ZX2
Gas-insulated medium voltage switchgear
Instruction manual BA 435/02 E
ABB Power Distribution
Your safety first – always!
That's why our instruction manual begins with these recommendations:
• Only install switchgear and/or switchboards in enclosed rooms suitable
for electrical equipment.
• Ensure that installation, operation and maintenance are carried out by
specialist electricians only.
• Comply in full with the legally recognized standards (DIN VDE / IEC), the
connection conditions of the local electrical utility and the applicable
safety at work regulations.
• Observe the relevant information in the instruction manual for all actions
involving switchgear and switchboards.
•
Danger!
Pay special attention to the hazard notes in the instruction manual marked
with this warning symbol.
• Make sure that under operation condition of the switchgear or switchboard
the specified data are not exceeded.
• Keep the instruction manual accessible to all persons concerned with
installation, operation and maintenance.
• The user’s personnel are to act responsibly in all matters affecting safety
at work and the correct handling of the switchgear.
WARNUNG
Anerkannte Regeln der Technik und Betriebsanleitungen
beachten !
Gefährliche Spannung
kann elektrischen Schock und Verbrennungen verursachen.
Vor Aufnahme von Arbeiten jeder Art dieses Gerät unbedingt freischalten,
erden und kurzschließen.
WARNING
Always observe the instruction manual and follow the rules
of good engineering practice !
Hazardous voltage
can cause electrical shock and burns.
Disconnect power, then earth and short-circuit before proceeding
with any work on this equipment.
If you have any further questions on this instruction manual, the members of
our field organization will be pleased to provide the required information.
Contents
Page
Contents
Page
1
Summary
6
4
Despatch and storage
28
1.1
General
6
4.1
Condition on delivery
28
1.2
Standards and specifications
6
4.2
Packaging
28
1.2.1 Switchgear manufacture
6
4.3
Transport
28
1.2.2 Installation and operation
6
4.4
Delivery
28
1.3
Operating conditions
6
4.5
Intermediate storage
28
1.3.1 Normal operating conditions
6
5
1.3.2 Special operating conditions
7
Erection of the switchgear
at site
30
2
Technical data
8
5.1
General site requirements
30
2.1
Panel type ZX2
8
5.2
Construction data
30
2.2
Disconnector/earthing switch type
UX2TE, and disconnector type UX2T
5.3
Fundamental notes on erection work
31
9
5.4
Foundation frame
31
2.3
Dimensions and weights
10
5.5
Laying of the foundation frame
31
2.4
Resistance to internal arc faults
11
5.6
Raised false floor
33
3
Design and function of the switchgear system and its equipment
5.7
Erection and connection of the panels
38
12
5.7.1 Preparatory work
38
3.1
Design and equipment of the panels
17
5.7.2 Erection of the switchgear
38
3.2
Gas system in the panels/switchgear
17
5.8
44
3.3
Vacuum circuit-breakers, type VD4 X
17
3.4
Disconnector/earthing switch,
type UX2TE
5.8.1 High voltage plastic-insulated cable
with plug connectors
44
18
5.8.2 Control cables and wiring
44
3.5
Disconnector, type UX2T
18
5.9
3.6
Sensor systems
18
3.7
High voltage connections
18
3.8
Bay control and protection unit
REF542 (SCU)
3.9
19
Protection against maloperation/interlock
dependencies/earthing of tee-off
19
3.9.1 Interlock dependencies
19
3.9.2 Earthing a tee-off in a single
busbar system
19
3.9.3 Earthing the busbar in a single
busbar system
3.9.4 Earthing a tee-off in a double
busbar system
20
20
Connection of cables and wiring
Preparing the insulating gas system
for operation
44
5.10
Final erection work
44
6
Commissioning/operation
45
6.1
Commissioning
45
6.1.1 Preparatory work
45
6.1.2 Initial start-up
45
6.2
45
Switching operations
6.2.1 Circuit-breaker
45
6.2.2 Three-position switch and
disconnector
46
6.2.3 Undervoltage release
46
6.3
Observation of the display and
monitoring facilities
46
3.9.5 Earthing the busbar in a double
busbar system
21
6.3.1 Gas monitoring
3.10
22
6.3.2 Electrical/mechanical display/monitoring 46
4
Test facilities
46
ABB Power Distribution
Contents
Page
6.4
46
Test procedures
6.4.1 Testing for the off-circuit condition
46
6.4.2 Testing for the in-phase condition
47
6.4.3 High voltage tests
47
6.4.4 Current tests
48
6.4.5 Maintenance earthing
48
6.5
Application of the X-ray regulations
49
7
Maintenance
53
7.1
General
53
7.2
Inspection/servicing
53
7.2.1 Vacuum circuit-breaker
54
7.2.2 Three-position switch and
disconnector
54
7.2.3 Gas system and gas servicing
54
7.2.4 Outlet filter
54
7.3
Repair
54
7.4
Working and auxiliary materials
55
7.4.1 Working materials
55
7.4.2 Auxiliary materials
55
We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual - or
extracts – to third parties is prohibited. The information supplied is without liability. Subject to alteration.
© ABB Calor Emag Mittelspannung GmbH, 2000
ABB Power Distribution
5
1
Summary
Details on the technical design and equipment of a
switchgear, such as
1.1
General
• technical data,
• detailed list of equipment fitted,
Fundamental features of the ZX2 panels:
• detailed circuit diagrams, etc.
• rated voltage up to 36 kV
can be found in the order documents.
• three-phase metal-enclosed
• gas-insulated
• gas-tight metal-clad busbar compartment
1.2
1.2.1 Switchgear manufacture
The panels comply with the following VDE standards and the corresponding IEC publications:
• gas-tight metal-clad circuit-breaker compartment
• computerised switchbay control system
• VDE 0670 and IEC 60056, 60129, 60298 and
60694
• sensor technology for adapted measured value
acquisition
• indoor installation
Standards and specifications
• VDE 0373 and IEC 60376 and 60480.
1.2.2 Installation and operation
• factory-assembled
• type-tested.
The relevant standards are to be observed during
installation and operation, in particular:
Basic panel variants:
• DIN VDE 0101, Power installations exceeding
AC 1 kV,
• incoming and outgoing feeders
• VDE 0105, Operation of electrical installations
• bus sectionalisers in single and double busbar
systems
• DIN VDE 0141, Earthing systems for special power
installations with rated voltages above 1 kV,
• the accident prevention regulations issued by
the appropriate professional bodies,
• bus coupler panels in single and double busbar
systems
• the safety guidelines for production materials,
• bus riser panels in single and double busbar
systems
• the order-related details provided by the
switchgear manufacturer.
• metering panels in double busbar systems
• supplementary equipment:
– busbar metering system in single busbar
systems
Operating conditions
1.3.1 Normal operating conditions
• vacuum circuit-breaker
Designed in accordance with VDE 0670 Part 1000,
”Common specifications for high-voltage and
controlgear standards” and IEC Publication 60694,
with the following limit values:
• single or double busbar systems:
• Ambient temperature:
Panel equipment, variants:
– busbar system 1 with disconnector/earthing
switch (three-position switch) with functions of:
• busbar connection,
• disconnection,
• earthing.
– busbar system 2 with disconnector with
functions of:
• busbar connection,
• disconnection.
6
1.3
– Maximum
+40 °C
– Maximum 24 hour average
+35 °C
– Minimum (corresponding to
”minus 5 indoor” class)
–5 °C
• Site altitude:
≤ 1000 m above sea level
• Ambient air:
The ambient air is not to be significantly
contaminated by dust, smoke, corrosive or
flammable gases, or salt.
ABB Power Distribution
1.3.2 Special operating conditions
Special operating conditions are to be agreed by
the manufacturer and operator. The manufacturer
is to be consulted in advance about each special
operating condition:
• Site altitude above 1000 m:
– Adjustment of the gas monitoring system is
required for greater altitudes.
• Increased ambient temperature:
– The current carrying capacity is reduced,
– Additional cooling facilities for heat dissipation
are to be provided.
• Climate:
– The risk of corrosion or other impairment, e.g.
in the control cabinets, is to be avoided in
areas:
• with high humidity and/or
• with major, rapid temperature fluctuations.
– Take countermeasures to prevent condensation phenomena (e.g. provide electric
heaters).
ABB Power Distribution
7
2
Technical data
2.1
Panel type ZX2
Electrical data
Rated voltage
kV
12
17.5
24
36
50 1)
70 1)
Rated power frequency withstand voltage kV
28 1)
38 1)
Rated lightning impulse withstand voltage kV
75
95
125
170
All voltages quoted apply to an insulating
gas pressure, absolute, at 20 °C, of
bar 2)
1.0
1.0
1.0
1.0
Rated frequency
Rated current of busbars
Rated current of tee-offs
3)
Hz
50/60
A
1250/2500
A
...2000/25004)
Rated peak withstand current 3)
kA
...100
...100
...100
...100
Rated short time current, 3 s 3)
kA
...40
...40
...40
...40
Rated short-circuit breaking current of
the circuit-breaker
kA
...40
...40
...40
...40
Rated short-circuit making current of
the circuit-breaker
kA
...100
...100
...100
...100
5)
Rated operating sequence
O-0.3 s–CO-3 min–CO
Break time:
• manual tripping
• protection tripping
ms
ms
45…90
40…55
45…90
40…55
45…90
40…55
45…90
40…55
Closing time:
• manual tripping
• protection tripping
ms
ms
65…95
60
65…95
60
65…95
60
65…95
60
Insulating gas system2)6)
N2 7)
Insulating gas
SF6 8)
SF6 8)
SF6 8)
Design pressure, absolute
bar
1.36
1.36
1.36
1.36
Operating pressure, absolute, 20 °C
(equals filling pressure)
bar
1.3
1.3
1.3
1.3
Rated pressure, absolute, 20 °C
(minimum operating pressure)
bar
1.2
1.2
1.2
1.2
Charging motor
W
<200
<200
<200
<200
Closing coil
W
250
250
250
250
Opening coil
W
250
250
250
250
Motor and release data
Rated supply voltage
DC voltage
60, 110, 2209)
V
Degree of protection (IEC 60529, DIN VDE 0470-1)
1)
2)
3)
4)
5)
6)
8
Gas-tight enclosure
IP 65
IP 65
IP 65
IP 65
Control cabinet
IP 4X 10)
IP 4X 10)
IP 4X 10)
IP 4X 10)
Higher values in accordance with international standards on request
1 bar = 100 kPa
For details refer to table: "Panel width-classification" section 2.4
Cooling included
Other operating sequences on request
For further details see BA 427 - insulating gas system for ZX switchgear
7)
8)
9)
10)
Insulating gas: nitrogen
Insulating gas: sulphur hexafluoride
Other voltages on request
IP 5X on request
ABB Power Distribution
2.2
Disconnector/earthing switch type UX2TE, and disconnector type UX2T
Test voltages
Rated voltage
Rated power frequency withstand
voltage across the isolating distance
Rated lightning impulse withstand
voltage across the isolating distance
kV
12
17.5
24
36
kV
32
45
60
80
kV
85
110
145
195
N2 3)
SF6 4)
SF6 4)
SF6 4)
Insulating gas system 1) 2)
Insulating gas
Operating pressure, absolute, 20°C
( equals filling pressure )
Rated pressure, absolute,20°C
( minimum operating pressure )
1)
2)
3)
4)
bar
1.3
1.3
1.3
1.3
bar
1.2
1.2
1.2
1.2
1 bar = 100 kPa
For further details see BA 427 insulating gas system for ZX switchgear
Insulating gas: nitrogen
Insulating gas: sulphur hexafluoride
Rated voltage
kV
12/17.5/24/36
Test currents
Rated current
A
630 5)
12501)
2500 2)
...100
Rated peak withstand current
kA
…63
…80
Rated short time current, 3 s
kA
…25
…31.5
...40
W
180
180
180
• Centre position to BB
s
18
18
20
• Centre position to earth
s
18
18
20
Motor data
Motor power, max 3).
