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ABB SafeGear, Technical And Application Manual

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ABB Inc.

655 Century Point
Lake Mary, FL 32746
Phone:   +1 407 732 2000 ext. 2510

 

+1 800 929 7947 ext. 5

[email protected]

abb.com/mediumvoltage

The information contained in this document is for general 
information purposes only. While ABB strives to keep the 
information up to date and correct, it makes no repre-
sentations or warranties of any kind, express or implied, 
about the completeness, accuracy, reliability, suitability or 
availability with respect to the information, products, ser-
vices, or related graphics contained in the document for 
any purpose. Any reliance placed on such information is 
therefore strictly at your own risk. ABB reserves the right 
to discontinue any product or service at any time.

© Copyright 2017 ABB. All rights reserved.

Summary of Contents for SafeGear

Page 1: ... TECHNICAL AND APPLICATION GUIDE SafeGear 5 15 kV up to 50 kA arc resistant switchgear ...

Page 2: ...eep the information up to date and correct it makes no repre sentations or warranties of any kind express or implied about the completeness accuracy reliability suitability or availability with respect to the information products ser vices or related graphics contained in the document for any purpose Any reliance placed on such information is therefore strictly at your own risk ABB reserves the ri...

Page 3: ...EGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR SafeGear is ABB s ANSI arc resistant metal clad switchgear line for short circuit currents up to 50 kA and below at rated maximum voltages of 5 and 15 kV ...

Page 4: ...onstruction doors 009 010 Circuit breaker compartment 011 Auxiliary modules 012 013 Instrument compartment 014 015 Bus compartment 016 017 Cable compartment 018 Arc chamber and plenum 019 One high frames 020 Two high frames 021 024 Breaker and auxiliary frames 025 028 Auxiliary frames ...

Page 5: ...ain Tie Main 3000 A greater than 40 kA 032 Main Tie Main 1200 A 2000 A greater than 40 kA 033 Main with Feeders 2000 A 1200 A greater than 40 kA 034 Main with Feeders 3000 A less than 31 5 kA 035 039 Civil engineering details typical side views floor plans and clearances 040 043 Civil engineering details seismic applications 044 Frame weights calculation 045 Heat dissipation ...

Page 6: ...oors must be closed Type 2C Front sides rear and between adja cent compartments and sections within a lineup Type 2BC Front sides rear LV compartment and between adjacent compartments and sec tions within a lineup SafeGear is offered in accessibility types 2 2B 2C and 2 BC Construction SafeGear is manufactured of hem bent 14 gauge galvanized steel for superior rust and scratch pro tection All non ...

Page 7: ...tions within temperature and altitude limitations as defined by IEEE C37 20 2 2015 metal clad standard 4000 A is forced air cooled For 5 kV applications SafeGear switchgear utilizes ABB VIY 60 potential transformers For 15 kV appli cations SafeGear uses ABB VIZ 11 and VIZ 75 PTs All PTs are available in wye wye open delta line to line and line to ground connections Rating tables and additional det...

Page 8: ...gn tool and helps design of fices in creating a switchgear lineup including front elevations and floor plans A version of this soft ware is available for consultants and designers Please contact your local ABB representative for more information Other reference documents Document Document Number SafeGear Descriptive Bulletin 1VAL108001 DB SafeGear Flyer 1VAL108004 FL Installation Operation and Mai...

Page 9: ...oors are constructed using 12 gauge painted steel Padlock provisions are available on all front and rear doors These padlock provisions are used to lock the door closed to prevent access inside the compartment On breaker compartment doors padlock provisions are also supplied on the rack ing release lever to prevent racking of the breaker Breaker and auxiliary unit doors include viewing windows use...

Page 10: ...ected primary and secondary control con tacts are engaged The racking system includes all necessary interlocks in compliance with ANSI IEEE standards to assure proper sequencing and safe operation For improved safety the interlocking system prohibits operation of the breaker while in an intermediate position and pro hibits insertion of an improperly rated breaker Secondary disconnect system A dual...

Page 11: ...ers Terminal blocks Automatic secondary disconnects CTs on epoxy bushings 10 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR CIRCUIT BREAKER COMPARTMENT Terminal blocks normally covered by grounded metal barrier have been removed in this photo ...

