreading to the healthy parts of the network.
Advantages of a complete protection
system
Operating speed, sensitivity, selectivity and reliabili-
ty of the protection system need attention.
There is a strong correlation between the operating
speed of the protection system and the damage
and danger caused by a network fault.
Substation automation provides remote control and
monitoring capabilities, which speed up the location
of faults and the restoration of the power supply.
32
Fast operation of the protection releases also
minimizes post-fault load peaks, which together
with voltage dips increase the risk of the distur-
bance spreading to healthy parts of the network.
The sensitivity of the protection must be adequate
to detect relatively high resistance earth faults and
short circuits in the most distant parts of the
network.
Reliable selectivity is essential in order to limit the
loss of power supply to as small an area as
possible, and to allow the faulted part of the
network to be reliably discovered. Corrective
actions can thus be directed to the faulty part of the
network, and the supply can be restored as rapidly
as possible.
The protection system must have a high degree of
reliability. This also means that if e.g. the circuit-
breaker fails to operate, the fault will be cleared by
the back-up protection.
Substation automation (SA) puts the operator in
perfect control of the substation. In addition, SA
system improves the power quality of the transmis-
sion and distribution network under normal opera-
tion, but especially in a situation of disturbance and
during substation maintenance. An SA system or
SCADA brings the full benefits of numerical
technology into protection and control of networks.
The terminals are easily set and parameterized
through easy and safe access via the operator’s
workplace.
Single-function and multi-function terminals
Proper protection methods and comprehensive
functionality increase the performance of the
protection system. The definition of comprehensive
functionality varies with the requirements of the
protected network. While single-function
protection releases are sufficient for some network
applications, more complex networks need ad-
vanced multi-functional releases.
Single-function releases include a set of protection
functions for a specific feeder application type. The
main advantages of these releases are redundancy
and price. One or more single-function releases
provide sufficient protection in most application
areas. Multi-function terminals include a large
number of protection functions that meet the needs
of a lot of applications. In addition, they include
control, measurement, power quality monitoring
and condition monitoring functions.
The use of one single IED incorporating all these
functions increases system usability, reduces costs
and diminishes the need for wiring in the switch-
gear.

Feeder protection
General
The protection functions can be divided into two
major groups: (1) protection functions that trip
circuit breaker of the faulted feeder on short-
circuit, earth fault, etc.; (2) protection functions
that monitor the operation of the feeder and the
rest of the network i.e. voltage, frequency and
overload protection functions (alarming / tripping).
The basic requirements of the protection system
are adequate sensitivity and operation speed,
taking into account the minimum and maximum
fault currents occurring in the IED locations,
selectivity, inrush currents and the thermal and
mechanical strength of the lines behind the
relaying point. In many cases, the above require-
ments can be fulfilled with non-directional/direc-
tional current or impedance measuring functions
with multiple stages. The purpose of the over- and
undervoltage protection system is to monitor the
voltage level of the network. If the voltage level
deviates from the target value by more than the
permitted margin for a specific time period, the
voltage protection system limits the duration of the
abnormal condition and the stresses caused.
To prevent major outages due to frequency
disturbances, the substations are usually
equipped with underfrequency protection releases,
which in turn control various load-shedding
schemes.
Fig. 1 Comparison between standard Fig. 2 Typical standard feeder
and high requirement
feeders
1.14
These are just a few examples of the major
protection functions for feeders. More details can
be found in the technical documentation produced
for the ABB protection releases.
Applications and features
Depending on the requirements, a suitable IED
type can be selected and configured in such a way
that an overall solution can be found for different
feeder types.
Generally, the required protection functionality of
the above feeder types differs greatly between
each one depending on, for instance, the charac-
teristics of the fault current sources and the types
of more advanced functions that may be
needed to fulfil the basic requirements of the
protection application.
A few examples will be given below to illustrate the
requirement level.
Recommended products
ABB supplies a wide range of feeder
protection releases and terminals to
fulfil the requirements of each different
application. For an application with standard
requirements and a basic need for additional
features, the REF 610, REX 521 units are excel-
lent choices. For applications with higher function-
ality requirements, the REF 54_ multifunction
terminals should be selected.
1) Optional arc protection 1) Optional Intermittent E/F protection
Fig. 3 Typical high requirement feeder
33
 Distribution and automation

Transformer protection Applications and features

General ABB divides transformer applications into standard
The power transformer is an important component transformer protection applications and high
and one of the most valuable discrete units in the requirement transformer applications. The core
power distribution network. High availability of the functionality levels are as follows:
power transformer is therefore of particular impor-
tance for preventing disturbances in the power Basic requirement (Typically <1MVA)
distribution system. Although high-quality power • Sudden pressure (Buchholz) –relay
transformers are very reliable, insulation break- • Residual current protection
down faults sometimes occur. These faults - • Overcurrent protection
appearing as short-circuits and/or earth faults - • Earth fault protection
generally cause severe damage to the windings • Overload protection
and transformer core. The damage is proportional
• Imbalance protection
to the fault clearing time so the power transformer
must be disconnected as quickly as possible. The • Oil level monitor
power transformer has to be transported to a
workshop for repair, which is a very time-consum- High requirement (Typically >5MVA)
ing procedure. The operation of a power network • Sudden pressure (Buchholz) –relay
where the power transformer is out of service is • Residual current protection
always cumbersome. Therefore, a power transform- • Overcurrent protection
er fault often constitutes a more severe power
• Restricted earth fault (REF) protection
system fault than a line fault, which can usually be
• Overload protection
rectified fairly quickly. It is extremely important for
fast and reliable protection releases to be used to • Imbalance protection
detect transformer faults and initiate tripping. • Over/Undervoltage protection
The size, voltage level and importance of the power • Over/underfrequency protection
transformer determine the quantity and choice of • Oil level monitor
monitoring and protection devices to be used to limit
the damage at a possible fault. When compared to Recommended products
the total cost of the power transformer and the costs The RET 541/543/545 Transformer
caused by a power transformer fault, the cost of the Terminals are designed for compre-
protection system is negligible. hensive protection, control,
meas urement and
supervision of two-
winding power trans-
formers and power
generator-transformer
blocks in utility distribu-
tion networks. It is
suitable for application
where on-load tap-
changer control is
required.
Functionality for
standard transformer
protection is provided in
the REF542plus
terminal.

Fig. 4 Typical standard transformer protection. Fig. 5 Typical high requirement transformer protection.