3)
Motor running times, max .:
Rated supply voltage
DC 4)
1)
2)
3)
4)
5)
V
60,110,220
Panel width: 600 mm
Panel width: 800 mm
At rated supply voltage
Other voltages on request
Panel width: 400 mm
ABB Power Distribution
9
2.3
Dimensions and weights
View X
A
C
D
A
B
B
2300
1232
895
2100
1)
X
26001)
ZX2
ZX2
n panels 2)
Figure 2/1:
800
600
220
30
1710
Dimensions, double busbar system
Figure shows panels with rated currents ≤ 2000 A.
A
B
C
D
E
1)
2)
Pressure relief duct with absorber
Pressure relief duct, top
Pressure relief duct, side
End cover
Pressure relief duct, rear
Panels with rated currents greater than 2000 A are also fitted with a cooling fan. The panel height is then increased by 200 mm
to 2500 mm or 2800 mm.
n≥1
View X
A
C
D
A
B
B
n panels
Figure 2/2:
2)
800
600
220
30
775
1105
E
2300
2100
1)
X
26001)
ZX2
ZX2
1710
Dimensions, single busbar system
Figure shows panels with rated currents ≤ 2000 A.
A Pressure relief duct with absorber
B Pressure relief duct, top
C Pressure relief duct, side
Optionally also with voltage sensors for busbar metering
D End cover
E Pressure relief duct, rear
1)
2)
10
Panels with rated currents greater than 2000 A are also fitted with a cooling fan. The panel height is then increased by 200 mm
to 2500 mm or 2800 mm.
n≥1
ABB Power Distribution
Weights:
• Weight of a standard panel, double busbar,
panel width 400 mm, rated current ≤ 630 A:
approx. 650 kg
• Weight of a standard panel, double busbar,
panel width 600 mm, rated current ≤ 1250 A:
approx. 1200 kg
• Weight of a standard panel, double busbar
panel width 800 mm, rated current ≤ 2000 A:
approx. 1700 kg
See section 5.2 for dimensions of the switchroom (construction data).
2.4
Resistance to internal arc faults
Panel width
400 mm
600 mm
800 mm
Core modul/BB-compartment
25 kA, 1s
31.5 kA, 1s
40 kA, 1s
Cable compartment
20 kA, 1s, three-pole
25 kA, 1s, three-pole
25 kA, 1s, three-pole
Resistance to internal arc faults:
Criteria 1 - 6 of PEHLA directive no. 4 (in conjunction with VDE 0670 Part 6 and IEC 60298) are fulfilled.
The panels have integrated pressure relief ducts with the opportunity for:
• channelling out of the switchroom in a manner suitable for the building dimensions, or
• channelling through an absorber on the last two panels (when the ceiling height is sufficient).
Table: Panel width-classification
Rated voltage
kV
IK, 3s
kA
25
31.5
31.5
40
40
20
25
31.5
40
IP
kA
63
80
80
100
100
50
63
80
100
Itee-off
A
630
1250
2000/
2500
1250
2000/
2500
630
1250
2000/
2500
1250/
2000/
2500
Panel width
mm
400
600
800
600
800
400
600
800
800
Rated voltage
kV
IK, 3s
kA
IP
kA
Itee-off
A
630
1250
2000/
2500
1250/
2000/
2500
1250/
2000/
2500
1250
1250/
2000/
2500
1250/
2000/
2500
Panel width
mm
400
600
800
800
800
600
800
800
ABB Power Distribution
12
17.5
24
20
36
25
25
31.5
40
25
31.5
40
63
63
80
100
63
80
100
11
3
Design and function of the switchgear system and its equipment
3
20
8
1.1
Figure 3/1:
Panel, front view
Figure 3/2:
Panel type ZX2 with control cabinet open
1.1
3
8
20
Control cabinet door
Three-position switch operating mechanism
Circuit-breaker operating mechanism
Disconnector operating mechanism
5
5.1
5.2
Figure 3/3:
6
12
Bay control and protection unit REF542
5
5.1
5.2
6
Bay control and protection unit
LCD display (example)
LEDs
Measuring sockets for capacitive voltage indicator
system
ABB Power Distribution
B
23.5
G
2
19
20
Figure 3/4:
E
H
Panel, double busbar, with pressure relief ducts at top
and rear
The side walls of busbar compartments 1 and 2, of the
circuit-breaker compartment and the cable termination
compartment have been cut open to provide a better
view.
I
B
E
G
H
I
Pressure relief duct, top
Pressure relief duct, rear
Control cabinet
Circuit-breaker compartment
Cable compartment
2
Disconnector/earthing switch (three-position switch)
in busbar compartment 1
Disconnector -Q2 in busbar compartment 2
Operating mechanism for item 19
Bushing for plug-in busbar connection
19
20
23.5
Figure 3/5:
Pressure relief disk for a busbar compartment in the
upper pressure relief duct
ABB Power Distribution
Figure 3/6:
Vacuum circuit-breaker type VD4 X (before installation
in the works)
13
-Q5
-Q1
-Q5
-Q1
-Q16 -Q11
-Q0
-Q15 -Q12
-Q0
Feeder
Cable connection
Coupler
Riser
Busbar metering
Figure 3/7a: Examples of panels type ZX2, with single busbars
-Q5
-Q1
-Q2
-Q25 -Q1 -Q15 -Q2
-Q0
-Q0
Feeder
-Q16 -Q11 -Q15 -Q12 -Q26 -Q21 -Q25 -Q22
-Q0
Bus coupler
-Q16 -Q11 -Q26 -Q21 -Q15 -Q12 -Q25 -Q22
Bus sectionaliser
(without C.B.)
-Q0
Bus sectionaliser
-Q51 -Q1 -Q52 -Q2
Trunking bar
connection
Busbar metering
Figure 3/7b: Examples of panels type ZX2, with double busbars
14
ABB Power Distribution
Figure 3/8:
ZX2 panel, single busbar, 1250 A
Figure 3/9:
ZX2 panel, single busbar, 2000 A
Figure 3/10: ZX2 panel, double busbar, 2000 A
ABB Power Distribution
15
26
B
B
25
G
24
1
2
23
22
SS2
SS1
(21)
3
(4)
20
5
19
18
7
17
H
K
16
8
-Q5
-Q1
-Q2
9
15
-Q0
-T1
10
14
I
13
11
-R1
-C1
12
Figure 3/11: ZX2 panel, double busbar, 1250 A, fundamental
structure
SS1
SS2
B
E
G
H
I
Busbar system 1
Busbar system 2
Pressure relief duct, top
Pressure relief duct, rear
Control cabinet
Circuit-breaker compartment
Cable termination compartment
-Q0
-Q1
-Q2
-Q5
-T1
-R1
-C1
Circuit-breaker
Tee-off disconnector
Tee-off disconnector
Tee-off earthing switch
Current sensor
Voltage sensor
Capacitive voltage divider
1
2
Panel enclosure
Disconnector/earthing switch -Q1/-Q5
(three-position switch)
3
Three-position switch operating mechanism
(4) Pressure sensor for busbar compartment 1
5
Bay control and protection unit REF542
6
Measuring sockets for capacitive voltage indicator
system
7
Pressure sensor for circuit-breaker compartment
8
Circuit-breaker operating mechanism
9
Cable or test plug socket
10 Cable socket
11 Cable plug
12 Surge arrester
13 Floor plate, split
14 Connecting link panel/panel for item 15
15 Main earthing bar
16 Combined current and voltage sensor
17 Pressure relief disk
18 Circuit-breaker
19 Disconnector -Q2
20 Disconnector operating mechanism
(21) Pressure sensor for busbar compartment 2
22 Tee-off conductor
23 Busbar connection, plug-in type
24 Busbar
25 Drying agent bag
26 Pressure relief disk
Inert gas
16
ABB Power Distribution
3.1
Design and equipment of the panels
(Figures 2/1, 2/2, 3/1 to 3/11)
• The circuit-breaker compartment and the
busbar compartments in each panel are separate gas compartments with their own filling connectors. The gas compartments in the individual
panels set up side by side are not connected
together.
The metal-enclosed ZX2 panels are laser cut and
welded panel enclosures, completely earthed and
thus protected against accidental contact.
The stainless steel encapsulation and the insulating
gas protect all live parts in the high voltage area
permanently from soiling, humidity, foreign bodies
and other injurious influences.
• The operating pressure (pe) (equals filling pressure) in the individual compartments is monitored by temperature compensated pressure
sensors:
The modular structure provides the conditions necessary for all panel variants normally required in a
relatively simple manner.
– Pressure sensor 7 for the circuit-breaker
compartment,
Facilities are also provided, for instance, for:
– Pressure sensors 4 and 21 for busbar
compartments 1 and 2.
• one or two busbar systems,
• three-position switch or disconnector,
• When the pressure drops below the ”minimum
operating pressure”, a pressure loss signal is
output.
• different connection methods, such as multiple
cables.
Relieved pressure is guided into pressure relief
ducts (A), (B), (C) and (E):
• With a rapidly rising pressure as a consequence
of an internal arc fault and a correspondingly
high current, the bay control and protection unit
REF542 shuts the incoming feeders or couplers
down.
• In the case of internal arcing fault, the following
pressure relief disks open:
– Pressure relief disk 17 on circuit-breaker
compartment (H) into pressure relief duct (E).
The gases are channelled out via ducts (C)
and (A).
• Details on the gas system and gas servicing of
the ZX2 switchgear can be found in instruction
manual BA 427 – Insulating gas system for ZX
switchgear.
– Pressure relief disk 26 on the busbar compartment into pressure relief duct (B).
• The gas compartments contain drying agent
bags 25.
• In the case of an arc in the cable compartment
(I), a pressure relief flap in pressure relief duct (E)
opens. The gases are channelled out via ducts
(C) and (A).
Each panel is a unit, They are linked together by
plug-in busbar connections 23.
Basic equipment in the panels:
• Circuit-breaker VD4 X
Further details on the drying agent material can be
found in instruction manual BA 427.
3.3
Vacuum circuit-breakers, type VD4 X
(Figures 3/2, 3/6 and 3/11, and separate manual
BA 436/E)
Functions of the vacuum circuit-breaker 18:
• Three-position switch UX2TE
• Disconnector UX2T
• Sensor system
• short-circuit breaking operations,
• Control cabinet with the bay control and protection unit REF542
• earthing function in conjunction with three-position switch 2.
• Cable and test plug sockets.
The earthing function of the three-position switch
prepares - under no current - for the connection to
earth. Earthing proper is performed by the circuitbreaker. This integration of functions is advantageous, as a circuit-breaker is of higher quality in
the earthing function than any other earthing
switch.
The insulation test criteria of VDE and IEC list 2 are
fulfilled by the ZX2 standard series up to and
including 36 kV even when the gas filling is at
atmospheric pressure.
3.2
• opening and closing on rated currents,
Gas system in the panels/switchgear
(Figures 3/11 and 3/15)
A permanently protected climate for the entire live
primary area is ensured by the gas-tight encapsulation of the panels and their filling with dry insulating
gas.
ABB Power Distribution
The circuit-breaker poles are installed horizontally
in the circuit-breaker compartment (H). The circuitbreaker operating mechanism is located outside
the gas compartment and is therefore easily accessible. It is connected to the breaker poles by a gastight thrust bushing.
17
3.4
Disconnector/earthing switch, type UX2TE
(Three-position switch)
(Figures 3/2, 3/4 and 3/11)
• Sensors 4, 7 and 21 for insulating gas pressure
monitoring
• Sensors to detect the switch positions of the circuit-breaker, disconnector/earthing switch and
disconnector
The ZX2 panels are fitted with specially designed
three-position disconnectors and earthing switches
-Q1/-Q5. These switches are motor-operated rodtype switches whose live switching components are
located in busbar compartment 1 (insulating gas
compartment), while the operating mechanism
block is easily accessible from the control cabinet
(G). The operating mechanism block contains the
drive motor, the position indicators (sensors and
mechanical indicators) and the emergency manual
operating system.
• Sensor to detect the charging condition of the
circuit-breaker spring energy store.
