ABB UniGear ZS3.2 Instruction Manual Download Page 3

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Table of contents

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1 Summary

2 Technical data

3 Switchgear panel structure

and equipment installed

4 Dispatch and storage

5 Assembly of the switchgear

at site

6 Operation of the switchgear

7 Maintenance

8 Product quality and

environmental protection

Summary of Contents for UniGear ZS3.2

Page 1: ... UniGear ZS3 2 Air insulated medium voltage switchgear INSTRUCTION MANUAL UniGear ZS3 2 Air insulated medium voltage switchgear Safety Reliability Flexibility Economy ...

Page 2: ......

Page 3: ...31 032 038 039 043 044 1 Summary 2 Technical data 3 Switchgear panel structure and equipment installed 4 Dispatch and storage 5 Assembly of the switchgear at site 6 Operation of the switchgear 7 Maintenance 8 Product quality and environmental protection ...

Page 4: ...cording to the rules of good working practice and safety in the work place are constructed Strictly follow the information given in this instruction manual Dangerous Pay special attention to the danger notes indicated in the manual by the following symbol Check that the rated performance of the apparatus is not exceeded during service Check that the personnel operating the apparatus have this inst...

Page 5: ...ce conditions 1 3 1 Normal service conditions The switchgears are fundamentally designed for the normal service conditions for indoor switchgears IEC publication 62271 1 The following limit values among others apply Ambient temperature Maximum 40 C Maximum 24 h average 35 C Minimum according to minus 15 indoor class 15 C Humidity Highest average value measured over 24 hours Relative humidity 95 Hi...

Page 6: ...ated lightning impulse withstand voltage Rated frequency Rated current of busbars Rated current of tee offs circuit breaker Rated peak withstand current 1 Rated short circuit breaking Current of circuit breaker Rated short time current 4 s 1 Auxiliary voltage IEC Chinese GB 36 40 5 70 95 170 185 50 1250 1600 2000 2500 3150 1250 1600 2000 2500 3150 3 63 80 25 31 5 25 31 5 DC 2 110 220 AC 110 220 Ru...

Page 7: ...ew 2 2 Dimension UniGear ZS3 2 1600 A section view C D R L1 Y L2 B L3 Service Position Test Position 2350 30 2500 35 450 2400 A B 2400 1200 55 47 A Circuit breaker compartment B Low voltage compartment C Busbar compartment D Cable connection compartment 2 1 2 2 ...

Page 8: ...ed together This method of construction prevents them from melting through if an arc fault should occur All heads of the structure bolts do not stick up the fitting surface on the side walls as result of embossing processing used Thanks to that it is possible to remove the middle panel of the switchgear without removing the adjacent panels The separately fitted low voltage compartment B is designe...

Page 9: ... 58 In conjunction with bushings 29 panel by panel partitioning is realised Cable connection compartment Figures 3 6 5 5 5 6 6 10 to 6 12 Current transformers and an earthing switch with manual operating mechanisms are located here Installation of surge arrestors is possible Multiple parallel power cables can also be entered without difficulty The cable sealing ends 16 can be fitted in particularl...

Page 10: ...rly short circuits within the parameters of their technical data Vacuum circuit breakers have particular ad switching frequency in the working current range and or where a certain number of short circuit breaking operations are expected Type VD4 vacuum circuit breakers are suitable for autoreclosing and have exceptionally high operating reliability and long life The vacuum circuit breakers designe...

Page 11: ...e arrester Protection of medium voltage AC networks against both multiple atmospheric and switching overvoltages as well as Very Fast Transients VFT Suitable for instance for the protection of transformers cables motors and other medium voltage equipment 3 5 4 Eearthing switch Earthing switches of Series EK6 are determined for indoor installation and fitted with snap action operating mechanisms fo...

Page 12: ...12 UniGear ZS3 2 INSTRUCTION MANUAL 3 5 UniGear ZS3 2 front view 3 5 ...

Page 13: ...g plug 10 3 Interlocking arm for wiring plug 14 Earthing switch operation mechanism 14 1 Hexagonal shaft 28 3 3 1 Y L2 B L3 HEATING PLATE R L1 29 30 1 29 1 5 6 20 2 3 2 30 2 23 16 9 1 21 17 2 19 17 A B C D 35 1 1 1 2 30 50 2 14 14 1 50 52 51 35 2 10 10 1 10 2 10 3 16 Cable sealing ends 17 Floor cover plate 17 2 Reducer ring 19 Main earthing bar 20 1 Spout above 20 2 Spout below 21 Cable clamp 23 C...