34

Motor protection
General
Motor protection is generally expected to provide
overcurrent, imbalance, earth-fault and short-
circuit protection. However, the fundamental issue
for motors is thermal protection, as overheating is
the worst threat for the motor.
Motors need to be protected not only against
electrical faults but also against any improper way
of running them. ABB solutions focus on advanced
thermal protection that prevents improper use of
the motors. The thermal overload
protection is needed to protect the motor against
both short-time and long-time overload and so it is
of great importance for the performance of the
motor. Overload conditions of short duration
mainly occur during motor start-up.
There are four crucial elements in thermal motor
protection. (1) The thermal overload protection is
the most important protection function of the motor
as it monitors the thermal load and memorizes the
related events. (2) A cumulative start-up time
counter supporting the overload protection limits
the number of consecutive cold starts. (3) The
thermal stress during any single start-up condition
is monitored by the start-up supervision function,
which protects the motor against locked rotor
situations and too long start-up times. (4) The
fourth element in thermal motor protection is
thermal protection based on RTD (Resistance
Temperature Detector) sensors. As RTD sensors
directly measure the temperature of the stator
Fig. 6 Typical standard motor protection.
1.14
Improper use of running motors does not neces-
sarily break the equipment but shortens its
lifetime.
Therefore, a reliable and versatile motor protection
system not only protects the motor but also
prolongs its life-cycle, which contributes to improv-
ing the return on motor drive investments.
Applications and features
Thanks to comprehensive communication proto-
cols, including the widely-used industrial protocols,
such as Modbus RTU/ASCII and Profibus DP, ABB
motor protection releases and terminals can be
easily integrated into various control systems.
Recommended products
The REM 610 is designed for
protection of standard medium and
large MV asynchronous motors in a
wide range of motor applications.
The typical size of protected motors ranges from
500 kW to 2 MW.
The REX 521 and REF542plus are suitable, when
there is a need to have functionality control in
addition to motor protection.
The REM 543/545 machine protection terminals
provide high-end protection, including residual
current protection, for all sizes of asynchronous or
synchronous motors.
Fig. 7 Typical high requirement motor protection.
35
 Distribution and automation
Communication
General
In the complex world of communication, ABB has
made a great effort to find communication buses
and protocols that fulfil the requirements of a
secure and efficient data flow. In addition to the
recently introduced IEC 61850 protocol, ABB uses
LON and SPA communication buses for communi-
cation between releases. In addition to these,
protocols such as IEC 60 870-5-103, Modbus,
Profibus and DNP 3.0 and OPC interface are
available. Depending on the application area,
different protocols are used according to industry
de-facto standards.
Utility Applications
IEC 61850
IEC 61850 is a flexible, future-proof standard that
copes with changing requirements, philosophies
and technologies. The function of the IEC 61850
standard is to ensure essential features, such as
interoperability between devices of different
suppliers, free allocation of functions, adaptability
to fast changing communication technology and
facility of engineering and maintenance. This
means that the long-term stability of the standard
safeguards investments of utilities. From the
beginning, ABB has taken a leading position in
elaborating the corresponding standard in the field
of substation automation.
36
SPA
The SPA protocol supported by all ABB releases
enables a wide range of distribution and automa-
tion functions. The information content that can be
transferred is similar to that of IEC 61850. For many
years, the SPA protocol has been the backbone
communication protocol for ABB releases and is a
well-proven serial bus. To ensure EMI immunity the
SPA protocol is run over an fibre optic network.
LON
The LON protocol is a fast bus-based protocol
featuring both vertical (to a master system) and
horizontal communication. When horizontal com-
munication is used, IEDs are able to exchange,
such as interlocking information, over the communi-
cation bus. This reduces the need for hard wiring
between devices, thus saving costs. The LON bus
runs at a substantially higher speed than the serial
buses. ABB has defined extensions to the basic
LON protocol, enabling any information appearing
in distribution and automation to be efficiently and
securely transferred. To ensure immunity to EMI
disturbances, the LON bus runs over optical fibres.
IEC 60 870-5-103
IEC 60 870-5-103 is a standard protocol designed
exclusively for communication between protection
IEDs and a master system. Allowing IEDs of
different vendors to be connected to a common
master system, it is widely supported in distribution
and automation. The range of information that can
be transmitted with the IEC 60 870-5-103 protocol
is smaller than the information range available
through the LON, SPA and IEC 61850 protocols.
DNP V3.0
The DNP protocol based on the IEC 60 870
standard family was originally developed by a
single vendor, but has now evolved into an open
standard controlled by a user group. It is designed
for local communication within a substation,
between a protection IED and an RTU (which
forwards information to a remote SCADA system).
Furthermore, protection IEDs can be connected
directly to a remote system using this protocol. The
DNP has a multitude of options enabling it to be
optimized for different types of applications and
communication environments (it can, for instance,
be optimized to run over a slow communication
link).
 1.14

Industrial Applications can be made available in different ways through

Profibus DP V1
Profibus is a major de-facto standard for connec-
tivity to industrial systems. All ABB releases can
be connected to Profibus master systems using
the SPA-ZC 302 SPA/Profibus converter. The SPA-
ZC 302 supports the Profibus DP V1 protocol and
can handle up to 16 SPA devices. The speed of
the Profibus is comparable with that of LON and is
substantially higher than the speed of the serial
protocols. To ensure EMI immunity, Profibus runs
over a double-shielded twisted pair cable.
Profibus is generally used when protection IED
information is to be transmitted to a controller or
PLC.
an OPC interface. One option is to use the SPA/
OPC or LON/OPC servers, which collect data
from protection IEDs using LON or SPA and make
the data available in the OPC environment.
Another option is to connect the protection IEDs
to the COM 610 gateway. All data in the COM 610
can be made available to an OPC client. OPC is
usually used when the data from protection IEDs
is to be transmitted directly to a control system (as
opposed to Profibus and Modbus that usually
supply data to a controller or a PLC) PC or over a
LAN/WAN computer network (in the latter case
using DCOM as the intermediate protocol).

Modbus
The Modbus protocol was first introduced by
Modicon Inc. and is a widely accepted communi-
cation standard for industrial controllers and PLCs.
It is a serial protocol designed for transfer of
binary and numeric data in a generic
format. The Modbus as such does not recognize
the data model of a distribution and automation
application (as the IEC 61850 does). The model-
ling is done in the application of the Modbus
master system. Modbus typically uses a twisted
pair RS-485 bus network as the transmission
medium.

OPC
OPC is commonly used to
interconnect systems in
industrial automation applica-
tions. A system exchanging
data using OPC consists of an
OPC Server (which provides
data and services) and an
OPC Client (which receives
data from and uses the
services of the OPC server).
The OPC server and the OPC
client are both software
components running on PCs.
The interaction between an
OPC Server and an OPC
Client can take place either
locally in a PC or over a LAN/
WAN computer network (in the
latter case using DCOM as the
intermediate protocol). Data
from protection IEDs

37
 Distribution and automation

Arc protection Furthermore, on cable compartment faults, auto-

General reclosures can be eliminated by using arc protec-
tion.
An electric arc short-circuit in a switchgear
installation is normally caused by a foreign object
entering the unit or a component failure. The arc
causes an explosion-like heat and pressure effect
usually causing vast damage to the switchgear
and the operation personnel. An adequate arc
protection system protects the substation against
arc faults by minimizing the burning time of the
arc, thus preventing excessive heat and damage.
It minimizes material damage and allows power
distribution to be smoothly and safely restored.
The system can also bring cost benefits even
before an arc fault occurs. As older switchgear is
more prone to arc faults, an arc protection system
will effectively extend the life of the switchgear and
make more of investments. But what is even more
important, this technology can help save lives. Fig. 8 Typical setup with REA 101 and subunits 103
Applications and features
Sources of arcing may be
insulation faults, malfunction-
ing devices, defective bus or
cable joints, overvoltage,
corrosion, pollution, moisture,
ferroresonance (instrument
transformers) and even
ageing due to electrical
stress. Most of these arc fault
sources could be prevented
by sufficient maintenance.
However, in spite of the
precautions taken, human
errors can lead to arc faults.
Time is critical when it comes
to detecting and minimizing
the effects of an electric arc.
An arc fault lasting 500 ms
may cause severe damage to the installation. Recommended products
If the burning time of the arc is less than 100 ms
The REA 101 arc protection system with its REA
the damage is often smaller, but if the arc is
103, REA 105 and REA 107 extension units, are
extinguished in less than 35 ms its effect is almost
designed to be used for protection of medium and
negligible. Generally, protection releases applied
low-voltage air-insulated switchgear.
are not fast enough to ensure safe fault clearance
The REA 101 central unit type operates independ-
times at arc faults. The operation time of the
ently or together with other REA 101 units.
overcurrent release controlling the incoming
REA is the fastest arc protection system on the
circuit-breaker may, for instance, have to be
market, providing tripping times down to 2.5 ms.
delayed by hundreds of milliseconds for selectivity
REA is equipped with a fast integrated overcur-
reasons. This delay can be avoided by installing an
rent-sensing element and therefore works inde-
arc protection system.
pendently of other feeder protection units. The
The total fault clearance time can be reduced to a
REF 610 feeder protection release includes an
max of 2.5 ms plus the circuit breaker contact
optional arc protection function for the feeder
travel time.
compartment.

38
 1.14

Selection guide

REF 54_ REF 610 REX 521 RET 54_ REM 54_ REM 610 REA 10_
Application
Feeder application ■ ■
High requirement feeder application ■ ■
Transformer application ■ ■
High requirement transformer application ■
Motor protection ■ ■ ■ ■
High requirement motor application ■
Generator & synchronous motor ■
Distance protection ■
Arc protection for feeder cubicle ■ ■
Arc protection system

Communication
IEC 60870-5-103 ■ ■ ■ ■ ■
IEC 61850 ■* ■* ■* ■* ■* ■*
DNP 3.0 ■ ■ ■ ■
SPA ■ ■ ■ ■ ■ ■
LON ■ ■* ■ ■ ■ ■*
Modbus ■ ■ ■ ■ ■
Profibus ■* ■* ■* ■* ■* ■*

Additional functions
Fault locator ■
Web interface ■
CAN interface ■
On load tap changer control ■
Disturbance recording ■ ■ ■ ■ ■ ■
Withdrawable release mechanics ■ ■
Condition monitoring ■ ■ ■ ■ ■
Single line diagram HMI** ■ ■ ■
Remote control ■ ■ ■ ■
Power quality monitoring ■ ■
Sensor inputs ■ ■ ■ ■
Auto re-closure 5 shots 3 shots 5 shots
RTD*** inputs 8 8 8 6
* With interface adapter
** HMI - Human Machine Interface
*** RTD - Resistive Temperature Detector