Arrangement of the sensors:
• Current and voltage sensors are located in the
rear part of the circuit-breaker compartment.
The external connections allow wiring to be fed
through the cable compartment (I) to the
REF542.
The three-position switch performs the functions of:
• Sensors for pressure monitoring:
• connecting,
– B0G for the circuit-breaker compartment:
on the circuit-breaker base plate in control
cabinet (G).
• disconnecting, and
• earthing.
– B1G for busbar compartment 1:
beside the operating mechanism for the
disconnector/earthing switch -Q1/-Q5 in the
control cabinet (G).
The three switch positions are unequivocally specified by the operating mechanism. The switch has
its disconnecting position at the centre. In the limit
positions, disconnector ON and earthing switch
ON, the moving contact (sliding part) driven by an
insulating spindle, reaches the isolating contacts,
which are fitted with one or two spiral contacts respectively.
3.5
– B2G for busbar compartment 2:
beside the base plate for the drive motor of
disconnector -Q2 at the rear of the panel.
• Sensors for detection of the switch positions:
– B0E and B0A for the circuit-breaker:
on its mechanism shaft.
Disconnector, type UX2T
(Figures 3/2, 3/4 and 3/11)
– B1E, B1A, B5E and B5A for the
disconnector/earthing switch:
on its operating mechanism in the control
cabinet.
Disconnector -Q2 is a motor-operated rod-type
switch. Its live switching components are located in
busbar compartment 2 (insulating gas compartment). The operating mechanism block is split and
located outside the gas compartment. The drive
motor is located at the rear of the panel behind a
removable cover. The position indicators (sensors
and mechanical indicators) and the emergency
manual operating system are accessible from control cabinet (G). Disconnector -Q2 is structured
similarly to the three-position switch, but without
the earthing switch assembly.
3.6
Sensor systems
(Figures 3/3, 3/11, 3/12 to 3/15, 6/3 and 6/7)
In comparison with conventional inductive instrument transformers, sensors require much less
space. They facilitate measured value acquisition
suitable for the control and automation system
REF542.
The following sensors are used in ZX2 panels:
• Sensors for current measurement 16
• Sensors for voltage measurement 16
– B2E and B2A for the disconnector:
beside its emergency manual operating
mechanism in the control cabinet.
• Sensor B0S for detection of the charging condition of the spring energy storage mechanism:
above the spring drum in the circuit-breaker
operating mechanism.
3.7
High voltage connections
(Figures 3/4, 3/8 to 3/11, 5/15 and 5/16)
Cable plug connector systems:
• high voltage plastic-insulated cable with internal
cone cable plug connector system and sockets
to DIN 47 637.
Plug-in cable sockets 9 and 10 mounted in a gastight manner in the floor plate of the circuit-breaker
compartment maintain the partitioning between
the insulating gas compartment and the cable
termination compartment.
• Capacitive pick off for voltage display
18
ABB Power Distribution
3.8
Bay control and protection unit REF542
(Figures 3/3 and 3/15)
3. Dependence of the disconnectors -Q1 or -Q2 on
the circuit-breaker -Q0.
The following functions are integrated in the bay
control and protection unit REF542:
4. Dependence of the circuit-breaker -Q0 on the
earthing switch -Q5.
• Busbar protection
5. Interdependence of the disconnectors -Q1 and
-Q2.
• Tee-off protection
• Control
• Measurement
• Position indication
• Hazard and fault signalling
6. Dependence of the disconnectors -Q1 and -Q2
on bus coupler circuit-breakers and vice versa.
7. Dependence of the bus section disconnector on
the busbar tee-off disconnectors and vice versa
(for bus sectionalising without circuit-breaker
only).
• Connection to control systems.
Panel interlocks and the sequence of switching
operations (e.g. isolation, testing of the off-circuit
condition and earthing) are controlled by the
REF542 panel unit.
The single-line diagram providing information on
switching device positions is made visible on LC
display 5.1.
Measured values such as conductor currents,
phase voltages, energy metering and active and
reactive power, number of operating cycles and
number of operating hours appear numerically
and/or as a bar diagram on the display. Further information, such as alarm and fault signals, is displayed with text by LEDs 5.2.
The bay control and protection unit REF542 can be
connected to a control system via optical fibre cables. Electromagnetic interference is avoided by the
use of optical fibre cables.
Please consult the REF542 instruction manual no.
BA 453 for details on handling of the bay control
and protection unit and the detailed technical
description.
3.9
Protection against maloperation/interlock
dependencies/earthing of tee-off
In order to prevent dangerous situations and
maloperation, a series of interlocks are provided to
protect the operators and the switchgear itself.
In ZX2 panels with digital control systems, protection against maloperation is fundamentally effected
by the software in the panel unit.
The circuit-breaker, three-position switch and
disconnector can be controlled directly at the panel
or from the control room using the local/remote
lock-switch. Operation at the panel is by selection
on the REF542.
3.9.1 Interlock dependencies
Details of interlocks/dependencies over and above
those listed in points 1 to 7 (e.g. with neighbouring
systems) can be found in the individual order
documents.
The interlock polling between panels is effected by
loop lines from panel to panel.
Operation on failure of the auxiliary power supply:
On failure of the auxiliary power supply, the devices
can be operated manually.
No provision is however made for interlocked
emergency manual operation of the three-position
switches and disconnectors.
Emergency manual operation:
Intervention in the interlock concept is possible by
opening the control cabinet door. Emergency
manual operation without maloperation prevention
is possible by means of a hand crank and mechanical push-button.
3.9.2 Earthing a tee-off in a single busbar system
(Figure 3/7)
1. Manual earthing
Operating sequence for tee-off earthing:
• Circuit-breaker -Q0 OFF.
• Disconnector -Q1 OFF.
• Earthing switch -Q5 ON.
• Test for off-circuit condition (display on
REF542 or capacitive voltage indicator system (see section 6.4.1)).
• Circuit-breaker -Q0 ON (only possible when
the REF542 has detected the off-circuit condition and enabled the switching operation).
1. Limit position blocking of the switching devices.
• Secure panel to prevent reconnection (m.c.b.
F101 and F106 OFF).
2. Dependence of the disconnectors -Q1 or -Q2 on
the earthing switch -Q5 and vice versa.
• Label the panel to indicate that earthing has
been effected.
ABB Power Distribution
19
2. Automatic earthing by selecting the earthing
sequence on the REF542 display (this facility
depends on the order placed)
• Condition: circuit-breaker -Q0 OFF.
• Select and start the automatic earthing sequence:
– Disconnector -Q1 OFF.
– Earthing switch -Q5 ON.
– Check on off-circuit condition by REF542.
– Circuit-breaker -Q0 ON.
– M.c.b. F101 and F106 OFF.
• Select and start the automatic earthing sequence:
– Disconnectors (-Q11 or -Q12) between the
busbar section to be earthed and the tie
breaker -Q0 ON.
– Earthing switch (-Q15 or -Q16) on the
opposite side of the tie breaker -Q0 ON.
– Tie breaker -Q0 ON.
– M.c.b. F101, F102 and F106 OFF.
– Feedback message ”Earthed and secured”.
– Feedback message ”Earthed and secured”.
• Label the panel to indicate that earthing has
been effected.
• Label the busbar section to indicate that
earthing has been effected.
3. Cancelling the earthing of a tee-off
• Open the control cabinet door and switch on
the m.c.b. F101 and F106 manually.
• Circuit-breaker -Q0 OFF.
3.9.3 Earthing the busbar in a single busbar system
(Figures 3/7 and 6/7)
Earthing of the busbar or a busbar section is
dependent on the switchgear configuration. Systems with bus ties / risers permit the earthing of a
single busbar section.
1. Manual earthing of a busbar section using the
bus tie / riser
The selected busbar section is then earthed.
All disconnectors in the earthed busbar section are blocked.
3. Cancelling the earthing of a busbar section
• Open the control cabinet door and switch on
the m.c.b. F101, F102 and F106 manually.
• Circuit-breaker -Q0 in the bus tie OFF.
4. Maintenance earthing of a busbar via free sockets in a tee-off
Condition:
• The tee-off is earthed.
Operating sequence:
• All disconnectors in the busbar to be earthed
OFF.
• Circuit-breaker -Q0 in the bus tie (tie breaker)
OFF.
Operating sequence:
• All disconnectors -Q1 in the busbar section to
be earthed OFF.
• Fit a short-circuiting bridge to the free sockets
and connect to main earthing bar 14.
• Circuit-breaker OFF.
• Disconnectors (-Q11 or -Q12) between the
busbar section to be earthed and the tie
breaker ON.
• Earthing switch OFF.
• Earthing switch (-Q15 or -Q16) on the
opposite side of the tie breaker ON.
• Circuit-breaker ON.
• Tie breaker -Q0 ON.
• Disconnector ON.
• M.c.b. F101 and F106 OFF.
• M.c.b. F101 and F106 OFF.
• Label the busbar to indicate that earthing has
been effected.
• Label the busbar section to indicate that
earthing has been effected.
All relevant panels are to be secured to prevent
switching operations, e.g. tripping m.c.b.
The busbar section is then earthed. All
disconnectors in the earthed busbar section are
blocked.
2. Automatic earthing of a busbar section by selecting the earthing sequence on the REF542
display (this facility depends on the order placed)
• Condition:
– Circuit-breaker -Q0 in the bus tie (tie
breaker) OFF.
20
– All disconnectors -Q1 in the busbar section
to be earthed OFF.
3.9.4 Earthing a tee-off in a double busbar system
(Figures 3/7 and 3/11)
1. Manual earthing
Operating sequence for tee-off earthing:
• Circuit-breaker -Q0 OFF.
• Disconnectors -Q1 and -Q2 OFF.
• Earthing switch -Q5 ON.
ABB Power Distribution
• Test for off-circuit condition (display on
REF542 or capacitive voltage indicator system (see section 6.4.1)).
• Circuit-breaker -Q0 ON (only possible when
the REF542 has detected the off-circuit condition and enabled the switching operation).
• Secure panel to prevent reconnection (m.c.b.
F101, F102 and F106 OFF).
• Label the panel to indicate that earthing has
been effected.
2. Automatic earthing by selecting the earthing
sequence on the REF542 display (this facility
depends on the order placed)
The busbar section of busbar 1 is then
earthed. All disconnectors in the earthed busbar section are blocked.
b) Busbar 2:
• Circuit-breaker in the bus coupler OFF.
• Disconnector -Q1 in the bus coupler OFF.
• All disconnectors -Q2 in the busbar section
to be earthed OFF.
• Disconnector -Q2 in the bus coupler ON.
• Earthing switch -Q25 in the bus coupler
ON.
• Circuit-breaker in the bus coupler ON.
• Condition: circuit-breaker -Q0 OFF.
• M.c.b. F101, F102 and F106 OFF.
• Select and start the automatic earthing sequence:
• Label the busbar section to indicate that
earthing has been effected.
– Disconnectors -Q1 and -Q2 OFF.
– Earthing switch -Q5 ON.
– Check on off-circuit condition (by REF542).
– Circuit-breaker -Q0 ON.
– M.c.b. F101, F102 and F106 OFF.
– Feedback message ”Earthed and secured”.
• Label the panel to indicate that earthing has
been effected.
3. Cancelling the earthing of a tee-off
• Open the control cabinet door and switch on
the m.c.b. F101, F102 and F106 manually.
• Circuit-breaker -Q0 OFF.
3.9.5 Earthing the busbar in a double busbar system
(Figures 3/7 and 3/11)
Earthing of the busbar or a busbar section is dependent on the switchgear configuration. Systems
with bus couplers permit the earthing of a single
busbar section.
1. Manual earthing of a busbar section
Operating sequence:
a) Busbar 1:
• Circuit-breaker in the bus coupler OFF.
• Disconnector -Q2 in the bus coupler OFF.
The busbar section of busbar 2 is then
earthed. All disconnectors in the earthed
busbar section are blocked.
2. Automatic earthing by selecting the earthing sequence on the REF542 display (this facility depends on the order placed)
• Condition:
– Circuit-breaker -Q0 in the bus coupler
OFF.
