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ABB UniGear ZVC, Installation, Operation And Maintenance Instructions Manual, Page: 49 / 56

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ABB UniGear ZVC Installation, Operation And Maintenance Instructions Manual Download Page 49

Fuse striker to this end (front) 

Remove these 4 screws
(for each fuse) 

Fuses

9.4.3.3 Fuse replacement V7/ZVC

If a fuse is blown we recommend that all fuses 
on the truck are replaced. Unbolt the four 
screws connecting each fuse to the moulding 
and remove each fuse. Replace with new fuses 
ensuring that the fuse’s striker pin is nearest 
the front of the truck and the majority of the 
fuse is facing into the moulding. Where two 
fuses per phase are used, the fuses are fitted, 
in the same way, back-to-back. Respect the 
torque limits on the label (25 Nm).

9.4.3.4 Racking blocking coil replacement for 

V7/ZVC

Ensure the voltage rating of the replacement 
matches that of the original racking blocking 
coil. Follow the procedure described in the 
illustrations shown.

1.  Remove the truck from the 

Panel to the service trolley 
following the safety 
procedures in the operating 
manual. Securely place the 
truck on a work bench.

2.  Undo four M4 pan head 

screws with spring 
washers & remove 
sub-assembly (when 
replacing sub-assembly 
tighten each screw to 
1.4 Nm).

M A I N T E N A N C E

49

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9/4 Fuses module
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9/5 ZVC racking 
blocking coil 
replacement 1 of 2

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9/4

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9/5

Summary of Contents for UniGear ZVC

Page 1: ...UniGear ZVC Installation operation and maintenance instruction manual Medium voltage products UniGear ZVC Installation operation and maintenance instruction manual Safety Reliability Flexibility Economy ...

Page 2: ......

Page 3: ...43 044 045 051 052 053 054 1 Safety precautions 2 Description 3 Technical data 4 Panel design and equipment 5 Dispatch and storage 6 Assembly of switchgear at site 7 Operation of the switchgear 8 Commissioning 9 Maintenance 10 Troubleshooting 11 Environmental protection ...

Page 4: ...n sheet before installing operating and maintaining your UniGear ZVC For safe operation the appropriate Chinese or International Standards should be applied Keep the instruction manual accessible to all personnel involved in installation operation and maintenance This instruction sheet should be available for reference wherever UniGear ZVCs are used Keep this instruction sheet in a location where ...

Page 5: ...le for normal operating conditions for indoor switchgear and switchboards in accordance with IEC The following limit values among others apply The maximum site altitude is 1000 m above sea level For higher site altitude refer to order related data 2 3 2 Special operating conditions The switchgear is suitable for operation in climate of Wda type according to IEC Special operating conditions must be...

Page 6: ...ception in normal operating conditions for indoor switchgear Preventive action e g fitting electric heaters must be taken in consultation with the manufacturer to avoid this condensation phenomenon and any resulting corrosion or other adverse effects The control of the heaters depends on the relevant project and details must be taken for the order documents 2 1 Curve for determination of the altit...

Page 7: ... rated normal current HV fuse type CT rated secondary current 1 On request 3 1 Electrical data kV kV kV Hz A A kA kA kA kA A A 3 6 10 40 50 60 4000 400 125 50 3 s 31 5 12 5 1 s 200 400 Tag type to BS2692 1986 type II 454 mm centres maximum 1 7 2 20 32 1 60 3 2 Resistance to internal arc faults The internal arc fault withstand capability is up to 50 kA for 1 s with 125 kAp Refer to the general arra...

Page 8: ...g fused vacuum contactor 1554 mm deep panel with busbars 4000 A excluding fused vacuum contactor V7 ZVC withdrawable vacuum contactor with HV fuses Standard gas duct per panel End covers per switchboard Mass kg 400 550 90 40 140 Depth C mm Power cable entry Control cable entry Gas duct 1304 Bottom entry rear access Bottom entry front access Yes No Top entry rear access Top entry front access No 15...

Page 9: ...he withdrawable fused contactor The withdrawable fused contactor is anchored to the cubicle with a truck lock operated by a double bit key The truck is moved between ISOLATED and SERVICE position by a racking screw Self aligning tulip contacts are located in epoxy resin spout bushings behind a metal partition plate Automatic metal shutters covering the busbar and cable spout bushing openings are a...

Page 10: ...eparated by epoxy resin phase barriers on the cable terminating module Complex combinations of cable type and size zero sequence CT cable clamps glands surge arresters and capacitive insulators must be decided at the time of manufacturer 4 1 5 Low voltage compartment Figures 4 12 6 19 The compartment contains control and protection equipment suitable for both conventional or microprocessor control...