39
 Automatic transfer systems
Automatic transfer systems are used to ensure
maximum service continuity, supplying the power
users uninterruptedly.
All this is possible using various systems based on
different kinds of techniques.
The most common of these are given below, with
the relevant average transfer times:
• Delayed: 1500 ms
• Depending on the residual
voltage: 400-1200 ms
• Synchronised (ATS): 200-500 ms
• High speed (HSTS): 30-120 ms
The first two systems are the simplest and can
also be made with conventional logics and instru-
ments. They guarantee average transfer times and
can therefore be used in installations where
voltage gaps are not particularly critical.
On the other hand, the other two systems (ATS –
Automatic Transfer System and HSTS – High
Speed Transfer System) require microprocessor-
based apparatus with high technological content.
They guarantee fast transfer times and their
application is in plants where the process is
particularly critical. Transfers which are not
extremely fast would cause serious malfunctions
or stoppage of the process itself.
ABB is able to offer all the transfer systems, from
the simplest to the most complex.
Single-line diagram of
UniGear switchgear with
REF542 plus architecture
applied, suitable for carrying
out automatic and manual
transfer (ATS), as well as the
switchgear protections and
measurements.
40
ATS
The REF542plus unit can be used in medium
voltage switchgear to manage automatic and
manual transfer between two different incoming
feeders.
The time needed for automatic transfer carried out
by means of the REF542plus unit is between 200
and 300 milliseconds (including the circuit-
breaker operating times). This time can vary within
the range indicated in relation to the
complexity of the software transfer logics.
Switchgear equipped with REF542plus, suitably
programmed, are complete and efficient systems
able to manage transfer between one power
supply system and an alternative one, or to
reconfigure the network, passing from double
radial distribution to a simple system, in a fully
automatic way.
It is also possible to carry out the same operation
manually from a remote control station, or from the
front of the switchgear with supervision of the user
personnel.
Manual transfer means making the passage
parallel: by means of the synchronism control
function (synchro-check – code 25) implemented
from the REF542plus, the power supply lines are
closed simultaneously with synchronisation of the
voltage vectors to then return to being disconnect-
ed when transfer has taken place. The applications
described do not require additional instruments.
 1.15

HSTS
The HSTS System (High Speed Transfer System) is the ideal solution for critical industrial processes
where the lack of electric power even for just one or two cycles can cause stoppage of the production
process and considerable damage to equipment.
This system, which is fully integrated in the switchgear, is able to transfer distribution of power from the
main switchgear unit to an alternative emergency supply in a few milliseconds. This avoids long and
costly machine stoppages, damage to production equipment, and dead production restarting times.
The HSTS SUE 3000 system makes it possible to obtain transfer times equal to 100 ms with the use of
all conventional circuit-breakers and 30 ms with VM1 circuit-breakers equipped with a magnetic actuator
in the high speed version and up to 1250 A.

HSTS system in the configu-

Unit 1 Unit 2 ration with two circuit-break-
ers without bus-tie: when the
lack of voltage in the main
power supply unit of the
switchgear is detected, the
closing command of the re-
serve unit and the opening
command of the main unit
are launched simultane-
ously.

N.O. N.C.

HSTS system in the configu-

Unit 1 Unit 2 ration with three circuit-
breakers with bus-tie: when
the lack of voltage in one of
the two power supply units
is detected, the closing com-
mand of the bus-tie and the
opening command for the
switchgear unit without volt-
age are launched simultane-
ously.

N.C. N.C.

N.O.

41
 Typical units and technical data

Single-line diagram of typical units

Withdrawable
Removable

IF - Incoming/outgoing BT - Bus-tie R - Riser RM - Riser with measure-

feeder ments
Withdrawable

Withdrawable
Removable

M - Measurements IFD - Direct incoming/ IFDM - Direct incoming/ DF - Switch-disconnector

outgoing feeder outgoing feeder unit
with measurements

42
 1.16

Single-line diagram of the busbar applications

Current transformers Voltage transformers Duct entry Earthing switch

Graphical symbols

Circuit-breaker Contactor Switch- Switch Isolating bar Socket and plug

disconnector

Voltage Current Fuse Earth Cable entry Busbar entry

transformers transformers

Key to components

Standard components
Accessories
Alternative solutions

43
 Typical units and technical data

... 12 kV - ... 31.5 kA

Depth (mm) 1340 1340 1340
Height (mm) 2100/2200/2595 (1) 2100/2200/2595 (1) 2100/2200/2595 (1)
Height with gas exhaust duct (mm) 2675 2675 2675
Width (mm) 650 800 1000
Rated current (A) 630 1250 1600 2000 2500 630 1250 1600 2000 2500 630 1250 1600 2000 2500
IF Incoming/outgoing (3) (2) (2)
BT Bus-tie
R Riser
RM Riser with measurements
M Measurements
IFD Direct incoming/outgoing
IFDM Direct incoming/outgoing with measurement
DF Switch-disconnector unit (4)

... 12 kV - ... 50 kA
Depth (mm) 1340 1390 1340 1390
Height (mm) 2100/2200/2595(1) 2100/2200/2595(1) 2100/2200/2595(1) 2100/2200/2595(1)
Height with gas exhaust duct (mm) 2675 2675 2675 2675
Width (mm) 800 800 1000 1000
Rated current (A) 630 1250 1600 2000 2500 3150 3600 4000 630 1250 1600 2000 2500 3150 3600 4000
IF Incoming/outgoing 40kA (2) (2)
BT Bus-tie 40kA
R Riser
RM Riser with measurements
M Measurements
IFD Direct incoming/outgoing
IFDM Direct incoming/outgoing with measurement

... 17.5 kV - ... 31.5 kA

Depth (mm) 1340 1340 1340
Height (mm) 2100/2200/2595 (1) 2100/2200/2595 (1) 2100/2200/2595 (1)
Height with gas exhaust duct (mm) 2675 2675 2675
Width (mm) 650 800 1000
Rated current (A) 630 1250 1600 2000 2500 630 1250 1600 2000 2500 630 1250 1600 2000 2500
IF Incoming/outgoing (2) (2)
BT Bus-tie
R Riser
RM Riser with measurements
M Measurements
IFD Direct incoming/outgoing
IFDM Direct incoming/outgoing with measurement
DF Switch-disconnector unit (4)

... 17.5 kV - ... 40 kA

Depth (mm) 1340 1390 1340 1390
Height (mm) 2100/2200/2595(1) 2100/2200/2595(1) 2100/2200/2595(1) 2100/2200/2595(1)
Height with gas exhaust duct (mm) 2675 2675 2675 2675
Width (mm) 800 800 1000 1000
Rated current (A) 630 1250 1600 2000 2500 3150 3600 4000 630 1250 1600 2000 2500 3150 3600 4000
IF Incoming/outgoing (2) (2)
BT Bus-tie
R Riser
RM Riser with measurements
M Measurements
IFD Direct incoming/outgoing
IFDM Direct incoming/outgoing with measurement

44
 1.16

... 24 kV - ... 25 kA
Depth (mm) 1560 1560
Height (mm) 2200/2325/2720 (1) 2200/2325/2720 (1)
Height with gas exhaust duct (mm) 2775 2775
Width (mm) 800 1000
Rated current (A) 630 1250 1600 2000 2500 630 1250 1600 2000 2500
IF Incoming/outgoing (2) (2)
BT Bus-tie (2)
R Riser
RM Riser with measurements
M Measurements
IFD Direct incoming/outgoing
IFDM Direct incoming/outgoing with measurement
DF Switch-disconnector unit (4)

Notes
(1) The height of the unit is a function of the height of the instrument compartment, available in the 580, 705 and 1100
mm versions. The instrument compartment of the unit from 3150A to 4000A is only available in the 705 and 1100
mm versions.
(2) Version only available with vacuum circuit-breakers.
(3) For the characteristics of the unit equipped with contactor refer to pages 20-21.
(4) For the characteristics of the unit equipped with switch-disconnector refer to pages 24-25.

E E
Height with gas exhaust duct

D B D
Height (1)

A A

Unit compartments
C C A Apparatus
B Main busbars
C Feeder
D Instruments
Width Depth E Gas exhaust duct

45
46
 2
UniGear 550

Page Chap.

Description 48 2.1

Characteristics 50 2.2

Typical units and technical data 52 2.3

47
 Description

The latest item in the large family of UniGear

products is the panel called UniGear 550 which
mirrors all the construction characteristics of the
standard panel.
UniGear 550 is available up to a maximum panel
current of 1250A: The circuit-breaker designated
for this product is called Vmax/L.
The peculiarity of this panel is its size. In fact, it
only measures 550 mm in width which makes it a
very compact and versatile product.
It has been built so that it can be connected
directly to the standard panel. In fact, it has the
same overall dimensions (height and depth) and
the same omnibus busbars up to a maximum
current value of 4000A.
For this panel, too, positioning against the wall is
possible. In fact, all the putting into service and
maintenance operations can be carried out directly
from the front.
Accessing the cable area is particularly convenient
by easily removing the base of the circuit-breaker
compartment. In this way, accessibility is in-
creased.
As a standard solution, it is possible to connect up
to three single-pole cables per phase (maximum
cross-section of 185 mm²), or two cables per
phase (maximum cross-section of 300 mm²).