– All disconnectors in the relevant busbar
section OFF.
• Select the operating sequence:
a) Busbar 1:
– Disconnector -Q2 in the bus coupler OFF.
– Disconnector -Q1 in the bus coupler ON.
– Earthing switch -Q15 in the bus coupler
ON.
– Circuit-breaker in the bus coupler ON.
– M.c.b. F101, F102 and F106 OFF.
– Feedback message ”BB1 earthed and
secured”.
– Label the busbar section to indicate that
earthing has been effected.
The busbar section of busbar 1 is then
earthed. All disconnectors in the earthed
busbar section are blocked.
• All disconnectors -Q1 in the busbar section
to be earthed OFF.
b) Busbar 2:
• Disconnector -Q1 in the bus coupler ON.
– Disconnector -Q2 in the bus coupler ON.
• Earthing switch -Q15 in the bus coupler
ON.
– Earthing switch -Q25 in the bus coupler
ON.
• Circuit-breaker in the bus coupler ON.
– Circuit-breaker in the bus coupler ON.
• M.c.b. F101, F102 and F106 OFF.
– M.c.b. F101, F102 and F106 OFF.
• Label the busbar section to indicate that
earthing has been effected.
– Feedback message ”BB2 earthed and
secured”.
ABB Power Distribution
– Disconnector -Q1 in the bus coupler OFF.
21
– Label the busbar section to indicate that
earthing has been effected.
The busbar section of busbar 2 is then
earthed. All disconnectors in the earthed
busbar section are blocked.
3. Cancelling the earthing of a busbar section
• Open the control cabinet door and switch on
the m.c.b. F101, F102 and F106 manually.
• Circuit-breaker -Q0 in the bus coupler OFF.
3.10
Test facilities
The panels are properly filled with insulating gas at
the works and tested to the VDE or IEC standards.
Testing on completion of switchgear installation is
therefore unnecessary. Should there be any need
to perform tests, the tests are to be performed as
follows:
• For voltage and current tests, direct access to
the conductors in the connection area is possible without removing the cable connection or
extracting the insulating gas. Access is effected
via free cable connecting sockets or via the cable sockets for the surge arresters.
The surge arresters must be removed during
voltage tests.
• Voltage tests:
– cable tests with DC voltage,
– cable fault location measurements with impulse voltage and
– system tests (without cables) with a AC voltage
can be performed with a test plug as shown in
Figure 6/8.
• A test plug for current tests as shown in figure
6/9 can be used to test the protection devices
by primary current injection (see also the note
in section 6.4.4). This configuration is short-circuit proof and can also be used as an
additional maintenance earth.
The possible testing processes are described in the
following sections:
22
• testing for the off-circuit
condition:
Section 6.4.1
• testing for the in-phase
condition:
Section 6.4.2
• high voltage tests:
Section 6.4.3
• current tests:
Section 6.4.4.
ABB Power Distribution
ABB Power Distribution
23
-XI.. ,-XU..
P1
Terminal
designation
-XI..
1
S1
-1
Primary conductor
2
S2
640A/150mV
2
In = 1250 A
Ip = 100 kA
Ith 3sec = 40 kA
Front view
80A /240A /640A /150mV
S3
240A/150mV
Class 1 without correction
factor 3
-XU..
Capacitance C1 ≥ 35pF
max 55pF
S4
80A/ 150mV
Pick-off: 10 000 :1
20kV/ V3
Class 1
2V/ V3
1
2
a
n
Working area
Leakage
capacitance ≤ 25pF
P2
S1 - S2: 320...1280A
S1 - S3: 120... 480A
S1 - S4: 40... 160A
Figure 3/12:
CK
Combined current and voltage sensor with capacitive pick-off KEVCI 24 AE1, for rated
voltages up to 24 kV and panel width 600 mm
The following changes apply to rated voltage 36kV:
•
Sensor:
KEVCI 36 AE1
•
Pick-off:
20 000:1 bzw.
•
Capacitance:
C1 ≥ 18 pF, max. 22 pF
30 kV / 3
1,5 V / 3
-XI.. ,-XU..
P1
Terminal
designation
-XI..
1
Primary conductor
S1
-1
In = 2500 A
Ip = 100 kA
2
1600A/150mV
2
S2
Ith 3sec = 40 kA
Front view
1600A/150mV
Class 1 without correction factor 3
-XU..
20kV/ V3
Klasse 1
2V/ V3
Capacitance C1 ≥ 35pF
max 55pF
Pick-off: 10 000 :1
a
1
2
n
Working area
Leakage
capacitance
≤ 25pF
P2
S1 - S2: 800...3200A
Figure 3/13:
CK
Combined current and voltage sensor with capacitive pick-off KEVCA 24 BE1, for rated
voltages up to 24 kV and panel width 800 mm
The following changes apply to rated voltage 36kV:
24
• Sensor:
KEVCI 36 BE1
• Pick-off:
20 000:1 bzw.
• Capacitance:
C1 ≥ 18 pF, max. 22 pF
30 kV / 3
1,5 V / 3
ABB Power Distribution
L1 L2 L3
P1
d28
II
IL1
IL2
-Q2
IL3
-XI.. ,-XU..
Terminal
designation
-Q0
-T1L1..L3
1
z24
2
2
1
2
3
150mV
-R1L1..L3
Tee-off
protection;
measurement,
metering
Front view
P2
2
2
UL1
d16
z16
1
2
1
UL2
d12
z12
1
UL3
d8
z8
T1L2
S1
-XIL2
S.
1
2
Current and
voltage
sensors
T1L3
-XItL2
S1
-XIL3
-XItL3
-XUL1
-XUtL1
-XUL2
2
2
-C1L1..L3
S.
-XItL1
2
1
3
20kV/ V 3
2V/ V 3
z20
-XIL1
1
1
1
P1
2
d24
d20
P1
S1
1
2
1
-A200
-Q1/Q5
z28
P1
T1L1
-X3
I
-XUtL2
S.
R1L1
P2
a
n
R1L2
P2
a
n
R1L3
P2
-XUL3
a
n
2
3 single core cables
1
-XUtL3
d4
1
-XIL0
z4
2
GND
IL0
2
1
-XItL0
Figure 3/14: Current and voltage sensors in an outgoing cable feeder
panel, up to 24 kV, double busbar
The circuit diagram is identical for the single busbar system,
but without tee-off disconnector -Q2.
-Q0
-Q1
-Q2
-Q5
-T1...
-R1...
-C1...
Circuit-breaker
Busbar tee-off disconnector
Busbar tee-off disconnector
Tee-off earthing switch
Current sensors
Voltage sensors
Capacitive voltage divider
Inputs and interfaces of the bay control and protection unit
REF542:
IL...
UL...
-XI...
-XU...
-XIt...
-XUt...
-A200
ABB Power Distribution
Measurement inputs for “current”
Measurement inputs for “voltage”
Interfaces of the current sensors
Interfaces of the voltage sensors
Test interfaces of the current sensors and the inputs
Test interfaces of the voltage sensors and the inputs
Bay control and protection unit REF542
25
110 kPa
26
4
-B0G
3
6
4
-B1G
3
6
4
3
-B5E2
2
12
-F106:24
-A200
-B2A -B2E
- F100 - F101 - F102 - F106
B
M
M
-M1
-M0
A7
F
A14
-Y3
-F102
2
4
23
1
3
24
A2
-V3
C1 C2
X6: z2
X6: d2
24
X6: z4
MMK
23
X6: d4
3
X6: z6
4
X6: z8
1
X6: d6
24
X6: z10
X6: d10
3
2
X6: d8
A3
23
X6: z12
A5
X6: d12
1
X7: z18
X6: z18
- F101
X7: z22
E16
4
X7: z20
X7: d18
-B5E1
X6: z20
2
X6: z22
X6: d18
4
X7: d22
E17
X6: d22
SPA - BUS
X7: d20
+
X6: d20
- F116
X5: z2
-B5E -B5A -B1E -B1A -B0E -B0A -B0S
X4: z16
-B5E3
X5: d2
E6
BK
BN
BU
X4: d16
X4: d12
X4: z2
X4: d2
X4: z4
X4: d4
X4: z12
4
BK
BN
BU
BK
BN
BU
BK
BN
BU
X4: z14
X4: d14
X1: 3
X1: 1
3
X5: z4
X5: d4
5
BK
BN
BU
E9
140 kPa
5
X5: z6
12
E1
110 kPa
11
E2
X5: d6
E5
E7
140 kPa
E10
BK
BN
BU
X4: z8
E4
110 kPa
12
X4: d28
12
X4: z18
11
140 kPa
11
140 kPa
6
BK
BN
BU
E12
X4: z28
-A200
110 kPa
5
X4: d8
X4: z24
X4: d24
E3
X4: d20
X4: z20
X4: z6
1
X4: d18
X4: z10
BK
BN
BU
X4: d6
2
110 kPa
140 kPa
X4: d10
-
110 kPa
3
140 kPa
BK
BN
BU
+
(1)
-F100
-F106
2
4
23
(2)
1
3
24
-F102: 24
A6
A1
E8
A4
-V2
C1 C2
-Y2
Figure 3/15a:
1
(1)+
11
(2)
E14
A13
A12 A15
E15
M
-M2
-B2G
Figure 3/15b:Continued from figure 3/15a
ABB Power Distribution
Figure 3/15: Circuit diagram of the panel controller for a double busbar system
The circuit diagram is identical for the single busbar system, but without M2, B2G,
B2E, B2A and F102. Inputs E15, E16 and E17 and outputs A12 to A15 on the
REF542 are not then used.
-B0A
-B0E
-B0S
-B5E
-B5A
-B5E1…3
-B1E
-B1A
-B2E
-B2A
-B0G
-B1G
-B2G
-M0
-M1
-M2
-MMK
-Y2 and -V2
-Y3 and -V3
-A200
-F100
-F101
-F102
-F106
-F116
ABB Power Distribution
Sensor, “Circuit-breaker -Q0 OFF signal”
Sensor, “Circuit-breaker -Q0 ON signal”
Sensor, “spring energy store charged signal”
Sensor, “Earthing switch -Q5 ON signal”
Sensor, ”Earthing switch -Q5 OFF signal”
Reed contacts, ”Earthing switch -Q5 ON” signal
Sensor, “Disconnector -Q1 ON signal”
Sensor, “Disconnector -Q1 OFF signal”
Sensor, “Disconnector -Q2 ON signal”
Sensor, “Disconnector -Q2 OFF signal”
Pressure sensor for circuit-breaker compartment
Pressure sensor for busbar compartment 1
Pressure sensor for busbar compartment 2
Charging motor for spring energy store, circuit-breaker
Drive motor for disconnector/earthing switch -Q1/Q5
Drive motor for disconnector -Q2
Man/machine communications
Shunt release off with series rectifier for -Q0
Shunt release on with series rectifier for -Q0
Bay control and protection unit REF542
M.c.b. for charging motor, circuit-breaker
M.c.b. for drive motor, disconnector/earthing switch -Q1/-Q5
M.c.b. for drive motor, disconnector -Q2
M.c.b. for controller, circuit-breaker ON/OFF
M.c.b. for auxiliary power supply to the REF542
27
4
Despatch and storage
4.1
Condition on delivery
The factory-assembled panels are checked for
proper assembly and function.
Condition on delivery:
• Compliance of the equipment with the order
checked.
• Routine testing to VDE 0670 Part 6 or ICE 60298
performed.
• Installation material and accessories packaged
separately.
• Bushings for the busbars closed off with
transport covers.
• Condition of the gas compartments:
– Filled with insulating gas at rated operating
pressure,
– Fitted with drying agent bags.
Note:
Air freight is to be discussed and agreed in
individual cases.
4.2
Packaging
• Panels with basic packaging or without packaging.
• Panels with seaworthy or similar packaging (also
containerised for overseas transport):
– sealed in polythene sheeting,
– transport drying agent bags inserted,
– moisture indicators inserted,
– sight window fitted for checking of the indicator
when AL composite sheeting is used.