Page 12: ...with recessed contacts During load break localized heating of the Delrin material due to arcing causes the material to release an inert gas which fills the small isolating gap to contain the arc and extin guish it safely The PT drawout units can be withdrawn beyond the front of the frame via rails which allow easy access to the fuses for inspection or replacement Control Power Transformer CPT and ...

Page 13: ... a neat and orga nized appearance This allows for easy addition of wiring should it be needed Devices and control switches are mounted on the door for easy readability and convenient access Those devices that do not require direct access are mounted inside the compartment Frame to frame interconnect wiring is achieved through openings located in the rear of the LV com partment Each opening is 3 x ...

Page 14: ...TECHNIC AL AND APPLIC ATION GUIDE 13 Compartment types Instrument compartment 01 Low voltage door panel 38 02 Low voltage cabinet door panel 57 01 02 ...

Page 15: ...ain bus and runbacks the connections from the stationary primary contacts to line or bus terminations Internal standoffs and inter frame supports are polyester for 1200 A and 2000 A applications porcelain for 3000 A applications and epoxy for 4000 A applications Porcelain bus supports are available as an option Compartment types Bus compartment SafeGear arc resistant metal clad switchgear design c...

Page 16: ...tity phase size 1200 A 25 31 5 40 50 1 1 4 x 4 1200 A 50 1 3 8 x 4 2000 A 25 31 5 40 50 1 3 4 x 4 3000 A 25 31 5 40 50 2 3 4 x 4 4000 A 25 31 5 40 50 2 1 2 x 6 Main bus Jumps to main bus Reusable boot Epoxy 3 phase interframe support TECHNIC AL AND APPLIC ATION GUIDE 15 ...

Page 17: ...sible zero sequence ground sensor current transformers surge arrestors or capacitors and or ground studs on the bus risers When a draw out fuse compartment is installed in the front of the switch gear the rear cable compartment offers room for a large three phase floor mounted control power trans former up to 75 kVA Primary cable compartments are provided with re movable non painted stainless stee...

Page 18: ...17 01 03 02 01 Surge arrestors 02 Connection of up to eight cables per phase three cable lugs shown 03 Large fixed mount CPT up to 75 kVA 3 phase or 50 kVA single phase ...

Page 19: ...xhaust clearance requirements For proper and safe arc fault by product exhaust ing it is recommended that an eight foot cylinder projecting out 15 feet be clear of all objects and personnel at the point where the plenum exits the building Refer to the Plenum Application Guide 1VAL108001 AP for more details Arc chamber and plenum 01 Low voltage instru ment module isolated for maximum safety when wo...

Page 20: ...AWG 4 8 BYZ S 4 AWG 4 8 BYZ S 500 MCM 4 8 BYZ S 750 MCM 4 8 BYZ L 1000 MCM 2 hole 2 4 BYZ S 1000 MCM 4 hole 1 2 BYZ S Bifurcated lug pad requires 93 5 inch depth Available frame types One high frames Dimensions Frame Width in Height in Depth in 2000 3000 4000 A breaker 36 129 5 86 5 or 93 5 All other frames 36 118 86 5 or 93 5 Height includes plenum Options Ground CTs Surge arrestors Distribution ...

Page 21: ...pad per phase GCT option 2 AWG 4 BYZ S 4 AWG 4 BYZ S 500 MCM 4 BYZ S 750 MCM 4 BYZ L 1000 MCM 2 hole 2 BYZ S 1000 MCM 4 hole 1 BYZ S Available frame types Two high frames Dimensions Frame Width in Height in Depth in 2000 3000 A breaker 36 129 5 86 5 or 93 5 All other frames 36 118 86 5 or 93 5 Height includes plenum Options Ground CTs Surge arrestors Distribution Intermediate Station Surge capacit...

Page 22: ... compartments with a 19 inch instru ment compartment in between for one breaker and an auxiliary device in a single frame or one 38 inch compartment with 19 inch low voltage and two 19 inch auxiliary compartments for equipment with short circuit ratings less than 40 kA Cable termination information Cable size of terms single pad per phase of terms bifurcated pad per phase GCT option 2 AWG 4 8 BYZ ...