The connection height of the cables in relation to

the floor is 600 mm.

UniGear 550 uses toroidal transformers as the

standard solution, which are fixed onto a “CT Rod”.
As an optional solution, the transformers can be
inserted on a DIN rail.
The panel has been built to be able to insert the
fixed voltage transformers, positioned on the front
of the panel itself. The capacitive signal for indicat-
ing voltage present is connected directly to the
insulators which support the busbars on the cable
side. The surge arresters can also be inserted in
the cable area.

The UniGear 550 switchgear is fitted with all the

interlocks and accessories needed to guarantee
top level safety and reliability for the installation and
for the operators.

UniGear 550 has undergone all the tests required

by the International Standards (IEC) and local
standards (for example the GB, Chinese and
Russian GOST standards).

48
 2.1

Electrical characteristics

Rated voltage kV 12 12 17,5

Rated insulation voltage kV 12 12 17,5
Rated power frequency withstand voltage kV 1m 28 38 38
Rated lightning impulse withstand voltage kV 75 95 95
Rated frequency Hz 50-60 50-60 50-60
Rated short time withstand current kA 3s 31.5 31.5 31.5
Peak current kA 80 80 80
Internal arc withstand current kA 1s 31.5 31.5 31.5
Main busbar rated current (1) A 630…4000 630…4000 630…4000
Branch connection rated current A 630 - 1250 630 - 1250 630 - 1250

(1) Up to 4000A if coupled with other UniGear units.

Apart from this, UniGear 550 is completing the

series of certifications required by the regulations
of the major shipping registers (LR, DNV, RINA,
BV and GL) for use of the switchgear in marine
installations.
In accordance with the IEC 62271-200 Standard,
UniGear 550 is defined as follows:
– PM (Partition metallic): i.e. it is provided with
metallic shutters and partitions between the
operating parts and an open compartment.
– LSC2B (Loss of service continuity): service of
the main busbar and of the cable compartment
is guaranteed when a normal maintenance
operation is to be carried out in one of the
compartments of the main circuit (e.g. circuit-
breaker compartment).
– IAC AFLR (Internal arc classified): UniGear 550
is classified as IAC AFLR, i.e. it is accessible
from the front, side and rear having respected
the five criteria during the internal arc tests.

49
 Characteristics

These units are designed to be equipped with the Their use is required in the case of a great need
following instruments: for just a few units, such as fiscal metering on
– Ring core type current transformer (standard). incoming feeders (Class 0.2), residual current
– Block type current transformer (optional). protection on transformer feeders, etc.
– Bushing type current transformer (optional). The use of block type current transformers will in
any case allow application of ring core type
current transformers on cables.
Ring core type of current transformer
Thanks to the new digital protection and measur-
ing instruments, the use of low power measuring
instruments can easily be extended to primary
distribution switchgear as well.
These current transformers are arranged on a
support inside the switchgear (CT rod) and above
the cable terminals to be unaffected by the
following choices: number of cables, cross section
and type of terminations.
These CT rods are designed to be equipped with
a maximum of two current transformers per phase
(metering and protection) and with the following
dimensional requirements:
– minimum internal diameter: 30 mm;
– maximum external diameter: 190 mm;
– maximum height: 80 mm.

Block type current transformer.

Bushing type current transformer

In a large part of the market, and especially in
those strongly affected by BS concepts, there is
widespread use of the bushing type current
transformers.

Ring core type current transformer.

Block type current transformer

As an alternative to the above specified current
measuring instruments, application of a set per
phase of block type current transformers, current
sensors and combi-sensors is possible with a
dedicated design. Bushing type current transformer.

50
 2.2

ST1-UG Earthing Switch The switch has been tested at two closing opera-
The 550 panel is equipped with ST1-UG type tions at 100% of the rated short-circuit making
earthing switch. This device is a patented switch current. The device is provided with auxiliary
with rectilinear movement. switches for signalling the open and closed
It is fitted with a snap action operating mechanism positions, operated by the rod mechanism.
for positive high speed closing and is sized to
conduct the rated short circuit making current The following are available on request:
when close to underload. – Locking magnet
The speed of the snap action closing operation is – Key locks for open and closed positions
independent of controls. – Padlock.
The switch is equipped with an earthing blade
which connects the three phases via the earthing
pins placed on the copper bars of the cable
connecting system.
The earthing bar is electrically connected to earth
by a stranded copper conductor.
The snap action closing mechanism of the earth-
ing switch functions independently of the rotation
of the drive shaft.
The switching speed and torque achieved are
independent of the action of the operating mecha-
nism.
On the other hand, in the opening process, the
toggle springs have no effect on the speed of
contact separation.
A manual operating lever is provided for operation
of the switch.

51
 Typical units and technical data

Single-line diagram of the typical units

Removable
Removable

IF - Incoming / Outgoing feeder BT - Bus-tie R - Bus Riser RM - Bus Riser with

measurements

Withdrawable
Removable

Removable

M - Measurements IFD - Direct Incoming / IFDM - Direct Incoming /

Outgoing Outgoing with
measurement

52
 2.3

Unit width 550mm

12-17.5 kV
Rated current [A] – 630 1250
IF Incoming / Outgoing feeder
IFM Incoming / Outgoing with measurements
BT Bus Tie
R Bus Riser
RM Bus Riser with measurements
M Measurements
IFD Direct Incoming / Outgoing
IFDM Direct Incoming / Outgoing with measurement
DF Switch-disconnector unit

– Depth (mm): 1340

– Height (mm): 2200 - (1) 2595 with higher instrument compartment)
– Height with gas exhaust duct (mm): 2675
Height with gas exhaust duct
Height (1)

Unit compartments
A Apparatus
B Busbar
C Feeder
D Instruments
E Gas exhaust duct

Width Depth

53
54
 3
Double Level UniGear

Page Chap.

Description 56 3.1

Characteristics 58 3.2

Typical units and technical data 60 3.3

55
 Description
UniGear is a single busbar system
switchgear in the double-level
configuration. Each panel consists of
two completely independent super-
imposed units and is functionally
identical to two single-level units
placed side by side.
Thanks to the numerous typical units
available, the switchgear can be
suitably configured to satisfy all
installation requirements.
Each unit can be equipped with
circuit-breakers or contactors, as well
as with all the accessories available
for conventional switchgear units. All
the significant components are
identical to those used for the single-
level units and therefore the same
service and maintenance procedures
are guaranteed.
The double-level UniGear switchgear
mainly stands out for its efficient use
of space. All the configurations allow
a drastic reduction in the space
occupied, with special regard to the
width of the switchgear (30...40% in
typical configurations).
630A
IF IF IF RM BT RM
1250A
630A
IF IF IF IF IF IF
1250A 1250A
Complete double-level con-
figuration.
56
Its use is recommended in installa-
tions with a high number of feeders,
fitted with either circuit-breakers or
contactors. It can be used as a motor
control center for applications up to
12 kV.
All the electrical characteristics of the
double and single-level units are
identical. The overall rated current of
the busbar system is given by the
sum of the currents of the two top
and bottom half-busbars. The double-
level units can be
coupled directly to single-level units,
with the possibility of extension at
both ends of the switchgear.
The switchgear requires access from
the rear for the installation and
maintenance procedures, whilst all
the service operations are carried
out from the front.
The double-level UniGear switchgear
can be used in two typical configura-
tions:
• Complete with double-level.
• Compound with simple and
double-level.
630A
IF IF IF
630A
IF IF IF
 3.1

The complete solution only uses Electrical characteristics

double-level panels to realise all the
typical units: incoming feeders, bus- Rated voltage kV 7.2 12 17.5
tie, riser, busbar measurement and Rated insulation voltage kV 7.2 12 17.5
outgoing units.
Rated power frequency withstand voltage kV 1min. 20 28 38
The compound one, on the other
hand, uses both the simple and Rated lightning impulse withstand voltage kV 60 75 95
double-level solution: the former for Rated frequency Hz 50-60 50-60 50-60
the incoming feeders, bus-tie and Rated short-time withstand current kA 3s …50 …50 …40
riser compartments, the latter for the
Peak current kA …125 …125 …100
busbar measurement and outgoing
units. Internal arc withstand current kA 1s …40 …40 …40
The complete double-level solution kA 0.5s …50 …50 -
achieves the maximum objective of Main busbar rated current A …1600 …1600 …1600
reducing dimensions and can be Branch connection rated current A 630 630 630
used for relatively limited rated
1000 1000 1000
currents (1600 A maximum current of
the incoming feeders). It is normally 1250 1250 1250
used to make local distribution 1600 1600 1600
switchgear, with a limited number of
outgoing feeders.
The field of application of the
compound solution is, on the other
hand, for main distribution switch-
gear, with high rated currents
(3150 A maximum current of the
incoming feeders) and numerous
outgoing feeders.