Page 11: ... air cushion remains between these walls when the panels are joined together door screws 4 in total double bit key The enclosure is completed a Above by top mounted pressure relief flaps which according to the rated branch conductor current are made of sheet steel or expanded metal and b Below by means of floor mounted sheet steel cable entry gland plate The pressure relief flaps are secured with ...

Page 12: ...rear wall of busbar compartment A mounting plate with shutters and horizontal partition and form part of the internal partitioning The low voltage compartment for the secondary equipment is completely protected from the high voltage area thanks to its steel sheet casing On the two ends of the switchboard end covers ensure good appearance and are mechanically and thermally arc fault proof should su...

Page 13: ...le horizontal partition End cover PANEL DESIGN AND EQUIPMENT 13 4 7 Typical top chimney arc duct arrangement 4 8 Switchboard with bolted end cover 4 9 View into contactor compartment with door open 4 7 4 9 4 8 ...

Page 14: ... Busbar Lower shutter Cable Secondary contacts plug Provision for padlock 14 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS 4 10 View inside contactor compartment 4 11 Lower shutter may be secured with padlock to prevent unauthorized operation 4 10 4 11 ...

Page 15: ...age compartment Enclosure Pressure relief flap Pressure relief flap Branch conductor Busbar Earthing switch Current transformers Voltage transformer Removable partition Control wiring plug connector Mounting plate Top shutter Lower shutter Withdrawable part Earthing switch operating mechanism Gland plate Main earthing bar Ventilation grid Emergency opening pushbutton Cable tags A B C D In the SERV...

Page 16: ...ontactor compartment door is open The contactor compartment door cannot be opened if the fused contactor is in SERVICE or in an undefined position The contactor cable compartment door cannot be opened if the earthing switch is open The contactor cable compartment door cannot be closed if the earthing switch is open 4 3 3 Locking devices Figures 4 10 4 11 4 12 The shutters can be secured independen...

Page 17: ...ZVC truck consists of an epoxy resin moulding containing fuse holders that accept parallel HV fuses vacuum interrupters the moving apparatus the electromagnet the multi voltage control feeder and auxiliary accessories HV fuses Truck guide Contact spout Control voltage transformer Truck lock Racking spindle Contactor ON OFF indicator Fuse blown indicator Truck position indicator Operation counter E...

Page 18: ...able Refer to shipping sections in the general arrangement drawing Note the location of the power cable entry in the contract drawings Pay special attention to clauses 6 4 to join panels and 6 5 to install busbars 4 7 2 Slip ring induction starter ROTOR STATOR Note external secondary resistor Slip ring induction ZVC SRI Ratings Circuit full load current Rated frequency Rated voltage Width Depth 1 ...

Page 19: ...responding total panel height 2400 and 2596 mm available Refer to shipping sections in the general arrangement drawing Note the location of the power cable entry in the contract drawings Pay special attention to clauses 6 4 to join panels and 6 5 to install busbars Double feeder ZVC DF Ratings Circuit full load current Rated frequency Rated voltage Rated frequency withstand Rated tmpuse withstand ...

Page 20: ... microswitch bracket Pressure relief flap made of steel sheet Rupture bolt plastic Truck compartment microswitch bracket 4 9 Resistance to internal arc faults The switchgear has been successfully tested in accordance with IEC Several arc control measures to meet the AFLR rating are adopted to suit the design of the switchroom The specific variation and installation parameters are given in the gener...

Page 21: ...ley jack Loading by crane Fit lifting ropes of appropriate load capacity with spring catches eyebolt diameter 30 mm Keep an angle of at least 60 from the horizontal for the ropes leading to the crane hook 5 4 Delivery The responsibilities of the consignee when the switchgear arrives at site include but are not limited to the following Checking the consignment for completeness and lack of any damag...

Page 22: ...es with safety hooks On completion of the operation and in any case before putting into service unhook the lifting accessories from the frame During handling take great care not to stress the insulating parts of the contactor truck Caution The contactor truck must be handled as recommended Should it be necessary to use this technique put the contactor onto a pallet or a sturdy supporting surface I...

Page 23: ...oor frame plinth precisely in the specified position on the concrete floor in accordance with the general arrangement drawing Use the floor frames plinth as a drilling template to install the leveling screws Carefully align the floor frame plinth horizontally over the entire surface and to the correct height by screwing up the jacking screws by an appropriate amount and using a leveling instrument...

Page 24: ...nderside of chassis Plate to be painted the same as chassis Double longitudinal members 3747 510 3747 External building height 3025 Internal ceiling height 2152 250 325 75 24 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS 6 1 Typical floor frame plinth for UniGear ZVC and ZS1 switchboard Switchboard holding down bolts to be spotted through and drilled and tapped on site Mounting is by M12x25LG HT bolts 6 1 ...