• Observe the directions for the drying agent bags
to DIN 55 473. The following applies:
– Coloured indicator blue: contents dry.
– Coloured indicator pink: contents moist (e.g.
relative humidity over 40%).
4.3
Transport
(Figures 4/1 to 4/3)
Note:
Do not walk on the tops of the panels (rupture point
for the pressure relief system!).
• The transport units are normally individual panels.
• Take account of the weights of the transport
units.
• Take account of the high centre of gravity.
• Handle the panels in the upright position.
• Only perform loading operations taking account
of all safety precautions to protect personnel
and the material transported with:
– a crane, and/or
– fork-lift truck.
• Handling by crane:
– Attach suspension ropes of a sufficient loadbearing capacity with shackles (opening angle ≥ 30 mm).
28
– Fit these to the four lifting lugs.
– Attach rope guide harness to the top of the
panel.
• Handling in the switchgear room can be effected
by a trolley with steerable wheels. Take account
of the high centre of gravity of the panels. Danger
of tipping!
4.4
Delivery
The responsibilities of the consignee include but
are not limited to:
• Checking the delivery for completeness and
freedom from damage (e.g. also for moisture
and its injurious effects).
• Any deficiencies/transport damage noted
– are to be documented on the waybill,
– reported to the shipper/carrier in accordance
with the ADSP or KVO liability conditions for
German insurance.
Note:
Always document major damage with photographs.
4.5
Intermediate storage
Conditions for optimum intermediate storage:
1. Panels with basic packaging or without packaging.
• Dry and well ventilated storage room. Climate
in accordance with VDE 0670 Part 1000/
IEC 60694.
• Room temperature not falling below -5°C.
• No other injurious environmental influences.
• Store the panels upright.
• Do not stack panels.
• Panels with basic packaging:
– open the packaging at least partially.
• Panels without packaging:
– loosely cover with protective sheeting.
– sufficient air circulation must be preserved.
• Check regularly for any condensation.
2. Panels with seaworthy or similar packaging with
internal protective sheeting:
• Store the transport units:
– protected from the weather,
– in a dry place,
– protected from damage.
• Check the packaging for damage.
• Check the drying agent (see section 4.2):
– on delivery,
– later at appropriate intervals.
• When the service life from the date of
packaging has been exceeded:
– the protective effect of the packaging is no
longer ensured,
– take action for further intermediate storage.
ABB Power Distribution
o
m
i
4
n.
5
ZX2
725
530
1232
895
Figure 4/1:
Preparation for handling by crane, double busbar system
1152 (for panel width 800)
952 (for panel width 600)
752 (for panel width 400)
ZX2
(170)
(64)
1)
565
530
1105
1464
775
Figure 4/2:
Preparation for handling by crane, single busbar system
Figure 4/3:
Preparation for handling by fork-lift truck
1)
ABB Power Distribution
Note: The forks must support the full section length.
29
5
5.1
Erection of the switchgear at site
General site requirements
At the start of erection, the switchgear room at site
must be complete, fitted with lighting and power for
the erection work, lockable, dry, and with good ventilation facilities. All necessary provisions for laying of
the power and control cables such as openings,
ducts, etc. must already be in place.
In the interests of the best possible erection sequence, and in order to ensure a high quality standard of the panels, local installation of the switchgear
should only be carried out, or at least responsibly
managed and supervised, by specially trained
skilled personnel.
Compliance with the conditions for indoor
switchgear to VDE 0670 Part 1000 etc., including
those for the ”minus 5 indoor” temperature class,
must be ensured.
5.2
Construction data
(Figures 5/4 to 5/7)
Panel width
mm
Rated current
A
Ceiling height1)2):
• without additional absorber
• with additional absorber
• with additional cooling fan and
without absorber
• with additional cooling fan and
with absorber
400
600
800
800
≤630
≤1250
≤ 2000
> 2000
mm
mm
2500
2800
2500
2800
2500
2800
–
–
mm
–
–
–
2800
mm
–
–
–
3100
mm
mm
mm
mm
500
1810
900
2300
700
1810
1100
2300
900
1810
1300
2300
900
1810
1300
2300
mm
mm
800
1100
800
1300
800
1500
800
1500
kg
ca. 650
ca. 1200
ca. 1700
ca. 1800
kg/m2
ca. 1200
ca. 1400
ca. 1500
ca. 1600
Assembly opening1):
• in ceilings:
• in doors:
width
length
width
height
Aisle width3):
• Inspection aisle
• Operator aisle
Panel weight
(outgoing feeder, double busbar)
Floor load
1)
2)
3)
Minimum dimensions
Panel including top pressure relief duct
Governed by DIN VDE 0101 and the data on maximum panel width.
• The ZX2 switchgear installations are mounted on
a foundation frame set into the screed, or on a
raised false floor.
Note:
• The openings shown in figure 5/4 are intended
as an aid to planning. Instead of the large openings shown, drill holes can also be used, depending on the number of high voltage cables.
• Single busbar systems:
• Openings (drill holes) for power cables in the
station floor are to be constructed so as to be
eddy-current free.
The following is to be taken into account in
determining the foundation data:
Any additional frame available for the voltage
sensors in the busbar metering system.
The distance from the additional frame including
end coffer to the side wall of the room should be
≥ 500 mm to ensure sufficient room for
movement (see also section 2.3).
• Double busbar systems:
From 5 panels onwards, a pressure relief duct is
required at both ends of the switchgear
installation.
30
ABB Power Distribution
5.3
Tolerance conditions for laying of the frame to DIN
43 661, version A:
Fundamental notes on erection work
DIN-bolts of tensile class 8.8 are to be used.
• Evenness tolerance:
+/- 1 mm per metre.
• Straightness tolerance: max. 1 mm per metre,
but max. 2 mm for the
entire length of the
frame.
Recommended
tightening torque1)
Nm
Lubricant2)
Thread
M
M
M
M
M
M
1)
2)
3)
6
8
83)
10
12
16
Without
Oil or
grease
10 ,5
26
12
50
86
200
4 ,5
10
4 ,5
20
40
80
• The rated tightening torques for fasteners without
lubrication are based on a coefficient of friction for the
thread of 0.14 (the actual values are subject to an
unavoidable, partly not inconsiderable, spread).
• Rated tightening torques for fasteners with lubrication in
accordance with DIN 43 673.
Thread and head contact surface lubricated.
These values apply to welded on studbolts only.
Any tightening torques which deviate from those in the
general table (e.g. for contact systems or device terminals)
are to be taken into account as stated in the detailed
technical documentation.
It is recommended that the threads and head contact
surfaces of bolts should be lightly oiled or greased, so as to
achieve a precise rated tightening torque.
• Remove any dirt from the surfaces in general
and from insulating material surfaces. Observe
the cleaning instructions in Section 7.2.
• When handling SF6, avoid any escape of gas into
the switchroom:
– as incorrect readings may be caused during
leakage testing.
– ventilate well if leakage occurs.
5.4
Foundation frame
(Figures 5/1 to 5/3)
Switchgear on a foundation frame:
The relevant data for the order in hand can be
found in the ABB documentation.
The single or multiple panel foundation frame can
be supplied with the switchgear. It is as a rule laid
by site personnel and should be aligned and inspected under the supervision of a responsible
specialist.
The specifications of DIN 43 661 are also to be
maintained when laying the foundation frame, in
particular the evenness and straightness tolerances as a condition for perfect switchgear assembly.
ABB Power Distribution
5.5
Laying of the foundation frame
(Figures 5/1 to 5/3)
• Bolt the individual parts of foundation frame
elements 27 together.
• Bolt the individual sections composed of foundation frame elements 27 (where the switchgear has
several panels) together using connecting links
27.1 and bolts 27.5.
• Set up the complete foundation frame on the
concrete floor precisely at the specified position.
• Fasten the foundation frame to the concrete
floor sufficiently firmly with the bolts and dished
washers 27.2, checking the correct dimensional
position continuously.
• Enter jacking screws 27.3 into the relevant
threaded bores (different lengths to correspond
to the height of the screed), inserting a steel shim
27.8 below each screw.
• Loosen the compensation bolts 27.4 and carefully align the entire surface of foundation frame
27 in the horizontal plane and at the correct
height, using a levelling instrument and screwing
in jacking screws 27.3 to the appropriate depth.
The top edge of the foundation frame must be 1
to 3 mm above the screed (take account additionally of the material thickness of any additional
floor covering).
• Tighten the compensation bolts 27.4, performing a final check on the dimensions and horizontal position of the frame.
• Weld jacking screws 27.3 firm to prevent inadvertent changes to their settings.
• Perform the necessary work for proper earthing of
the foundation frame with 30 x 4 mm galvanised
steel strip. Two connections are necessary in
switchgear with more than 6 panels.
• Carefully backfill the foundation frame when
applying the screed.
Note:
Before applying the screed, insert auxiliary bolts
27.9. These prevent the screed from penetrating
into the rivet nuts. Remove auxiliary bolts 27.9
when the screed has hardened.
• The foundation frame must not be subjected to
any undue impacts or pressures, particularly,
during the installation phase.
31
27.1
27.4
Figure 5/1:
Individual parts of a foundation frame element, 2-panel
example version
27.1 Connecting link
27.4 Compensation bolt
n x FT = a
Panel width FT
27.3
1333
(1423)
27
27.1
27.9
Panel
width
Figure 5/2:
FT
1
400
400
600
800
2
3
4
800
1200
1600
600
1200
1800
2400
800
1600
2400
_
27.2
27.6
Foundation frame
27
27.1
27.2
27.3
27.6
27.9
32
Foundation frame width a
Number of panels n
Foundation frame element, individual parts bolted
together
Connecting link
Bolt and dished washer for foundation frame
fastening to concrete floor
Jacking screw for foundation frame
Plug
Auxiliary bolt for frame mounting and panel
fastening bolt 1.4
ABB Power Distribution
Section A-A
(without item 1)
(1423)
1
1333
1…3 mm
1.5
1.4
27.3
27.5
27.9
27.4
h
A
A
27
Figure 5/3:
27.2,27.6
Foundation frame on concrete floor (showing the panel)
1
1.4
27
27.2
27.3
27.4
27.5
27.6
27.8
27.9
h
5.6
27.8
Panel
Panel fastening bolt
Foundation frame element
Bolt and dished washer for fastening of the
foundation
frame to the concrete floor
Jacking screw for foundation frame
Compensation bolt
Bolt for the connecting link
Plug
Steel shim
Auxiliary bolt for frame installation
Screed height 40 to 50 mm
Raised false floor
(Figures 5/6 and 5/7)
When a raised false floor is used, the manufacturer’s installation instructions are to be observed. The false floor must satisfy all requirements
specific to the switchgear installation.