Compound configuration
with simple and double level.

57
 Characteristics
Compartments
Each panel consists of two superimposed units [1st
level and 2nd level] and each unit is therefore made
up of three independent power compartments:
apparatus [A], busbar [B] and feeder [C].
There is metallic segregation between all the
compartments.
In its middle part, the panel is fitted with a com-
partment to take the auxiliary instruments of both
the units [D]. This solution means the machine-
user interfacing apparatus is at a convenient
height. In the top part of the panel, an additional
compartment is available to house any further
instruments provided [d].
The arc-proof switchgear is normally fitted with a
duct for evacuation of the gases produced by an
arc [E]. Each compartment of the unit placed on
the 2nd level is fitted with a flap on the top of it. The
pressure generated by the fault makes this open,
allowing the gas to pass into the duct.
The gases produced by faults generated in the
power compartments of the unit placed on the 1st
level are evacuated towards the main duct by
means of a dedicated duct placed laterally to the
switchgear [e]. Each compartment of the unit
placed on the 1st level is fitted with a flap posi-
tioned on the side of the switchgear. The pressure
generated by the fault makes this open, allowing
the gas to pass into the duct. This solution means
the units placed on the 2nd level are not
involved in the effects of the fault.
The apparatus compartments are accessible from
the front. Door closing of these compartments is
available in two versions, with screws or central
handle. Removal of the apparatus from the
switchgear (circuit-breakers, contactors and
measurement truck) placed on the two levels and
from its relative compartments takes place by
means of a single dedicated fork-lift truck. This
truck can also be used for the same procedures
for the single level units.
The busbar and cable compartments are accessi-
ble from the rear of the switchgear by means of
removable panels.
All the normal service operations are carried out
from the front, whereas maintenance and start-up
operations also require access from the rear of the
switchgear.
The fact that the switchgear is clearly identified as
belonging to the two superimposed units, makes it
impossible to carry out incorrect operations.
58
The characteristics of the busbar system, branch
connections, earthing busbar, earthing switch,
insulator bushings and shutters are the same as
those for the single-level units. A maximum of six
single or three-core cables per phase can be
used depending on the rated voltage, on the unit
dimensions and on the cross-section of the cables.
Configurations
The typical units available allow the most suitable
configurations for the installation requirements.
The incoming/outgoing feeder panel [IF] is the one
most widely used: both switchgear levels consist
of units of this type and can be used both as
incoming and outgoing feeders.
The bus-tie [BT] and riser [R] units are used to
make complete double-level switchgear. These
units are positioned on the 2nd level, whereas the
incoming/outgoing feeder units are included in the
1st level. The bus-tie units can be fitted with
current transformers on the load side of the circuit-
breaker for busbar measurement. Installation of
the current transformers on the supply side is also
possible to realise special protection schemes.
The riser compartment is also available in the
version with withdrawable instrument truck with
voltage transformers with fuses [RM].
The compound configuration with simple and
double-level requires connection between the two
pieces of switchgear by means of the connection
unit. This unit makes all the connections between
the two types of switchgear (busbars, earthing
busbar, gas exhaust duct, ducts for connection of
the auxiliary circuits) and can integrate the
earthing switch of the busbars [J] and also the
withdrawable instrument truck with voltage trans-
formers with fuses [JM]. These units are posi-
tioned on the 2nd level, whereas the incoming/
outgoing feeder units are included on the first
level.
 3.2

2
3

2° Level 4

1° Level 4

2
3

1 Door of the apparatus compartment

2 Racking-in/racking-out operation
3 Earthing switch operation
4 Control unit

59
 Typical units and technical data

Single-line diagram of typical units

IF BT R RM J JM
Incoming/outgoing Bus-tie Riser Riser with Connection unit Connection unit with
feeder measurements measurements
2° Level

Withdrawable

Withdrawable
1° Level

IF IF IF IF IF IF
Incoming/outgoing Incoming/outgoing Incoming/outgoing Incoming/outgoing Incoming/outgoing Incoming/outgoing
feeder feeder feeder feeder feeder feeder

Key to components

Standard components
Accessories
Alternative solutions

60
 3.3

... 12 kV - ... 50 kA ... 17.5 kV - ... 40 kA

Depth (mm) 1976 Depth (mm) 1976
Height (mm) 2698 (1) Height (mm) 2698 (1)
Height with gas exhaust duct (mm) 2698 (1) Height with gas exhaust duct (mm) 2698 (1)
Width (mm) 750 750 900 900 Width (mm) 750 750 900 900
Rated short-time current (kA) ... 31.5 .. 31.5 ... 50 ... 50 Rated short-time current (kA) ... 31.5 .. 31.5 ... 40 ... 40
Rated current (A) 630 1000 1250 1600 Rated current (A) 630 1000 1250 1600
2nd IF Incoming/outgoing (2) 2nd IF Incoming/outgoing
1st IF Incoming/outgoing (2) 1st IF Incoming/outgoing

2nd BT Bus-tie 2nd BT Bus-tie

1st IF Incoming/outgoing 1st IF Incoming/outgoing

2nd R Riser 2nd R Riser

1st IF Incoming/outgoing 1st IF Incoming/outgoing

2nd RM Riser with measurements 2nd RM Riser with measurements

1st IF Incoming/outgoing 1st IF Incoming/outgoing

2nd J Connection 1250A 2nd J Connection 1250A

1st IF Incoming/outgoing (2) 1st IF Incoming/outgoing

2nd JM Connection with measurements 1250A 2nd JM Connection with measurements 1250A
1st IF Incoming/outgoing (2) 1st IF Incoming/outgoing

Notes
(1) The height of the switchboard in the compound configuration with simple and double-level is the same as that of the double-level unit.
(2) For the characteristics of these units equipped with contactor refer to page 22.

d d
B2 E

A2
C2 A2
Height

D e B1 D

A1 C1 A1
Unit compartments
A Apparatus
B Main busbars
C Feeder
D Instruments
Width Depth E Gas exhaust duct

61
62
 4
Double Busbar System UniGear

Page Chap.

Description 64 4.1

Characteristics 66 4.2

Typical units 68 4.3

Technical data 70 4.4

63
 Description

Most switchgear used in installations with normal

service conditions is based on single busbar
systems.
When compared with double busbar switchgear,
single busbar switchgear is definitively easier to
operate and maintain, requires less space and the
total cost of the installation is lower (equipment,
site procedures, maintenance, square metres,
etc.).

The use of double busbar switchgear may be

necessary when some of the following features
are required:
– Operation of incoming feeders with non-syn-
chronised circuit breakers.
– Load shedding of outgoing feeders with a
different level of importance during emergency
conditions.
– Isolation of particular outgoing feeders from the
normal network.
– Outgoing feeders balancing on two busbar Both the schemes provide full busbar system
systems during normal service. redundancy (physical isolation between source
– Flexibility during inspection and maintenance busbar systems) and allow uninterrupted and
procedures without load interruption. reliable service conditions.
– Extension without switchgear shutdown.
The first solution has two main advantages
The double busbars systems are based on two compared with the second one:
different schemes: – Free access to one busbar system during
– Two busbars systems, two line disconnectors maintenance operations while the other is in
and one circuit breaker (pure double busbars service.
system). – Fast switching between the two busbar systems
– Two busbars systems, two circuit breakers during emergency situations thanks to the use
compartments with one or two circuit breakers of line disconnectors.
(duplex system).

Single Busbar Section.

64
 4.1

Electrical characteristics

Rated voltage kV 12 17.5 24

Rated insulation voltage kV 12 17.5 24
Rated power frequency withstand voltage kV 1min. 28 38 50
Rated lightning impulse withstand voltage kV 75 95 125
Rated frequency Hz 50-60 50-60 50-60
Rated short time withstand current kA 3s ...31.5 ...31.5 ...25
Peak current kA ...80 ...80 ...63
Internal arc withstand current kA 1s …31.5 …31.5 …25
Main busbars rated current A 1250...4000 1250...4000 1250...2500
Branch connection rated current A 630...3150 630...3150 630...2000
Branch connection rated current with forced ventilation A 3600...4000 3600...4000 –

The second solution has two main advantages
compared with the first one:
– Incoming feeders and very important outgoing
feeders can be equipped with two circuit-
breakers in order to allow apparatus redundancy
as well.
– Circuit-breaker maintenance and testing without
feeder shutdown.
– Fewer number of components and less switching
apparatus.
Thanks to the numerous typical units available, the
switchgear can be suitably configured to satisfy all
installation requirements.
Each unit can be equipped with circuit-breakers or
contactors, as well as with all the accessories
available for conventional switchgear units.
All the significant components are identical to
those used for the single level and double level
units and therefore the same service and mainte-
nance procedures are guaranteed.
The units can be arranged as required by the
installation requirements, but, according to the
technical literature, the switchgear must be
configurable as per the following two schemes:
– Single busbar section
– Double busbar section

Double Busbar Section.