Page 25: ...5 150 145 1304 75 100 843 311 34 M12 Bolts 87 5 8 5 45 325 87 5 150 40 245 40 Power cables bottom entry Control cables bottom entry Standard version ASSEMBLY OF SWITCHGEAR AT SITE 25 6 2 Typical floor plan drawing which is applicable for 1304 mm depth panel Front access bottom power cable entry 6 3 Typical floor plan drawing which is applicable for 1304 mm depth panel Rear access bottom power cabl...

Page 26: ...nchoring bolts to concrete floor Clean the installation area On the slab visibly trace the perimeter of all the units making up the switchboard taking the minimum wall and obstacle clearances into account Level the floor both longitudinally and transversally Drill the floor at the foreseen fixing points referring to the slab drilling drawings To make the holes use a hammer drill Insert the expansi...

Page 27: ...e them with suitable protection Observe the interlocks and operation sequences when removing it Transport the switchgear panels to the prepared installation point following the layout shown on the general arrangement drawing Remove the lifting lugs after the panels are in their final position Refit the hardware after removing the lifting lugs It is advisable to start from the centre of the switchb...

Page 28: ...10x20 Hexagon head screw M10 Belleville washer Torque 50 Nm 3 off M8x16 Hexagon head screw M8 Belleville washer Torque 25 Nm Right hand side of cubicles provided with captive nuts in all joining points Refer to 6 11 for the hardware details and tightening torque 28 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS 6 11 Cubicle joining hardware 6 11 ...

Page 29: ...sile 8 8 nuts spacers when required and two Belleville washers per bolt to a tightening torque of 50 Nm 3150 A 4000 A Busbar 2x D100 12 copper bar 80x60x15 mm copper spacer at intermediate and end joints M10x60 mm high tensile hexagon socket head screw M10 hexagon nut grade 8 0 M10 Belleville washers under screw and nut spacer joining boot bus riser module busbar insulation busbar connection right...

Page 30: ...er screw and nut 1600 A 2000 A 2500 A Busbar 2x 80x10 mm round edge copper bar 80x60x15 mm copper spacer at intermediate and end joints Torque 50 Nm M10x60 mm high tensile hexagon socket head screw M10 hexagon nut grade 8 0 M10 Belleville washers under screw and nut DETAIL X DETAIL Y 30 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS 6 14 3150 A 4000 A Busbar arrangement 6 15 1600 A 2000 A 2500 A Busbar arran...

Page 31: ...50 A Busbar arrangement 6 16 1250 A Busbar 1x 80x10 mm round edge copper bar Copper spacer not required Torque 50 Nm M10x35 mm high tensile hexagon socket head screw M10 hexagon nut grade 8 0 M10 Belleville washers under screw and nut DETAIL Z ...

Page 32: ...ed connections This means that quality of the copper busbar connections does not change depending on the operating time and therefore it is not necessary to inspect tightness of busbar connections regularly But this is on condition that correct assembly is carried out as described above and especially that all connections are tightened with the prescribed torque We recommend only inspecting tightn...

Page 33: ...t the cables into the control wiring duct 6 18 on the left hand Fasten the control cables at the top end of the duct strip the insulation and convey cable control cores into the low voltage compartment D 4 12 Connect control cables to the terminal strip according to the circuit diagram Make the control wiring connections to adjacent panels using bushing 6 19 ASSEMBLY OF SWITCHGEAR AT SITE 33 6 18 ...

Page 34: ...n The standard method for entry of power cables in the switchgear is shown in 6 20 and 6 21 The cables are conveyed from below through a gland plate 34 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS 6 20 View with optional surge arrestor capacitive insulators and zero sequence current transformer 6 21 Rear bottom power cable entry configuration 6 20 6 21 ...

Page 35: ... cable connecting bars or tags 6 18 from the gland plate 4 12 The bars are equipped with M10 nuts The earthing of cable screens is carried out directly to the earth bar adjacent to the cable entry position in the floor It is possible to place three fixed mounted surge arresters in the cable compartment It is also possible to install voltage indication bushings here Connection of cables in typical ...

Page 36: ...n check list Check painted areas of the switchgear for possible damage touching up where required Check bolt connections and tighten where required in particular all those carried out during on site erection of the busbars and earthing system After the lifting lugs have been removed the Ith limiter auxiliary switch if ordered must be adjusted as required The auxiliary switch holder is fixed by mea...

Page 37: ...ithdrawable fused contactor Switching of the contactor is carried out via the control features fitted to the instrument compartment The contactor status is indicated on the front of the contactor and can be viewed through the top viewing window Switching operations can only be carried out with the withdrawable contactor in service or in the test position We highly recommend that all switching be d...