Page 14: ...9 1 50 50 2 14 14 1 14 2 51 10 30 1 Rear cover above 30 2 Rear cover below 19 1 Earthing rail 35 1 Hinged shutter system above 35 2 Hinged shutter system below 35 3 Fishplate for inserting a padlock 43 1 Duct cover for control cables 44 Heater Control wiring plug connection engaged 10 Control wiring plug connector 14 Earthing switch operation mechanism 14 1 Hexagonal shaft 14 2 Slide 50 Withdrawab...

Page 15: ...it breaker compartment withdrawablepart removed hinged shutters opened 3 14 Withdrawable part with circuit breaker HD4 operation side 3 11 3 13 3 12 3 14 Control wiring plug connection engaged Interlocking arm not in blocking position 10 1 Control wiring socket 10 2 Control wiring plug 10 3 Interlocking for control wiring plug disengaged 20 1 Spout above 20 2 Spout below 25 1 Contact pin 1600 A 10...

Page 16: ...erating side 3 17 Withdrawable part with metering unit left and operator s side view 3 15 3 17 3 16 50 2 57 1 57 8 57 2 50 1 50 8 50 2 9 2 50 50 3 50 4 50 1 Earthing contact 50 2 Front partition plate 50 8 Wheel 57 1 Upper contact arm 57 2 Lower contact arm 57 3 Contact system 57 8 Embedded pole 9 2 Voltage transformer 50 Frame of the withdrawable part 50 2 Front partition plate 50 3 Pin for openi...

Page 17: ...individual panels The switchgear panels are each fitted with four lifting lugs Transport switchgear panels upright Only ever carry out loading operations when it has been ensured that all precautionary measures to protect personnel and materials have been taken and using a Crane Fork lift truck and or manual trolley jack The circuit breaker or metering truck should be transported separately the tr...

Page 18: ...tchgear panels with simple packaging or no packaging A dry and well ventilated storeroom atmosphere in accordance with IEC 62271 200 Room temperature which does not fall below 15 C No other detrimental environmental influences Store switchgear panels standing upright Do not stack switchgear panels Do not remove or damage the packaging Loosely cover unpackaged switchgear panels with plastic film to...

Page 19: ...personnel and should if possible be aligned and inspected under the supervision of a ABB specialist Installation of the foundation frame If the foundation frame consists of several part bolt these together at the prepared joint locations using links in the specified sequence and so as to achieve a level surface Place the foundation frame precisely in the specified position on the concrete floor in...

Page 20: ...lts Structural data Table for figure 5 1 and 5 2 Rated voltage Panel type Panel equipment Panel width Aisle width front side of panel 1 Aisle width rear side of panel 1 Assembly openings in ceilings Width Length in doors Width Height 2 Panel weight Ceiling load kV mm mm mm mm mm mm mm kg kg m2 36 40 5 UniGear ZS3 2 Withdrawable 1200 2000 1500 1400 2800 1400 2600 1200 to 3000 1000 1 Determined by V...

Page 21: ...he cover until it clicks into place 5 5 Connection of the power and control cables Figures 3 6 5 5 and 5 6 Insert cut to length and strip the power cable Release floor cover and open the control cable duct on the left hand side Prepare and secure cable sealing ends 16 in accordance with the manufacturer s instructions Connect the cable cores to the prepared connection points 23 with strain relief ...

Page 22: ...600 1600 1200 1200 600 600 1000 1340 300 60 33 300 300 33 33 60 60 M12 4X 35 50 300 105 480 130 1000 665 30 260 30 940 940 280 280 280 280 B A C1 C1 C1 C2 C2 2565 2000 E A Operator aisle B Inspection aisle C1 Opening for power cables C2 Opening for control cables instead of individual openings continuous openings or drilled holes are possible E Points for fixing the switchgear panel on the floor f...

Page 23: ...ion aisle 3 Opening for control cables instead of individual openings continuous openings or drilled holes are possible 5 Openings for power cables 7 Panel type UniGear ZS3 2 31 5 kA 8 Power cables 9 Projecting of floor frame 5 12 mm above finished floor level 10 Conductor to main earthing bar 11 Screen 50 mm to 60 mm 12 Hight of the cable cellar to be determined by the client 14 Guiding ramp opti...