65
 Characteristics

Compartments
Each panel is made up of four independent power
compartments: apparatus (A), busbar 1 (B1),
busbar 2 (B2) and feeder (C). There is a metallic
segregation between all the compartments.
In its front/top part the panel is fitted with a com-
partment to take the auxiliary instruments (D).
The arc-proof switchgear is normally fitted with a
duct for evacuation of the gases produced by an
arc (E).
Each compartment of the unit is fitted with a flap on
the top of it. The pressure generated by the fault
makes this open, allowing the gas to pass into the
duct.
The apparatus compartment is accessible from the
front. Door closing of these compartments is
available in two versions, with screws or central
handle.
Removal of the apparatus from the switchgear
(circuit-breakers, contactors and trucks measure-
ments) and from its relative compartments takes
place by means of a single dedicated truck.
The busbar and cable compartment are accessible
from the rear of the switchgear by means of
Line disconnectors
removable panels.
All the normal service operations are carried out IF unit line disconnectors are designed to act as
from the front, whereas maintenance and start-up two positions switches - open and closed positions
operations also require access from the rear of the - and operation is manual (e.g. without springs).
switchgear. The opening and closing operation of the line
It is not possible to achieve full front access to all disconnector is operated from the front of the
compartments and components with the double panel.
busbar system switchgear, so installation not The position of the line disconnector is indicated on
standing against the wall is mandatory. the front of the panel with reliable indicators.
The line isolators are clearly separated and the
relevant busbar compartments must be segregated
from each other in order to achieve the following:
A fault generated in one compartment (e.g. insula-
tion discharge) will not generate any damage to the
others or require the shutdown of the unit.
It should be possible to carry out maintenance and
also extend the switchgear with additional unit/s,
keeping one of the two busbars systems energised.
They are provided of limit switches for the position
detection.
The line disconnectors can be operated manually
or, as an option, motor operated. Motor operation is
locked while the manual-operating crank is inserted
into the operating slot.
The line disconnectors are provided with the
necessary interlocking facilities.

66
 4.2

The interlocks between the two line disconnectors

and the circuit breaker are implemented by means
of locking magnets. This solution allows maximum
flexibility and the required service conditions.
The line disconnector consists of a moveable
copper tube included inside an epoxy insulator.
Electrical contact is guaranteed by two or four
connection springs (depending on the rating of the
disconnector). Additional protective insulating caps
are mounted on both sides of the insulator, thus
providing the device with a high level of reliability.

1 – Door of the apparatus compartment

2 – Control unit
3 – Racking-in/racking-out operation
4 – Earthing switch operation
5 – Open/closed line disconnector B1
6 – Open/closed line disconnector B2

67
 Typical units

Single-line diagram of the typical units

IF - Incoming/Outgoing IF and IFM - Busbar A Duplex IF and IFM - Busbar B Duplex

BTT - Transv. Bus Tie M - Metering BTL - Longitudinal Bus Tie

68
 4.3

Single-line diagram of the typical units

RL - Bus Riser Long. RLM - Bus Riser Long. with Metering

Busbar applications

Top-mounted VTs Top-mounted earthing switch Top entry duct

69
 Technical data

12-17.5 kV
Unit width (mm) 650

Rated current (A) 630 1250 1600 2000 2500 3150 3600 4000

IF Incoming/outgoing feeder

IF Incoming/outgoing duplex feeder

IF Incoming/outgoing duplex with measurement

BTT Transverse bus-tie

M Measurements

BTL Longitudinal bus-tie

RL Longitudinal riser

RML Longitudinal riser with measurement

12-17.5 kV
Unit width (mm) 800

Rated current (A) 630 1250 1600 2000 2500 3150 3600 4000

IF Incoming/outgoing feeder

IF Incoming/outgoing duplex feeder

IF Incoming/outgoing duplex with measurement

BTT Transverse bus-tie

M Measurements

BTL Longitudinal bus-tie

RL Longitudinal riser

RML Longitudinal riser with measurement

12-17.5 kV
Unit width (mm) 1000

Rated current (A) 630 1250 1600 2000 2500 3150 3600 4000

IF Incoming/outgoing feeder

IF Incoming/outgoing duplex feeder

IF Incoming/outgoing duplex with measurement

BTT Transverse bus-tie

M Measurements

BTL Longitudinal bus-tie

RL Longitudinal riser

RML Longitudinal riser with measurement

– Depth (mm): 2021

– Height (mm): 2075 - (2595 with higher instrument compartment)
– Height with gas exhaust duct (mm): 2700

IF and IFM duplex feeders, M, BTL, RL and RLM will be available for both A and B busbar system connections.

70
 4.4

24 kV
Unit width (mm) 800

Rated current (A) 630 1250 1600 2000

IF Incoming/outgoing feeder

BTT Transverse bus-tie

M Measurements

BTL Longitudinal bus-tie

RL Longitudinal riser

RML Longitudinal riser with measurement

24 kV
Unit width (mm) 1000

Rated current (A) 630 1250 1600 2000

IF Incoming/outgoing feeder

BTT Transverse bus-tie

M Measurements

BTL Longitudinal bus-tie

RL Longitudinal riser

RML Longitudinal riser with measurement

– Depth (mm): 2570

– Height (mm): 2400 - (2720 with higher instrument compartment)
– Height with gas exhaust duct (mm): 2700
M, BTL, RL and RLM will be available for both A and B busbar system connections.
Height with gas exhaust duct

Height (1)

Unit compartments
A Apparatus
B1 Busbar 1
B2 Busbar 2
C Feeder
D Instruments
E Gas exhaust duct
Width Depth

71
72
 5
UniGear type ZVC

Page Chap.

Description 74 5.1

Characteristics 76 5.2

Typical units and technical data 78 5.3

73
 Description

The UniGear range is completed by the

compact contactor unit with fuses. This
uses vacuum contactors and is designed
specifically for motor, transformer and
capacitor bank switching and protection
for rated voltages up to 7.2 kV and rated
currents up to 400 A. Thanks to the use
of fuses as the main means of protection,
it can be used in installations with faultcur-
rents up to 50 kA.
This unit is able to combine maximum
accessibility of all the components with
the most limited dimensions available
on the market today for medium voltage
switchgear. The innovative integration
of the components offers a solution with
extremely reduced weight and footprint,
allowing efficient use of space in electrical
installations.
The most evident characteristic of this unit
is its extreme compactness, just 325 mm.
It therefore finds ideal application in installations
with a high number of contactor outgoing feeders The use of medium voltage protection fuses
or in situations with very limited space available. strongly limits the fault let-through energy, allowing
The use of the contactor unit with fuses is prefera- the contactor to be used in installations even with
ble to the use of circuit-breakers when a high high fault currents.
number of daily operations is required. This characteristic also helps to safeguard the
The interrupters for use in the contactor guarantee levels of insulation and increase the electrical life
an extremely high number of closing and opening of the cables and of the connected machine.
operations under normal load conditions and with For the same reason, the switchgear unit can use
a maximum rated short-time withstand current earthing switches for the power cables with
of 6 kA. reduced making capacities compared to the rest of
The electrical life of the contactor is defined as the switchgear components, but suitable in any
being in category AC3 with 100,000 operations case for the fault current available on the load side
(closing-opening), 400 A interrupted current. of the fuses.

IF IF IF IF IF IF IF IF IF IF
IF BT R IF

74
 5.1

The limiting properties of the fuses also allow cables with reduced cross-
sections to be used for the connection between the switchgear and the
machines to be protected (reductions between 60 and 80% can be obtained),
leading to a considerable reduction in costs.
The unit can be coupled directly with the main switchgear, with possibility of
extension on both ends of the switchgear. The same service and mainte-
nance procedures are guaranteed as well as full wall-mounting.

Standards
IEC 60470 for the contactor.
IEC 60282-1 for the fuses.

Electrical characteristics

Rated voltage kV 3.6 7.2

Rated insulation voltage kV 3.6 7.2
Rated power frequency withstand voltage kV 1min. 16 20
Rated lightning impulse withstand voltage kV 40 60
Rated frequency Hz 50-60 50-60
Rated short-time withstand current kA (1) …50 …50
Peak current kA …125 …125
Internal arc withstand current (2) kA 1s …40 …40
kA 0.5s …50 …50
Main busbar rated current A …4000 …4000
Branch connection rated current A 400 400

Maximum performances of the

contactor with fuses
Rated voltage kV 3.6 7.2
Motors kW 2000 4000
Transformers kVA 2250 4500
Capacitors kVAR 1000 2000

(1) Limited by the fuses.