Page 23: ...22 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR Available frame types Breaker and auxiliary frames All ratings breaker above Less than or equal to 31 5 kA breaker below ...

Page 24: ...TECHNIC AL AND APPLIC ATION GUIDE 23 Available frame types Breaker and auxiliary frames Less than or equal to 31 5 kA Greater than or equal to 40 kA breaker below Breaker below Breaker above ...

Page 25: ...24 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR Available frame types Breaker and auxiliary frames Greater than or equal to 40 kA breaker above ...

Page 26: ...3 5 Height includes plenum Options Space heaters Description The two high auxiliary frame consists of compart ments with a 19 inch instrument compartment in between multiple auxiliary devices per frame All ratings 01 CPT control power transformer 02 LVC low voltage compartment instru ment compartment 03 PT potential transformer 04 DOF drawout fuse ...

Page 27: ...26 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR Available frame types Auxiliary frames Less than or equal to 31 5 k A ...

Page 28: ...TECHNIC AL AND APPLIC ATION GUIDE 27 Available frame types Auxiliary frames Less than or equal to 31 5 kA Greater than or equal to 40 kA ...

Page 29: ...28 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR Available frame types Auxiliary frames Greater than or equal to 40 kA ...

Page 30: ...TECHNIC AL AND APPLIC ATION GUIDE 29 Typical arrangements Main Tie Main 1200 A 2000 A up to and including 31 5 kA Arrangements are the same for 5 8 25 and 15 kV ...

Page 31: ...30 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR Typical arrangements Main Tie Main 3000 A and 4000 A up to and including 31 5 kA Arrangements are the same for 5 8 25 and 15 kV ...

Page 32: ...TECHNIC AL AND APPLIC ATION GUIDE 31 Typical arrangements Main Tie Main 3000 A and 4000 A 40 kA and 50 kA Arrangements are the same for 5 8 25 and 15 kV ...

Page 33: ...32 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR Typical arrangements Main Tie Main 1200 A 2000 A 40 kA and 50 kA Arrangements are the same for 5 8 25 and 15 kV ...

Page 34: ...TECHNIC AL AND APPLIC ATION GUIDE 33 Typical arrangements Main with Feeders 1200 A 2000 A 40 kA and 50 kA Arrangements are the same for 5 8 25 and 15 kV ...

Page 35: ...34 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR Typical arrangements Main with Feeders 3000 A and 4000 A up to and including 31 5 kA Arrangements are the same for 5 8 25 and 15 kV ...

Page 36: ...ar switchgear two high frames Circuit breaker 1200 A 1200 A SECTION VIEW 1200A 1200A FLOOR PLAN CONTROL CABLE ENTRY AREA 4 1 2 13 UNC ANCHOR BOLTS PER FRAME POWER CABLE ENTRANCE 18 5 469 9 mm 27 685 8 mm 4 5 114 3 mm 4 5 114 3 mm 36 914 4 mm 86 35 2193 29 mm 93 35 2371 09 mm 0 375 9 52 mm 0 375 9 52 mm 25 5 647 7 mm ...

Page 37: ...ear breaker and auxiliary Circuit breaker 2000 A with PTs greater than 40 kA SECTION VIEW 2000A PT COMPT CLOSED OPEN FLOOR PLAN CONTROL CABLE ENTRY AREA 4 1 2 13 UNC ANCHOR BOLTS PER FRAME POWER CABLE ENTRANCE 18 5 469 9 mm 27 685 8 mm 4 5 114 3 mm 4 5 114 3 mm 36 914 4 mm 86 35 2193 29 mm 93 35 2371 09 mm 0 375 9 52 mm 0 375 9 52 mm 25 5 647 7 mm ...

Page 38: ... auxiliary Circuit breaker 2000 A with PTs less than 31 5 kA SECTION VIEW 2000A CLOSED OPEN PT COMPT PT COMPT FLOOR PLAN CONTROL CABLE ENTRY AREA 4 1 2 13 UNC ANCHOR BOLTS PER FRAME POWER CABLE ENTRANCE 18 5 469 9 mm 27 685 8 mm 4 5 114 3 mm 4 5 114 3 mm 36 914 4 mm 86 35 2193 29 mm 93 35 2371 09 mm 0 375 9 52 mm 0 375 9 52 mm 25 5 647 7 mm ...