ABB Power Distribution
33
A
B
D
C
250
600
600
110
1)
85
1710
660 1)
3x160
430
800
800
800
180
85
500
660
8
600
600
250
800
4
1)
c 1)
7
d
b
1)
1)
1)
580 1)
a 1)
400
190
265
815
150
665
6
(1423)
150
150
210 210
230
150
160 160 230
5
190
150
870 1)
1
8x150
800 1)
3
2
2000
50
A
Figure 5/4:
C
D
Guideline construction data for a foundation frame on a
concrete floor
See figure 5/5 for sections
1)
34
B
Minimum
1
Inspection aisle
2
Operator aisle
3
Basement entrance
4
Platform, approx. 25 kN
5
Pressure relief duct at side, including end cover
6
Instead of individual openings, continuous
openings or drilled holes are possible
7
Earthing bar
8
Panel without cable connection, e.g. bus coupler
panel
9
Door
10
Waste air opening
11
Intake air opening
12
Intake air opening, if required
13
Waste air opening
14
Or as shown in figure 5/7
15
( 27 )
(155)
60
Panel width
in switchgear
a
b
c
d
mm
mm
mm
mm
600 mm
1327
1455
1300
1100
800 mm or
600 mixed with
800 mm
1527
1655
1500
1300
Room height
22
:
Rated
current
A
Absorber
Room height
Height of cable basement as required
≤ 2000
with
2800
16
To earthing bar
≤ 2000
without
2500
17
Opening for control cable
18
Opening for power cable, plug size 2
> 2000
with
3100
19
Opening for power cable, plug size 3
> 2000
without
2800
20
Instrument transformer for billing purposes
21
Screed, see also figure 5/3
mm
ABB Power Distribution
Section A - A
11
16
(27)
10
16
1)
815
(155)
12
265 180
18
20
17
14
12
a 1)
(1423)
1)
a 1)
Section D - D
c
1)
800
1)
1710
c
11
2
11
ZX2
19
(1423)
14
a 1)
b 1)
19
85 180
(1423)
17
22
13
15
21
870
12
1)
2300 1)
2600
2100
22
2600
17
13
9
d
(155)
(27)
c) Panel width 800 mm, with instrument transformer
Figure 5/5:
16
160 160 160 500
21
b 1)
870
85 180
10
(27)
20
12
d 1)
15
16
9
2300 1)
10
230 160 160 660
(155)
2100
1)
1)
ZX2
1
200
2
200
1)
200
200
1710
1
14
b) Panel width 600 mm, with instrument transformer
Section C - C
800
13
17
(1423)
a) Panel width 600 mm, without instrument transformer
1)
b 1)
265 180
18
d
21
660
15
13
b 1)
660
9
(27)
21
2800
2800
230 150
1)
d
1)
1)
2100
2600
150 150 665
(155)
2300
10
9
11
2
ZX2
1)
ZX2
1
2300
2
200
200
1
c 1)
1710
15
800 1)
c 1)
1710
2100
2600
800 1)
Section B - B
14
a 1)
d) Panel width 800 mm, without instrument transformer
Sections for figure 5/4
See figure 5/4 for legends and dimensional table
1)
Minimum
ABB Power Distribution
35
B
250
600
3x160
1710
190
8
600
800
7
2
500
800
800
4
600
600
250
800 1)
b 1)
3
c
1)
1)
210 210
a 1)
400
190
660
665
6
815
1333
150
150
5
1
8x150
150
230
150
160 160 230
150
800
1)
A
2000
M 10
A
M 10
M 10
B
100
400
100
a
b
c
mm
mm
mm
600
100 100
Figure 5/6:
Guideline construction data for a raised false floor
See figure 5/7 for sections
1)
36
Panel width
in switchgear
Minimum
1
Inspection aisle
600 mm
1327
1300
1100
2
Operator aisle
3
Basement entrance
4
Platform, approx. 25 kN
800 mm or
600 mixed
with 800 mm
1572
1500
1300
5
Pressure relief duct at side, including end cover
6
False floor structure, only shown in the area of the
switchgear
7
Earthing bar
8
Panel without cable connection, e.g. bus coupler
panel
9
Door
10
Waste air opening
11
Intake air opening
12
Intake air opening, if required
13
Waste air opening
Room height
21 :
Rated
current
A
Absorber
Room height
14
Or as shown in figure 5/5
15
Height of cable basement as required
16
To earthing bar
≤ 2000
with
2800
17
False floor structure, supplied by others
≤ 2000
without
2500
18
Power cable, plug size 2
> 2000
with
3100
19
Power cable, plug size 3
20
Instrument transformer for billing purposes
> 2000
without
2800
mm
ABB Power Distribution
Section A - A
800 1)
Section B - B
b 1)
800
1)
b 1)
1710
665
c 1)
10
(72)
11
2
1)
21
ZX2
14
2300
150 150
16
10
1)
ZX2
14
1
230 160 160 660
16
9
c1)
2300 1)
13
200
9
11
2100
2600
2
2800 1)
1
200
13
2100
2600
200
1710
20
X
1333
a 1)
12
17
19
X
1333
a) Panel width 600 mm, without instrument transformer
(72)
a
1)
15
18
15
17
12
b) Panel width 800 mm, with instrument transformer
Detail X
3
(72)
Figure 5/7:
Sections for figure 5/6
See figure 5/6 for legends and dimensional table
1)
Minimum
ABB Power Distribution
37
5.7
Erection and connection of the panels
(Figures 5/3 and 5/8 to 5/14)
Note:
Do not walk on the top of the panels (rupture point
for pressure relief system!).
5.7.1 Preparatory work
• Grease the upper surfaces of the foundation
frame (this facilitates erection and alignment of
the individual panels).
• Enter the two or four guide pins 35 at the sides of
the panels into the relevant bores (see figure 5/10,
section A-A).
5.7.2 Erection of the switchgear
• Erect the end panel of the switchgear at the precise position specified on the foundation frame.
• Lightly enter panel fastening bolts 1.4 into the relevant threaded bores in the foundation frame.
• Align the panel if necessary.
• Perform a final check on the aligned position of
the panel and fasten it to the foundation frame by
tightening the panel fastening bolts 1.4.
• Remove the protective caps from the busbar
sockets 23.1.
• Carefully check insulating parts 23.2 and
contact tubes 23.3 for any dirt, and clean if
necessary (see also section 7.2).
Note:
Only prepare insulating parts and contact tubes
for the panel currently being erected. Protect
them from further contamination!
• Evenly apply a thin coating of assembly paste AP
to the conical surfaces A of insulating parts 23.2.
Note:
• Slide the adjacent panel carefully and evenly
(without tipping) against the erected panel in
such a way that the contact tubes, insulating
parts and guide pins slide into the corresponding bores without the use of force.
If necessary, align the panel appropriately with
the panel height adjustment bolts 1.5.
• As soon as the distance between the two panels
is so small that bolts 36 and 37 can be entered in
the bores in the erected panel, insert these, each
with nuts and dished washers respectively.
Spacer 38 is also to be fitted on socket head bolt
37 (see figure 5/9, section B-B).
• Then join the two panels together by tightening
bolts 36 and 37 step by step.
• Completely bolt the panels together with bolts
40, each with dished washers (see figure 5/8).
• When the panels have been completely joined,
check the second panel again for correct alignment and fasten it to the foundation frame with
the panel fastening bolts 1.4.
• Dismantle connecting link 14 for the main earthing bar 15 in the cable compartment and lead it
through to the adjacent panel. Bolt the connecting link to the main earthing bar with bolts 39 and
one dished washer at each of the bolt head and
nut ends.
• Check the bolted connection between main
earthing bar 15 and the connecting link 14 in the
previously erected panel and tighten bolt 39 if
necessary.
• Erect the further panels by following the same
procedure.
• Assembly of the top pressure relief duct, the absorber and the cooler if fitted can be effected
during installation of the individual panels or
when all panels have been joined together.
Leave no ungreased areas on conical surface A.
• Carefully insert contact tubes 23.3 and
insulating parts 23.2 into the busbar sockets
23.1.
38
ABB Power Distribution
View X
40
37.2
40
37.2
A
35
23.1
23.2
23
40
37.1
37.2
A
23.3
B
B
40
37.2
40
37.1
37.2
X
C
40
37.2
40
37.2
C
40
37.2
a) Double busbar
40
37.2
40
37.2
A
40
37.1
37.2
B
A
B
40
37.2
40
37.1
37.2
C
40
37.2
C
40
37.2
40
37.2
b) Single busbar
Figure 5/8:
Switchgear erection
(See figure 5/9 for sections and details)
23
23.1
23.2
23.3
35
37.1
37.2
40
ABB Power Distribution
Busbar connection, plug-in type
Busbar socket
Insulating part
Contact tube
Guide pin
M8 hexagon nut
Dished washer 8
Socket head bolt M8 x 25
39
Section A-A
23.4
23.1
23.2
23
1)
ca. 50
10
1)
A
Evenly greased with
assembly paste AP
Panel division
Busbar connection
Insulating part
Section C-C
Section B-B
Panel division
10
Panel division
15
39
38
37.2
37
Panel/panel connection
Figure 5/9:
Earthing bar connection
Switchgear erection
(section for figure 5/8)
14
15
23
23.1
23.2
23.4
35.1
35.2
37
37.2
38
39
40
35.2
14
35.2
35.1
Panel/panel connecting link
Main earthing bar
Busbar connection, plug-in type
Busbar socket
Insulating part
O-ring
M10 hexagon nut
Dished washer 10
Socket head bolt M8 x 40
Dished washer 8
Spacer
Socket head bolt M10 x 35
ABB Power Distribution
Section A-A
35
A
36
35.2
35
A
35.1
B
B
Section B-B
35.2
35.2
35.1
36
a) Panel joined up from the right
36
35
b) Panel joined up from the left
Figure 5/10: Switchgear erection
panel/panel connection, view from top
(without pressure relief duct)
35
35.1
35.2
36
ABB Power Distribution
Guide pin
M10 hexagon nut
Dished washer 10
Socket head bolt M10 x 50
41
Detail X
35.2
35.2
43
35.1
X
42
Detail Y
37.2
41
40
Evenly greased,
assembly paste AP
42
Y
Figure 5/11: Busbar end in an end panel
35.1
35.2
37.2
40
41
42
43
M10 hexagon nut
Dished washer 10
Dished washer 8
Socket head bolt M8 x 25
Plate for blanking plug
Blanking plug
Socket head bolt M10 x 30
1330
250
220
665
44
45
A
B
C
D
2600
F
Figure 5/12: Pressure relief duct, side, double busbar,
right-hand side mounting shown
A
B
C
D
F
42
Pressure relief duct with absorber
Pressure relief duct, top
Pressure relief duct, side
End cover
Panel
44
45
Fastening material, packed in bag group ”Screw
fasteners for side pressure relief duct”
Plug
ABB Power Distribution
23.1
23.2
23.3
Figure 5/13: Busbar connection
L3
L2
L1
Figure 5/14: Assembly of the busbar connection, shown for 1250 A
23.1 Busbar socket
23.2 Insulating part
23.3 Contact tube
• L1: Protective cap removed
• L2: Contact tube 23.3 fitted
• L3: Insulating part 23.2 and contact tube 23.3 fitted
12
27
10
11
13
Figure 5/15: Plug connector for single-core plastic-insulated cable
10
11
K
Socket
Cable plug
Cable earthing conductor to be connected to
switchgear earth, do not establish cable earthing via
the plug
13.1
13.3
13.4
Figure 5/16: Cable compartment
(panel side wall cut out)
12
13
13.1
13.2
13.3
13.4
27
ABB Power Distribution
13.2
Surge arrester
Floor plate, split
Reducer ring
Cable mounting
Supporting section, at earth potential
Insulated earthing point for cable jacket (nonstandard)
High voltage cable
43
5.8
Connection of cables and wiring
The cable compartments (I) in the panels are fitted
with cable connection fittings in accordance with
the cable types and sizes specified in the project
planning for the switchgear as a whole.
5.10
Final erection work
• Clean the external surfaces of the enclosure and
control cabinets in the switchgear where necessary and check for any damage to the paintwork,
touching up with a suitable paint if necessary
(see Section 7.3).
5.8.1 High voltage plastic-insulated cable with plug
connectors
(Figures 3/4, 3/11, 5/15 and 5/16)
• Properly refit any cladding and covers of operating mechanisms, cable ducts, etc. removed during the erection work.
• Lay the single-core plastic-insulated cables as
specified in the project planning to the individual
panels.
• Remove all tools and other foreign bodies from
the switchgear.
• Remove the transport covers fitted to protect
the sockets.
• Expose the cable cores, check the correct
phase assignment, and secure.
• Check the general condition of the switchgear.
• Check that the areas adjacent to the switchgear
are in the proper condition.
• Fit cable plug 11 in accordance with the manufacturer’s instructions.
• Fit the plugs to the sockets 10 mounted in the
circuit-breaker compartment floor (without opening the insulating gas compartment) and secure
them with bolts.
• Align the cables and fasten them at mountings
13.2
• Close off any unused sockets, e.g. in spare
panels, with suitable cable blanking plugs to
ensure the necessary insulation.
5.8.2 Control cables and wiring
(Figures 3/2 and 5/11)
• Establish the necessary connections for incoming and outgoing cables and wiring, and cross
connections.