Page 24: ...max 4 parallel cables possible 5 6 Partial view into the cable connection compartment prepared for connection of two parallel cables 5 7 View into the busbar compartment 5 4 5 5 5 6 5 7 3 11 3 1 20 1 1 11 1 9 1 10 1 5 28 1 3 1 3 Aperture for main earthing bar 1 5 Lifting lug 1 9 Threaded bushing for switchgear assembly 1 10 Bores bushings for switchgear assembly 1 11 Cut out for control wiring bus...

Page 25: ...h double D profile tee off 1600 A 5 9 Bushings with busbar mountings for busbar system with double D profile tee off 2000 A to 3150 A 5 8 5 9 3 Busbar 3 1 Tee off conductor busbar side 25 5 Sealing ring 28 Bushing plate 29 Busbar bushing 29 2 Busbar mounting for double conductor 84 Partitioning ...

Page 26: ...gle rectangular copper busbar with single branch bar system 1600 A 5 10 8 3 Contact spring for rectangle busbar 8 4 Socket head bolt M6x16 8 5 Dished washer DIN 6796 8 6 Nut M6 8 7 Busbar mounting for single conductor 8 3 8 4 8 5 8 6 8 7 8 7 8 3 ...

Page 27: ...mation before installation 3 Busbar 29 3 Contact spring b Pull open the contact spring 29 3 insert it into the hole of busbar 3 3 Busbar 29 3 Contact spring c Turn the contact spring 29 3 out from hole of busbar 3 3 Busbar 29 3 Contact spring d Press the contact spring 29 3 turn it down and make sure that the bottom plane is parallel to the busbar 3 3 Busbar 29 3 Contact spring ...

Page 28: ...3 Busbar 29 3 Contact spring f Finally using multimeter to check the contact resistance between busbar 3 and metal tube 29 4 of busbar bushing 29 The contact resistance must be less than 5 ohm Please recheck the installation correctness from step a to step e if thecontact resistance greater than 5 ohm until it meet the test requirement 3 Busbar 29 Busbar bushing 29 3 Contact spring 29 4 Metal tube...

Page 29: ...ing for double conductor 29 3 Contact spring 29 4 Metal tube b Installation position of the phase barriers viewed from top 28 Bushing plates 29 Busbar bushing 29 2 29 4 29 3 3 12 The shrink on sleeves must be cut out above the bores in the busbars The bores are required for the inset of the contact spring 29 3 5 14 Caution The contact arm springs 29 3 or 8 3 must be inserted during the installatio...

Page 30: ... bushing 58 Insulation cover 58 5 Lid of cover 163 M10 socket head bolt 164 M10 nut 165 10 mm dished washer a Arrangement for tee off current up to 1600 A and 1600 A or 3150 A busbar current During assembly cut out the insulation cover and lid to fit cross section of the feeder or busbar 3 Busbar 3 1 Tee off conductor 3 5 Spacer plate 15 mm 3 6 Spacer plate 10 mm 58 Insulation cover 58 5 Lid of co...

Page 31: ...rs 5 18 Guiding ramp for circuit breaker insertion optional The rail on the guiding ramp must be in line with the guiding rail in the UniGear ZS3 2 panel Cut place for abzweig schienen system 2x100x10 Cut place for sammel schienen system D 100 5 17 5 18 58 5 Lid for cover ...

Page 32: ...ormers and cables etc Switch on the auxiliary and control voltage Carry out test operations of switching devices manually or by electrical control and simultaneously observe the relevant position indicators Check mechanical and electrical interlocks for effectiveness without using force Set the protective devices in the switchgear to the required values and check their function with test equipment...

Page 33: ...d condition indications in the secondary area and watch for any irregulatities 6 2 2 Circuit breaker Figures 6 1 to 6 5 For operation refer to Manual BA 483 02E VD4 vacuum circuit breaker on withdrawable part or 1YHA000046 en HD4 SF6 circuit breaker 6 2 3 Earthing switch Figures 3 2 6 7 to 6 12 For operation refer also to instruction manual 1YHA000063 en EK6 earthing switch The earthing switch typ...

Page 34: ...he instructions for the particular indicator for your switchgear system Interface testing Perform an interface test as a functional test on all coupling components e g with interface tester KSP The interface test is a repeat test as specified in IEC 61243 Part 5 Always follow the details given in the instructions for the particular indicator for your switchgear system 6 3 2 Testing of in phase con...