(2) The internal arc with-
stand values are guar-
anteed in the compart-
Maximum load currents of the fuses
ments on the supply
side of the fuses (bus-
Feeder Transformers Motors Capacitors bars and apparatus) by
Rated Fuse Maximum Fuse Maximum Fuse Maximum the structure of the
voltage load load load switchgear and on the
3.6kV 450A (2x250) 360A 550A (2x315) 400A 550A (2x315) 360A load side (feeder) by the
limiting properties of the
7.2kV 450A (2x250) 360A 550A (2x315) 400A 550A (2x315) 360A
fuses.

75
 Characteristics
Compartments
Each unit consists of three power compartments:
apparatus, busbar and feeder.
The apparatus and feeder compartments are
accessible from the front by means of a single
access door. Door closing is carried out with
screws.
Each unit is fitted with an auxiliary compartment,
where all the instruments and cabling are housed.
The arc-proof switchgear can be fitted with a duct
for evacuation of the gases produced by an arc.
All the units are accessible from the front and
maintenance and service operations can therefore
also be carried out with the switchgear wall-
mounted.
The compartments are segregated from each
other by metallic partitions.
Integration of the components
The switchgear is built up around three basic
functional structures, consisting of macro blocks of
epoxy resin where the components of the switch-
gear are incorporated. The top block [A] contains
the whole system of branch connections (towards
the main busbars and towards the cable terminals)
and the fixed contacts (for connection of the
contactor to the
busbar and feeder compartment).
The bottom block [B] creates the insulation
required between the phases at cable terminal
level and that of the fixed contacts of the earthing
switch.
The third block [C] is represented by the main
body of the withdrawable contactor.
Segregation between the apparatus, busbar and
feeder compartments is carried out by means of a
system of metallic shutters. These are activated
automatically during movement of the apparatus
from the racked-out position to the service
position and vice versa. In the case where back-
feed of the unit from the cable side is not possible,
the bottom segregation shutter of the latter can be
eliminated. Even in the unlikely case of back-feed,
safety of the operating personnel is guaranteed in
any case by the presence of an interlock only
allowing the unit door to be opened after the
power cable earthing switch has been closed.
76
The current transformers are normally coupled
onto the bottom branch connections of the top
monobloc. They are of the toroidal type and are
completely insulated from the medium voltage
system. They can also be replaced from the front
of the switchgear after having removed the
contactor and the shutter segregation system.
The unit can also be equipped with toroidal
transformers placed on the power cables in the
feeder compartment.
Each unit can be equipped with an earthing switch
to earth the cables. The earthing switch is fitted
with short-circuit making capacity up to
12.5 kA x 1s and 31.5 kA peak. The apparatus is
controlled from the front of the switchgear with
manual operation. The position of the earthing
switch can be seen from the front of the switch-
gear by means of an indicator.
The characteristics of the busbar system, earthing
busbar and gas exhaust duct are the same as
those of the other UniGear units. A maximum of
two single and three-core cables per phase can be
used, depending on the rated voltage and on the
cross-section of the cables.
Contactor
The apparatus is dedicated to use in this typical
unit.
The epoxy resin monobloc [C] contains the
connections embedded between the top isolating
contacts, the fuse connections, vacuum interrupt-
ers and finally the bottom isolating contacts. This
structure also houses the following components:
vacuum interrupters, moving equipment, control
electromagnet, multivoltage feeder and auxiliary
contacts.
The contactor can be fitted with an operating
mechanism with electrical or mechanical latching.
The contactor can be fitted with a two-pole voltage
transformer complete with protection fuses. The
voltage transformer must be used for supplying
the coils of the contactor operating mechanism.
The contactor is fitted with medium voltage fuses
for protection of the operated feeders. Coordina-
tion between contactor, fuses and protection unit
is guaranteed in accordance with the IEC 60470
Standards for apparatus in class C.
 5.2

The monobloc also acts as a fuse-holder frame

and is preset for installation of one or two sets of
three fuses per phase with average type of
dimensions and striker, according to the BS 2692
Standard, with a maximum length of 454 mm.
The contactor has an automatic opening device
when even a single fuse blows.
Contrary to the apparatus of the conventional
compartment, where the connections of the
auxiliary circuits of the apparatus with the auxiliary
unit are made by means of a plug-socket system
with manual coupling, the contactor
dedicated to this unit uses an automatic coupling
system. This is activated automatically during
movement of the apparatus from the racked-out
position to the service position and vice versa.

77
 Typical units and technical data

Single-line diagram of the typical units

Typical motor start-ups

A
A Direct

B Reverse direction

1 2 C Reactor

D Autotransformer

E Star-delta

3 Off
Key to components

1 Contactor with electrical latching

2 Contactor with mechanical latching.

3 Two-pole voltage transformer for supplying the con-

trol circuits

Standard components
Accessories
Alternative solutions

B C D E

M M M M
~3 ~3 ~3 ~3

78
 5.3

The compact contactor units with fuses in the
UniGear range have been specifically studied to
offer the best performances with direct motor
starting, as this is the type most widely used.
The switchgear can, however, also be used for
complex starting, which requires the use of several
contactor units.
The connections between the various units used
during the starting and running stage, such as
between the machines (motor, reactor, autotrans-
former), are made using cables.
The phase inversions are carried out directly on
the output of the switchgear by means of the
power cables. The units which make the star
centre of the machines must be positioned at the
end of the switchgear.
The contactors used to operate each motor are
interlocked together by means of electromechanical
devices.
These operate by means of locking magnets with
active logics and therefore auxiliary voltage cut-off
makes the lock operative. The starting and switch-
ing sequences can be fully automated by means of
the REF542plus unit.
The unit software makes the control logics and its
great flexibility allows it to be adapted efficaciously
to the characteristics of the machine to be operat-
ed. The interlocks between the contactors dedicat-
ed to operation of the machine can also be man-
aged safely by the REF542plus unit.

... 7.2 kV - ... 50 kA

Depth (mm) 1125
Height (mm) 2200/2595 (1)
Height with gas exhaust duct (mm) 2675 (1) The height of the unit is
Width (mm) 325 a function of the height
of the instrument com-
Rated current (A) 200 400
partment, available in
IF Incoming/outgoing the 675 and 1070 mm
versions.

E E
Height with gas exhaust duct

D B D
Height (1)

A A

C C Unit compartments
A Apparatus
B Main busbars
C Feeder
Depth D Instruments
Width E Gas exhaust duct

79
80
 6
Marine Applications

Page Chap.

Description 82 6.1

Characteristics 84 6.2

Typical units and technical data 86 6.3

81
 Description

In the recent past, the electrical network of marine

plants was manufactured with low voltage compo-
nents. The increase in power and short-circuit
current has obliged shipyards to move to medium
voltage.
In the beginning 3.6kV was used in most cases,
but the current requirements are 7.2 and 12kV.
The plants are rapidly reaching the limits (50kA)
even at these voltages and the long-term vision is
for 12kV only.
The use of 13.8kV could be taken into considera-
tion (few builders have already used this voltage).
The switchgear suitable for marine applications is
therefore 7.2-12kV switchgear (with the option for
17.5kV), with the need for many dedicated fea-
tures and some special typical units.
The temperature range, vibrations and variable Over 5,000 ABB panels are in service in the world
inclination are particularly severe conditions on board all kind of ships. ABB delivers about 500
affecting the functional efficiency of on-board units per year.
components such as the switchgear.
Other conditions (e.g. high humidity and saline Registers and end-customers (shipyards or ship
concentration) only affect off-board equipment and owners) require switchgear manufactured to
therefore not the switchgear. comply with Shipping Register test requirements
ABB is the leading manufacturer of air-insulated for on-board apparatus.
switchgear for marine applications, installed by all For this purpose, tests have been performed in
main shipyards (Brazil, China, Denmark, Finland, compliance with the main Shipping Register
France, Germany, Japan, Korea, Italy, Norway, regulations; DNV, LR, RINA, BV, GL and ABS
Singapore, Spain, UK and USA). regulations.