• The control cables and wiring are to be laid in
cable ducts at the right of the cable compartment (for external wiring).
• The connections from panel to panel are to be
made by plug connectors in the control cabinets.
5.9
Preparing the insulating gas system for operation
Observe the relevant data in instruction manual
BA 427/E – Insulating gas system for ZX switchgear.
44
ABB Power Distribution
6
Commissioning/operation
• Cancel any existing short-circuiting and earthing
connections in the critical switching area.
Note on safety at work
• Energise the switchgear step by step, observing
the displays on the REF542.
• Operation by trained specialists familiar with the
particular switchgear only.
6.1
• Check that corresponding conductor sections
are in phase where relevant with several incoming feeders and switchgear sections.
Commissioning
• Check measurements and functions dependant
on high voltage.
6.1.1 Preparatory work
In preparation for commissioning, the following
work is to be performed prior to connection with
the high voltage power supply:
• Connect the auxiliary and control voltage and
check the correct polarity.
• Check mechanical and electrical interlocks for
compliance with the specified conditions.
• Perform a functional test on the protective devices (observe DIN VDE 0141).
• Check the general condition of the switchgear
and external conditions for detrimental factors of
any kind.
• Display the instructions for handling SF6 in the
switchroom. The handling specifications for SF6
also apply accordingly to nitrogen.
• Display the ABB instruction manual on the handling of insulating gas and behaviour during
faults in the switchroom.
• Instruct the local operators on the fundamental
details of operating the switchgear in normal
service.
• Check the readiness for operation and the
switching condition of the upstream and downstream electrical equipment.
• Perform further checks where necessary on the
following equipment from the areas adjacent to
the switchgear:
• Look out for irregularities of any kind.
6.2
Switching operations
6.2.1 Circuit-breaker
(Figures 3/2, 6/1, 6/2 and 6/4)
The circuit-breaker is fitted with a charging motor.
Charging of the spring energy storage mechanism
takes place automatically.
Opening and closing the circuit-breaker:
• Opening and closing are effected by selection on
the bay control and protection unit REF542.
• ON-OFF switching operations may only be
performed with the control cabinet door closed.
• Opening the control cabinet door constitutes
intervention in the interlock system.
• Observe the position indicator.
Emergency manual operation:
1. On failure of the charging motor, the charging
process can be performed or completed by
hand:
• Open control cabinet door 1.1.
• Insert charging lever 8.9 into recess 8.8 and
pump for approx. 25 strokes until the charged
condition is displayed.
– control wiring
When the charged condition is reached, the
charging mechanism automatically disengages
and further strokes of the charging lever have no
effect.
– auxiliary voltage and its polarity
Key to the charging condition displays:
– power cables
– remote controls
– external earth with connection to main
earthing bar 15
– switchroom equipment
– switchroom condition.
6.1.2 Initial start-up
Discharged
Charged
2. If the control voltage fails with the circuit-breaker
closed, it is possible to open it using the
mechanical OFF push-button 8.3.
• Comply with all relevant safety regulations
Note:
• Ensure that the switchgear circuit-breakers are
in the OFF position.
On failure of the control voltage, there is no
maloperation protection for the circuit-breaker,
three-position switch and disconnector during
emergency manual operation.
• Close the disconnector for the relevant busbar
system.
ABB Power Distribution
45
6.2.2 Three-position switch and disconnector
(Figures 3/2, 3/11, 6/3, 6/5 and 6/6)
Note:
Always perform every switching operation right
up to the stop in the relevant limit position.
• The three-position switch 2 and the disconnector
19 are fitted with motor-operated mechanisms.
Opening and closing are effected by selection on
the bay control and protection unit.
• ON-OFF switching operations may only be performed with the control cabinet door closed.
• Observe the mechanical and electrical position
indicators.
6.2.3 Undervoltage release
Undervoltage releases may be fitted as an option. In
order to prevent the circuit-breaker being opened by
the undervoltage release on power failure with teeoff earthing, an interlock rod or wire is provided.
• Opening the control cabinet door constitutes intervention in the interlock system.
• Observe the position indicator on LCD display
5.1 or on the control unit.
• Sensors 29 to 32 on the three-position switch
operating mechanism 3 detect the following
switch positions:
Disconnector -Q1 ON and OFF, and earthing
switch -Q5 ON and OFF.
6.3
6.3.1 Gas monitoring
(Figures 3/11 and 6/1)
All high voltage compartments in the switchgear
must have a sufficient insulating gas pressure during operation. The minimum operating gauge pressure (pe) is listed in section 2.1. This is monitored by
sensors 4, 7 and 21.
• Sensors 33 and 34 on disconnector operating
mechanism 20 detect the following switch positions:
Disconnector -Q2 ON and OFF.
If the gas pressure falls below the minimum operating gauge pressure, an LED on the bay control and
protection unit signals that the gas should be
topped up.
Emergency manual operation:
In place of motorised operation, the switching
process can also be initiated and completed manually.
Note:
• Open control cabinet door 1.1
If a panel is isolated for a relatively long period
(several weeks), m.c.b. F116 for the auxiliary
voltage supply to the REF542 must remain on. Only
in this way is monitoring of the insulating gas
ensured.
• Prior to emergency manual operation, switch the
relevant m.c.b. (F101 or F102) off.
Details on the gas system of the ZX2 switchgear
can be found in instruction manual BA 427.
Caution!
The interlock is ineffective on emergency manual
operation.
• Insert the crank in the hollow shaft.
6.3.2 Electrical/mechanical display/monitoring
• Three-position switch -Q1/-Q5:
If the three-position switch is in the central position (i.e. disconnector and earthing switch OFF),
the disconnector can be closed with approx. 24
clockwise turns, and the earthing switch with
approx. 24 anti-clockwise turns. If the ”earthing
switch ON” position is to be reached from the
”disconnector ON” position, or vice versa, the
crank is to be removed in the self-inhibiting central position (disconnector and earthing switch
OFF) and refitted. When the crank is refitted, the
further switching operation is automatically enabled.
• Disconnector -Q2:
Close the disconnector with approx. 24 clockwise turns and open it with approx. 24 anticlockwise turns.
46
Observation of the display and monitoring
facilities
During operation of the switchgear, observe all visible operating data and condition displays in the
secondary system and watch out for irregularities
of any kind, including the external conditions of the
switchgear.
6.4
Test procedures
6.4.1 Testing for the off-circuit condition
(Figure 6/1)
The panels are fitted with the low impedance,
capacitive voltage indicator system LRM, including corresponding (hand-held) display units with
connecting plugs for testing of the off-circuit condition.
For details, see draft DIN VDE 0682 Part 415, or
IEC 61243 Part 5.
ABB Power Distribution
Note:
Only display units which comply with the IEC or
VDE standards and the technical design of the
indicator system in the relevant switchgear may be
used!
6.4.3 High voltage tests
(Figures 6/1 and 6/8)
Note:
The test plugs available for high voltage tests,
shown in figure 6/8, are suitable for the following
applications up to and including 24 kV rated voltage.
The measuring sockets must on no account be
short-circuited, except during voltage testing of the
system (e.g. with power frequency withstand
voltage or impulse withstand voltage)!
For high voltage tests on the 36 kV rated voltage
level, separate test facilities are required. Information on these can be obtained from the switchgear
manufacturer.
Testing for the off-circuit condition is performed
with a plug in display unit at corresponding pairs of
measuring sockets 6 in the vicinity of the panel controls.
Taking account of the sensor systems used and
the bay control and protection unit, the test
voltages must not exceed the following values:
Use of the display unit:
• Cable tests with DC voltage:
– 12 kV switchgear:
• Perform a functional test on the display unit immediately before and after use, e.g. with interface tester KSP. The display must be clearly visible.
• The presence of operating voltage is indicated
by a signal.
– 24/36 kV switchgear: 70 kV1) up to 1 hour.
Higher values on request.
• Insulation testing of the switchgear at the relevant power frequency withstand voltage:
– 12 kV switchgear: 28 kV
• Observe the individual operating instructions for
the display unit for the relevant switchgear!
– 24 kV switchgear: 50 kV
Interface testing:
• Perform interface testing as a functional test on
all coupling components, e.g. with interface
tester KSP.
• The interface test is a repeat test to IEC 61243
Part 5 or draft DIN VDE 0682 Part 415.
6.4.2 Testing for the in-phase condition
Testing for the in-phase condition, e.g. when there
is more than one incoming feeder, can be performed with a suitable phase comparator at measuring sockets 6 on the capacitive voltage indication
system.
Test procedure:
• Only use phase comparators which comply with
the IEC or VDE specifications and the technical
design of the display system in the relevant
switchgear!
• Perform a functional test on the equipment at the
start of testing.
• Do not exceed the maximum permissible length
of measuring leads per phase.
• Connect the measuring leads precisely assigned
to the corresponding main conductor sections.
• Always follow the details in the operating
instructions for the phase comparator!
– 36 kV switchgear: 70 kV.
Performance of voltage tests:
• Isolate the switchgear area in accordance with
the safety rules of VDE 0105 and secure it to
prevent reconnection.
• Verify the off-circuit condition with a suitable
hand-held display unit at measuring sockets 6
on the capacitive voltage indicator system.
• Unscrew surge arresters where fitted, or
• unscrew the cable blanking plugs from the free
cable sockets.
• Check the test plug to ensure that the surface is
clean and dry, and clean it if necessary.
• Grease the silicone part of the test plugs in
accordance with the directions.
• Insert the test plug into the prepared cable
socket and screw it tight.
Notes:
• Only fit the test plugs for voltage tests for the
duration of those tests.
• Short-circuit the measuring sockets 6 in the
panels concerned for the duration of the testing
process at test voltages up to rated power frequency withstand voltage.
1)
ABB Power Distribution
48 kV1)
Applies to integrated voltage sensors. With plug-in voltage
sensors/instrument transformers, the cable test voltages
permissible to DIN standards may be used if the sensors are
withdrawn.
47
• For performance of cable tests, in the switching
condition ”tee-off disconnected and earthed”,
earthing of the cable has to be cancelled by opening the circuit-breaker. This is accomplished by
using the mechanical OFF button to open the
circuit-breaker (see also Section 3.9).
6.4.4 Current tests
(Figures 6/1 and 6/9)
6.4.5 Maintenance earthing
a) Double busbar systems:
In the double busbar system, there is an opportunity to earth the busbar via the bus coupler.
b) Single busbar systems:
• Earthing of the busbar with the bus tie / riser,
as described in section 3.9.3.
The test plugs available for current test are suitable
for the following applications:
• Earthing with an earthing and short-circuiting
set.
• Testing of the protection functions in the bay
control and protection unit REF542 by means of
primary current injection.
Handling during earthing with an earthing and
short-circuiting set:
(Figures 6/1 and 6/9)
Test instruction:
The following is to be observed when testing the
protection system of the REF542:
In order to prevent damage to the OFF-release coil
during testing, either the OFF-release coil has to be
disconnected or the protection test equipment
must be deactivated by the trip command.
This ensures that the opening release is not
energised in the meantime by the trip command,
which could lead to the coil burning out.
• Establishment of maintenance earthing in conjunction with an earthing and short-circuiting set.
The short-circuit resistance of the current test
plugs for the switchgear must correspond to the
condition of the individual switchgear.
Handling of the plugs for current tests:
• Isolate the switchgear area in accordance with
the safety rules of VDE 0105 and secure it to
prevent reconnection.
• Verify the off-circuit condition with a suitable
(hand-held) display unit at measuring sockets 6
on the capacitive voltage indicator system.
• Unscrew surge arresters where fitted, or
• unscrew the cable blanking plugs on the free
cable sockets.
• Check the test plug to verify that the surface is
clean and dry, and clean it if necessary.
The plugs for current tests described under 6.4.4
are used in conjunction with corresponding cable
sets for short-circuiting and earthing to establish
maintenance earths. The short-circuit resistance of
the cable set must correspond to the conditions of
the switchgear.
Caution!