Page 35: ...ker by turning the double bit key approx 15 clockwise ON or approx 15 anti clockwise OFF 51 1 51 2 51 52 54 1 50 4 50 7 55 7 55 4 55 5 50 6 55 8 55 6 128 6 1 6 2 6 3 6 4 50 4 Guide cam 50 6 Front cover plate right hand side 50 7 Front coverplate left hand side 51 nterlock yoke 51 1 Catch pin spring loaded 51 2 Sliding handle 52 Spindle 52 1 Square spigot 146 Hand cranck 54 ON OFF operating shaft 1...

Page 36: ... 51 4 Blocking shaft interlocking circuit breaker and earthing switch 122 Operating lever for earthing switch 128 Charging lever for circuit breaker 145 Three bit key ON OFF operation 146 Hand 128 145 146 122 cranck for moving the withdrawable part 10 Control wiring plug connector closed 10 1 Control wiring socket 10 2 Control wiring plug 10 4 S8 Limit switch for test position indicator 10 5 S9 Li...

Page 37: ...10 6 9 14 3 Auxiliary switch Q8S1 earthing switch OFF 14 4 Auxiliary switch Q8S2 earthing switch ON 14 5 Interlocking rod Earthing switch withdrawable circuit breaker unit 5 Insulated separating plate 6 1 Bearing bracket 6 3 Short circuit bridge 6 4 Pair of earthing blades 6 6 Bevel gear mechanism not belonging to the earthing switch 6 7 Operating shaft 6 10 Fixed earthing contact 14 1 Hexagonal s...

Page 38: ...N MANUAL 6 11 Earthing switch EK6 mounted in the cable connection compartment shown in closed position 6 12 Bevel gear mechanism and earthing switch EK6 in open position 6 11 6 12 58 6 10 6 4 14 1 6 2 6 5 6 1 6 5 6 7 6 6 6 8 14 1 ...

Page 39: ...46 en Earthing switch EK6 9AKK1074920025 If necessary further details can be taken from the technical documentation for the switchgear instal lation including for example any agreed special service conditions 7 2 Inspection and servicing Inspection Inspection of the switchgear should be carried out approximately every two to four years depending on the service conditions and local environment in a...

Page 40: ...ssary Observe the maintenance instructions in the manuals for the individual switch types 7 3 Repair 7 3 1 Switchgear surface Carry out repair work immediately after a defect has been discovered Completely remove all rust from damaged paintwork areas on steel sheet and other steel parts by mechanical means e g with a wire brush Lightly grind the surrounding paint coat and carefully degrease the en...

Page 41: ...then operate when the hand crank has a remaining angle of 60 to turn up to the stop 7 4 2 Testing of interlock conditions Figures 6 1 to 6 9 1 The withdrawable part must only be movable from the test disconnected position into the ser vice position when the circuit breaker is open and the earthing switch is open Check the following conditions individually With the circuit breaker closed insertion ...

Page 42: ...ear panel 7 5 1 Auxiliary switch setting on the earthing switch Figures 6 8 and 6 9 1 There must be a run on of 0 5 mm in the fully operated position before the plunger reaches the stop for safety reasons 2 Limit position auxiliary switch Q8S2 for earthing switch ON must be operated immediately after the dead centre position of the toggle spring mechanism is reached in the closing process and the ...

Page 43: ...t system from the auxiliary arbour onto the contact arm and engaging it here 130 1 130 57 13 57 6 57 7 130 1 130 57 13 57 6 57 7 127 1 1 2 127 57 3 127 1 1 2 127 57 3 7 1 7 2 7 3 7 4 1 Left front view 2 Right rear view 57 13 Contact system 2000 A to 3150 A 57 6 Internal annular tension springs 57 7 External annular tension springs 130 Auxiliar arbour 2000 A to 3150 A 130 1 Plug 2000 A to 3150 A 57...

Page 44: ...ate subsequent recycling or disposal at the end of product life During disposal of the product it is always necessary to act in accordance with local legal requirements in force The following methods of disposal Disposal can either be carried out thermally in an incineration plant or by storing on a waste site Raw material Metal material Fe Cu Al Ag Zn W others Thermoplasts Epoxy resin Rubber Oil ...

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Page 48: ...iEr Road Xiang an District Xiamen Fujian 361101 Tel 0592 602 6033 Fax 0592 603 0505 ABB China Customer Service Hot Line TEL 800 820 9696 400 820 9696 mail cn ep hotline abb com www abb com Copyright 2019 ABB All rights reserved Specifications subject to change without notice ...

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