Page 39: ... SafeGear switchgear one high frames Circuit breaker 3000 A or 4000 A SECTION VIEW 3000A CLOSED OPEN FLOOR PLAN CONTROL CABLE ENTRY AREA 4 1 2 13 UNC ANCHOR BOLTS PER FRAME POWER CABLE ENTRANCE 18 5 469 9 mm 27 685 8 mm 4 5 114 3 mm 4 5 114 3 mm 36 914 4 mm 86 35 2193 29 mm 93 35 2371 09 mm 0 375 9 52 mm 0 375 9 52 mm 25 5 647 7 mm ...

Page 40: ...neups 40 inches for 2000 A 3000 A lineups Additional clearance may be eneded during assembly of the plenum Indoor and outdoor applications SafeGear is available in indoor construction For outdoor applications SafeGear is installed in a sheltered aisle or PDC building Both applications offer the flexibility of one high or two high construction Standard indoor construction meets the requirements of ...

Page 41: ...pth 6 00 Bolt Material ASTM A 193 Grade B7 Base Material Cracked concrete 4000 fc 4000 psi h 8 at 32 F Installation Hammer drilled hole Installation condition Dry Seismic Washer ABB Part No 926396A00 Seismic applications for SafeGear in indoor shel tered aisle or PDC applications require special an choring in order to assure proper installation in seismic regions SafeGear is qualified to the fol l...

Page 42: ...s Seismic applications BUS CABLE COMPT CIRCUIT BREAKER COMPT BUS CABLE COMPT BUS CABLE COMPT FRONT OF SWGR REAR OF SWGR CIRCUIT BREAKER COMPT CIRCUIT BREAKER COMPT 02 Bolt Location for Ip 1 5 2X Front on each frame 2X Middle on each frame 2X Rear on each frame 02 ...

Page 43: ...C RESISTANT SWITCHGE AR Civil engineering details Seismic applications BUS CABLE COMPT CIRCUIT BREAKER COMPT FRONT OF SWGR REAR OF SWGR TYPICAL FRAME TYP 4 PLACES 03 Weld Location for Ip 1 0 2X Front on each frame 2X Rear on each frame 03 ...

Page 44: ... ONE TWO OR FRAME SHIPPING SPLIT THREE FRAME SHIPPING SPLIT INTERMEDIATE ONE TWO OR THREE FRAME SHIPPING SPLIT 10 04 Weld Location for Ip 1 5 Left End Shipping Split 2X Front on each frame 3X Left and Right side of shipping split 2X Rear on eachframe Intermediate Ship ping Split 2X Front on each frame 3X Right side of shipping split 2X Rear on each frame Right End Shipping Split 2X Front on each f...

Page 45: ...to 50 of the empty weight of the module Typical frame weights are listed in the adjoining ta ble Weights include all modules and components previously listed Frame weights calculation All frame styles Basic frame configuration Circuit breaker rating Weight lbs kg One circuit breaker 1200 2023 918 2000 2441 1107 3000 3331 1511 4000 3461 1570 Two circuits breakers 1200 1200 3013 1367 1200 2000 3302 ...

Page 46: ...otal 1200 A CB 413 713 1426 2000 A CB 845 1145 2290 3000 A CB 845 1520 3040 4000 A CB 1502 2702 5404 CTs sets of 3 600 5 23 45 1200 5 45 90 2000 5 75 150 3000 5 113 225 4000 5 150 300 Auxiliary frames 150 300 Main bus per frame 1200 A 108 216 2000 A 180 360 3000 A 115 230 4000 A 204 409 CPTs CPT 5 KVA 1 Phase 60 120 CPT 10 KVA 1 Phase 115 230 CPT 15 KVA 1 Phase 175 350 CPT 25 KVA 1 Phase 295 590 C...

Page 47: ...46 SAFEGEAR 5 15 K V UP TO 50 K A ARC RESISTANT SWITCHGE AR ...

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