82
 6.1

Electrical characteristics

Rated voltage kV 7.2 12

Rated insulation voltage kV 7.2 12
Rated power frequency withstand voltage kV 1 m 20 28
Rated lightning impulse withstand voltage kV 60 75
Rated frequency Hz 50-60 50-60
Rated short-time withstand current kA 3s ...50 ...50
Peak current kA ...125 ...125
Internal arc withstand current kA 1s …40 …40
kA 0.5s ...50 ...50
Main busbars rated current A 1250...4000 1250...4000
Branch connection rated current A 630...3150 630...3150
Branch connection rated current with forced ventilation A 3600...4000 3600...4000

The Marine Market can be divided into four Applications

different segments:
– Passenger vessels (cruise ships and ferries).
– Industrial vessels (shuttle tankers, drill ships, oil
carriers, cargo vessels, etc.).
– Rigs (drill and oil rigs).
– Navy (Military navy).
In this type of plants where there is high humidity
and saline concentration as well as a variable
temperature range, the vibrations and the variable
trim are particularly severe conditions affecting the
functional efficiency of ships, tankers, container
ships, etc.
Moreover, in order to guarantee the necessary
comfort and facilities, high electrical power
generation plants and control systems must be
concentrated in significantly reduced overall
dimensions.
UniGear, coupled with double level and/or ZVC,
offers a wide range of apparatus and control units
to satisfy marine installation requirements.
UniGear apparatus provides ideal technical
solutions for marine applications:
– Arc-proof construction, mechanical safety
interlocks, automatic segregation shutters and
apparatus control with the door closed guaran-
tee personnel safety during installation, mainte-
nance and service;
– High degree of protection (up to IP43) on the
external enclosure;
– Metallic partitions between each compartment
and earthing of all components accessible to
personnel: apparatus, shutters, doors and the
whole switchgear frame;
– High fire resistance thanks to scarce use of
plastic and resins: the auxiliary equipment and
wiring are highly self-extinguishing.

Ambient conditions for classification of on-board apparatus

– Ambient temperature from 0 °C to + 45 °C
– Inclination up to 25° permanent
Vibration in the frequency range of 2 … 100Hz at the following motion width
– 1mm amplitude in the frequency range of 2…13.2Hz
– 0.7g acceleration amplitude in the frequency range of 13.2…100Hz

83
 Characteristics
The features required, which are not part of the
standard design, are described below.
Degree of Protection
The standard external degree of protection of
marine switchgear is IP42 or IP43.
Wiring duct
Every switchgear unit is equipped with the top-
mounted interconnection wiring duct and the total
switchgear height must be 2500 mm (2530 mm
with gas duct and top chimneys). The duct is fixed
on the top of the auxiliary compartment.
Gas duct
UniGear is always in the arc-proof version and
therefore equipped with the gas duct.
The duct is fixed on the top of the auxiliary
compartment. In marine plants, the exhaust gases
cannot normally be evacuated out of the room and
therefore the gas duct must always be closed on
both the end-sides and equipped with top chim-
neys.
If there are cases where it is possible to evacuate
hot gases out of the room, the standard gas duct
can be supplied.
Cables
Single Level UniGear
Single level IF and IFM units will mainly be in the
deeper version (1840-1890 mm). This design will
allow the following targets to be achieved:
– bottom and top cable entry;
Arc venting system
84
– appropriate cable terminal distance (minimum
requirements):
- 700mm in case of bottom entry;
- 1000mm in case of top entry.
Standard depth IF units (1340-1390 mm) are also
used as an alternative in case of problems with
space.
This feeder version will only allow bottom cable
entry and a cable terminal distance in the range of
440…535 mm, depending on the rated current.
UniGear ZVC
Bottom cable entry units are equipped with two
cables per phase. The terminal distance from the
floor is 630 mm. The unit is 1124 mm deeper.
Top cable entry units are equipped with two cables
per phase. The terminal distance from the ceiling
is 900 mm. The unit is 1654 mm deeper.
Double Level UniGear
Double level units will be in the standard depth
design. All the described recommendations for
single level units must be applied to double level
units.
The cable terminal distance of IF units is 600 mm
for all the following configurations:
– Bottom entry
– Top entry
– Bottom and top entry.
Doors
As standard, all the doors (auxiliary, apparatus
and feeder compartments) are equipped with an
appropriate stop to fix them in the open position.
1 Gas exhaust duct
2 Flaps
3 Top chimneys
 6.2

Outgoing Metering unit Incoming Slim Bus tie Bus riser Slim Incoming Metering unit Outgoing
feeders with feeder contactor contactor feeder feeders with
circuit- Outgoing feeder feeder Outgoing circuit-
breakers feeder feeder breakers

Compound configuration with single level, double level and ZVC

Thermo-graphic inspection With regard to Double Level UniGear, we can point

Thermo-graphic inspection is normally required on out that due to the switchgear design constraints,
power cables terminations and sometimes on main both the main busbar and the power cables
busbar systems. thermo-graphic inspection can only be carried out
Customers are normally much more sensitive to using the SensyCal IR system.
the former, because cable termination faults
represent a considerable part of all the faults in
switchgear, whereas faults in main busbar systems
are quite rare.
Thermo-graphic inspection and supervision can be
done in two ways:
– Temporary inspection by means of an IR camera
through an appropriate inspection window.
– Continuous supervision by means of IR sensors
located inside the switchgear.

The first system (temporary inspection) requires an

IR camera and an inspection window for each
compartment to be supervised.
The second system (continuous supervision)
requires the SensyCal IR system. This is a non-
touch temperature monitoring system based on IR
temperature probes connected to a central unit (12
sensors can be plugged in to each central unit).
Due to the switchgear design constraints, the main
busbar thermo-graphic inspection can only be
carried out using the SensyCal IR system, whereas
the power cables can be supervised with both the
SensyCal IR and the IR camera.

85
 Typical units and technical data

The units required, which are not part of the

standard design, are described below.

Earthing transformer units

From the electrical point of view, marine plants are
based on isolated networks (isolated neutral
point).
The main consequences regard the following:
– the network can be operated with single-phase
earth fault;
– earth fault detection is very difficult, due to the
very low earth fault current.
In order to increase this and therefore allow
releases to operate on single-phase earth faults,
two solutions can be used:
– connecting the secondary winding of the
generator to ground by means of a resistor;
– installing an earthing transformer in the network.

For this reason, the UniGear range must be

enriched with two addition typical units: M – Metering with earthing RLM – Bus Riser with
transformer. metering and earthing
– ME: Busbar metering unit with earthing trans- transformer.
former feeder;
– RE: Rise with earthing transformer feeder.

In the case of switchgear with a single busbar

section, ME can be used for this purpose; in the
case of switchgear equipped with two busbar
sections, both ME and RE units must be used, in
order to cover all the schemes.

Additional features of M and R units

Out of choice, M and R units should be equipped
with fixed VTs instead of withdrawable VTs with
fuses.
In this configuration the so-called “VT compart-
ment” will be used as an additional auxiliary
compartment. It must be fully segregated from the
power compartments with metallic partitions and
designed as an auxiliary compartment with
respect to the safety rules.
The inside rear and side walls of the compartment
must be fitted with the grid plate for fixing the
auxiliary equipment. This will be equipped with the
relevant left-hand side duct for wiring entry from
the bottom and exit to the top-mounted auxiliary
compartment.

86
 6.3

7.2-12 kV – 31.5 kA

Unit width/depth (mm) 650 / 1840

Rated current (A) 630 1250 1600 2000 2500
IF Incoming/outgoing feeder (1) (3)
IFM Incoming/outgoing with measurement (1) (3)

Unit width/depth (mm) 650 / 1340

Rated current (A) 630 1250 1600 2000 2500
IF Incoming/outgoing feeder (1) (3)
BT Bus-tie
R Riser
RE Riser with earthing transformer
RM Riser with measurements
M Measurement
ME Measurement with earthing transformer

7.2-12 kV – 40-50 kA

Unit width (mm) 800 1000

Unit depth (mm) 1840 1890 1840 1890
Rated current (A) 630 1250 1600 2000 2500 3150 4000 630 1250 1600 2000 2500 3150 4000
IF Incoming/outgoing feeder (1)
IFM Incoming/outgoing
with measurement (1)

Unit width (mm) 800 1000

Unit depth (mm) 1840 1890 1840 1390
Rated current (A) 630 1250 1600 2000 2500 3150 4000 630 1250 1600 2000 2500 3150 4000
IF Incoming/outgoing feeder (1)
BT Bus-tie
R Riser
RE Riser with earthing transformer
RM Riser with measurements
M Measurement
ME Measurement with earthing
transformer

– Depth (mm): refer to the above table.

– Height (mm): 2530 mm (gas duct with top chimneys included).
– (1): Bottom and top cable entry.
– (2): Bottom cable entry.
– (3): Up to 50kA with V-Contact

87
 Notes

88
1

ABB Power Technologies S.p.A.
Unità Operativa Sace
Via Friuli, 4
I-24044 Dalmine
Tel: +39 035 395111
Fax: +39 035 395874
E-mail: sacetms.tipm@it.abb.com
Internet://www.abb.com
The data and illustrations are not binding. We reserve the right to make
changes in the course of technical development of the product.
1VCP0000138 – Rev. B, en – Technical catalogue – 2005.11
ABB s.r.o.
Org. unit EJF
Videnská 117, 619 00 Brno
Czech Republic
Tel: +420 5 4715 2413, 1111
Fax: +420 5 4715 2190
E-mail: info.ejf@cz.abb.com
Internet://www.abb.com