Observe the notes in Section 3.9 on the interlock
dependencies for all work with earthing and shortcircuiting sets!
• Isolate the switchgear area in accordance with
the safety rules of VDE 0105 and secure it to
prevent reconnection.
• Verify the off-circuit condition with a suitable
(hand-held) display unit at measuring sockets 6
on the capacitive voltage indicator system.
• Unscrew surge arresters if fitted, or
• unscrew the cable blanking plugs on the free
cable sockets.
• Check the test plugs to ensure that the surface is
clean and dry, and clean them if necessary.
• Carefully screw the short-circuiting and earthing
cable set to the test plug.
• Connect the common earthing connector of the
cable set to the earthing terminal of the panel.
• Insert the test plugs into the prepared cable
sockets and screw them tight.
• Insert the test plug into the prepared cable
socket and screw it tight.
• Only fit the test plugs for the duration of the tests.
48
ABB Power Distribution
6.5
Application of the X-ray regulations
One of the physical properties of vacuum insulation
is the possibility of x-ray emissions when the contact gap is open. The specified type test performed
by the Physikalisch-Technische Bundesanstalt
(PTB) in Brunswick demonstrates that the local
dosage output of 1 µSv/h at a distance of 10 cm
from the touchable surface is not exceeded.
The results are as follows:
• The use of the vacuum interrupters at rated voltage is completely safe.
• Application of the rated power frequency withstand voltage specified for the switching device
by VDE 0670 and IEC 60056 or a DC voltage of
48 kV or 70 kV during cable tests is also safe.
• Higher voltages than the rated power frequency
withstand voltage specified in DIN VDE or IEC
standards or the DC voltage must not be applied!
• Fulfilment of the above requirement with the
vacuum interrupter in the open position is dependent on maintenance of the specified distance between the contacts (which is automatically ensured with correct mechanism function
and force transmission).
ABB Power Distribution
49
1.1
1.1
28
5
28.4
28.1
(28.2)
5.1
5.2
28.3
6
Figure 6/1:
Display area on the panel
1.1
5
5.1
5.2
6
Figure 6/2:
Control cabinet door
Bay control and protection unit REF542
LCD display (example)
Light-emitting diode (LED)
Measuring sockets for capacitive voltage indicator
system
Handling of the door-lock
• Opening the control cabinet door:
- Open the safety lock (if fitted)
- Release the catch with the double bit key
- Draw the closing lever out to an angle of 45° and
then swing it upwards to the left through approx.
135° until the stop is reached
• Closing the control cabinet door:
- reverse the procedure for opening
1.1
28
28.1
(28.2)
28.3
28.4
Control cabinet door
Door-lock
Catch
Safety lock (if ordered)
Double bit key
Closing lever
31 30 29 32
3
3.1
3.2
3.3
3.4
20
20.1
20.2
34
50
Figure 6/3:
Operating mechanisms for the three-position switch
and disconnector
3
3.1
3.2
3.3
3.4
20
20.1
20.2
29
30
31
32
33
34
Three-position switch mechanism
Hollow shaft (emergency manual operation shaft)
Mechanical position indicator
Cam for OFF position of the three-position switch
Drive motor for three-position switch
Disconnector mechanism
Hollow shaft (emergency manual operation shaft)
Mechanical position indicator
Sensor, disconnector -Q1 ON
Sensor, disconnector -Q1 OFF
Sensor, earthing switch ON
Sensor, earthing switch OFF
Sensor, disconnector -Q2 ON
Sensor, disconnector -Q2 OFF
33
ABB Power Distribution
8
8.1
8.2
8.9
8.3
8.4
8.8
8.5
8.7
8.6
Figure 6/4:
Emergency manual operation, circuit-breaker type
VD4 X
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
Figure 6/6:
Emergency manual operation, three-position switch
UX2TE
Figure 6/7:
View of the stored-energy spring mechanism for the
circuit-breaker, front plate removed
Circuit-breaker operating mechanism
Front plate
ON push-button
OFF push-button
Operating cycle counter
Mechanical position indicator
Rating plate
Charging condition indicator
Recess for charging lever 8.9
Charging lever for emergency manual operation
Emergency manual operation, disconnector UX2T
ABB Power Distribution
Figure 6/5:
51
Figure 6/8:
Test plug for high voltage tests up to 24 kV rated
voltage
Figure 6/9:
Test plug for current tests
Also usable as a maintenance earth in conjunction with
an earthing and short-circuiting set
52
ABB Power Distribution
7
7.2
Maintenance
Maintenance serves to preserve trouble-free operation and achieve the longest possible working
life of the switchgear. In accordance with DIN 31 051
and IEC 61208, it comprises the following closely
related activities:
Inspection: Determination of the actual condition
Servicing: Measures to maintain the specified
condition
Repairs:
7.1
Measures to re-establish the specified condition
General
It is essential to observe the following during all
maintenance work:
• The relevant regulations in section 1.2.2
• The notes on safety at work in section 6
• Standards and specifications in the country
where the switchgear is erected.
Inspection/servicing
• Under normal operating conditions (see section
1.3), checking of the operating mechanisms is to
be carried out by a suitably qualified electrician
after 10 years at the latest or after 10,000 operating cycles of the circuit-breaker and 2,000 operating cycles of the three-position switch or
disconnector.
• In exceptional operating conditions (including
adverse climatic conditions) and/or particularly
adverse environments (including heavy contamination and aggressive atmosphere) inspection
at shorter intervals may be required.
• Inspection is first and foremost to be visual examination for contamination, corrosion and
moisture.
• The inspection should however also include
checking of the mechanical and electrical functions of the following devices:
– Switching devices
– Bay control and protection unit REF542.
It is recommended that ABB after sales service
personnel be called in to perform servicing and
repair work.
• If an incorrect condition is found, the corresponding repair work is to be initiated immediately.
Follow/observe the instructions on SF6 systems
and the ABB instruction manual on the handling of
insulating gases and procedures for fault conditions. The handling regulations for SF6 also apply
accordingly to nitrogen.
Cleaning
• Keep these instructions and manual permanently on display and available in the switchroom.
• Prior to cleaning, isolate and secure the working
area if necessary in accordance with the safety
rules of DIN VDE and IEC.
The inspection and servicing intervals for the
switching devices are determined by fixed criteria
such as switching frequency and number of shortcircuit breaking operations.
• Cleaning of surfaces in general:
The length of the intervals for inspection and servicing of the control cabinet and its equipment is influenced by ambient conditions (for instance pollution
and aggressive atmosphere).
If the necessity of cleaning is established during
inspections, the following procedure is to be
adopted:
– Remove weakly adhering dry dust deposits
with a soft dry cloth.
– Remove more strongly adhering contamination with slightly alkaline household cleanser,
or with Rivolta BWR 210.
• Cleaning of insulating material surfaces and conductive parts (outside the gas compartments):
In addition to this instruction manual, the following
instruction manuals must be observed:
– Minor contamination with Rivolta BWR 210.
• Insulating gas system
BA 427/E
– Strongly adhering contamination with Cold
cleanser 716
• Bay control and protection
unit REF542
BA 453/E
• Cleaning of busbar insulating parts, cable sockets
and busbar sockets with cable cleanser MAB.
• Circuit-breaker VD4 X
BA 436/E
Further details can be found in the technical documentation for the switchgear installation (including,
for example, any agreed special operating conditions).
ABB Power Distribution
• Observe the manufacturer’s instructions and the
special ABB instruction manuals BA 1002/E and
BA 1006/E on safety at work.
• Wipe down after cleaning, using clean water,
and dry properly.
53
7.2.1 Vacuum circuit-breaker
(Figure 6/7)
7.3
• The vacuum circuit-breaker has a long service
life. It has a low maintenance operating mechanism and the breaker poles are maintenancefree.
Consult the relevant sections of instruction
manual BA 436/E for further information.
7.2.2 Three-position switch and disconnector
• The three-position switch and disconnector are
maintenance-free for 2000 operating cycles.
7.2.3 Gas system and gas servicing
• Consult the relevant sections of instruction
manual BA 427/E for further information.
Repair
• Remove all rust from damaged paintwork areas
on sheet steel and other steel parts mechanically, e.g. with a wire brush. Lightly grind the surrounding paint coat and carefully degrease the
entire area. Then immediately apply an anti-rust
primer and, after an appropriate hardening period, apply the top coat. Only use suitable and
compatible paint products.
Use top coat paint in the standard colour
RAL 7032, or the relevant special colour.
• Carefully remove any white rust from galvanised
and chromium plated functional parts and rust
on phosphated parts with a wire brush or a
cleaning pad, e.g. Scotch-Brite, and clean with a
dry cloth. Then grease evenly with Isoflex Topas
NB 52.
Notes:
7.2.4 Outlet filter
The filter mats in the outlet filter are to be changed
as required. Note the information on inspection and
servicing in section 7.2.
• It is essential to observe the section on safety at
work in instruction manual BA 427/E for all work
on gas compartments.
Replacement procedure:
• Caution when working in gas compartments!
High gas concentrations may result in a danger
of asphyxiation!
• Draw off the grille. This is done by prising off with
the fingertips in the recesses at the bottom end
of the filter.
• Change the filter mat.
• Replace the grille.
Spare filter mats:
54
Part no. (order ref.)
• Filter mat for
fan system:
GCE0995403P0100
• Filter mat for
control cabinet:
GCE0995404P0100
ABB Power Distribution
7.4
Working and auxiliary materials
7.4.1 Working materials
Part no. (Order ref.)
• Insulating gas system:
– Nitrogen (N2)
GCE0990267P0100
Degree of purity 4.6
Delivery form: liquid gas in steel cylinders
Observe the relevant ABB instruction manual
BA 1007/E on safety at work!
GCEA901007P0102
– Sulphur hexafluoride (SF6 )
Delivery form: liquid gas in steel cylinders
Observe the quality requirements to IEC 60376/
VDE 0373!
GCE0990253P0103
Observe the relevant ABB instruction manual
BA 1004/E, pp. 1 to 3, on safety at work!
GCEA901004P0102
Note:
If extreme temperatures ≥ 50°C cannot be ruled
out where gas cylinders are stored, transported or
temporarily stored in the open air in direct sunlight,
a reduced filling factor of 0.75 kg/l cylinder contents is to be required when ordering for safety
reasons!
• Drying agent material:
Drying agent bag to DIN 55 473,
capacity per bag 210 g
GCE0990443P0100
7.4.2 Auxiliary materials
• Lubricants:
Isoflex Topas NB 52,
• Assembly paste AP,
for insulating part/cast resin plug connections
GCE0007249P0100
GCE0009098P0100
• Cleaning agents for general cleaning:
Rivolta BWR 210,
GCE0007707P0100
Observe the relevant ABB instruction manual BA 1002/E
GCEA901002P0102
• Cleaning agent for conductive parts, parts in insulating material, and all parts with heavy contamination:
Cold cleaner 716,
GCE0007706P0100
Observe the relevant ABB instruction manual BA 1006/E
GCEA901006P0102
• Cleaning agent for busbar insulating parts,
busbar sockets and cable sockets:
Cable cleaner MAB
GCE0009100P0100
• Paintwork:
Paint in standard colour RAL 7035
– 1 kg-box
GCE9014060R0103
– Spray tin
GCE0007895P0100
ABB Power Distribution
55
We reserve the right to make changes in the course of technical development.
Instruction manual no. GCEA 68 0435 P0102 Printed in Germany (12.00-500-PPI)
ABB Calor Emag Mittelspannung GmbH
ABB Sace T.M.S. S.p.A
Oberhausener Strasse 33
D-40472 Ratingen
Via Friuli, 4
I-24044 Dalmine
Petzower Strasse 8
D-14542 Glindow
Phone: +49(0)21 02/12-12 30, Fax: +49(0)21 02/12-19 16
E-mail: calor.info@de.abb.com
Internet: http://www.abb.de/calor
Phone: +39 035/395111, Fax: +39 035/395874
E-mail: sacetms.tipm@it.abb.com
Internet: http://www.abb.com