Page 38: ...vering the racking hole Engage the racking handle 7 2 with the spindle and rotate the handle fourteen revolutions clockwise 7 3 While in service the contactor compartment door cannot be opened and the earth switch cannot be closed To rack the contactor truck out of service into its test position please ensure the contactor is off Insert the racking handle in the racking hole and rotate the handle ...

Page 39: ...er other conditions we recommend connecting a temporary test supply via terminals in the instrument compartment A Truck position indication label as shown on the picture below is visible through the top viewing glass Please note that the contactor cannot be closed while the truck is in an intermediate position indicated by the yellow position indication Important note Insertion and withdrawal of c...

Page 40: ...tition plate under the contactor truck Unlock the contactor truck using a double bit key and push the contactor off the trolley into the panel Lock the contactor truck into the panel unhinge the trolley from the partition plate and remove the trolley 7 1 3 Racking from IN SERVICE to ISOLATED position With the contactor IN SERVICE you need to rotate the racking handle anti clockwise to withdraw the...

Page 41: ...gh number of operations The contactors basically consist of a moulded resin monoblock where the vacuum interrupters moving apparatus control electromagnet multi voltage control feeder and auxiliary accessories are housed The monoblock is also support for the HV fuses Closing of the main contacts is carried out by means of the control electromagnet Opening is carried out by means of a special oppos...

Page 42: ... stop is reached to close the earthing switch or anticlockwise until the stop is reached to open the earthing switch Observe the mechanical electrical switch position indicator Remove earth switch handle Caution Make sure that the earth switch handle is turned right up to the stop in the opening process to ensure that the earthing switch is in its defined limit position The manual operating mechan...

Page 43: ...st rod is available for carrying out current injection tests It is suitable for supplying primary current to any current transformers which may be fitted during measurements in the protection circuit Isolate and secure the working area in accordance with the IEC safety regulations For primary current supply fix the connecting cable of the test transformer to the current test rod Voltage insulating...

Page 44: ...ut testing operations on switching devices manually or by electrical control and simultaneously observe the relative position indicators Pressure relief duct 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 Check readiness for operation and switching stat...

Page 45: ...e equipment in the system The aim is to perform the asset condition and risk assessment and define the appropriate maintenance tasks 9 2 Inspection Caution The switchgear should first be de energised in accordance with the site procedures and the recommendations in the ZVC Operating Manual The checks listed below must be carried out by ABB personnel or suitably qualified client staff During normal...

Page 46: ...e of vacuum If necessary contact ABB service Refer to section 9 2 2 below Check correct operations and signals Check whether the cable ties are loose or broken and check the connections are tight Check the seal over the spring register is intact Check tightness and absence of any traces of overheating or oxidation Check tightness of the connections As per routine test report Close the contactor an...

Page 47: ...rs have to be put back into service after a fault Carry out a voltage test with the contacts open at 25 6 kV 50 Hz for one minute If there is a discharge during the test the interrupter must be replaced because this type of phenomenon corresponds to deterioration in the degree of vacuum In case of need contact ABB Service Should this test also be positive it is reasonable to put the interrupters b...

Page 48: ...op up grease on contact areas in the contact system when corroded or otherwise as necessary or when lubrication is inadequate or missing thoroughly clean the areas concerned and grease them again with Isoflex Topas NB 52 lubricant 9 4 2 Replacement of complex functional groups Precise matching of functions for control interlocking and signalling only permits replacement of individual components to...

Page 49: ... fitted in the same way back to back Respect the torque limits on the label 25 Nm 9 4 3 4 Racking blocking coil replacement for V7 ZVC Ensure the voltage rating of the replacement matches that of the original racking blocking coil Follow the procedure described in the illustrations shown 1 Remove the truck from the Panel to the service trolley following the safety procedures in the operating manua...

Page 50: ...sh with the end of the screw 5 Undo the two M3 x10 socket head cap screws to remove the defeat plate when fitting these two screws on the replacement blocking coil add a drop of loctite before engaging four threads 3 Undo the four M3 pan head screws with spring washers to remove the blocking magnet with coil when replacing the blocking magnet with coil tighten each screw to 0 6 Nm 50 UNIGEAR ZVC M...

Page 51: ...rip coil 48 60 V DC 6250802 Y2 trip coil 110 130 V DC 6250803 Y2 trip coil 220 250 V DC 6250804 Y2 trip coil 110 130 V AC 6250805 Y2 trip coil 220 250 V AC 6200103 current interlock assembly 6250306 3 6 kV fuse adapter 6230310 door interlock 9 5 2 Auxiliary materials lubricants Lubricant Isoflex Topas NB 52 Halogen free cleansers ETHANOL F 25 M for general cleaning Touch up paint Standard colour R...

Page 52: ...ontactor truck Solution Select contactor truck of correct current rating 10 1 2 Racking mechanism not closed against the front of the truck Rotate racking handle to the anti clockwise stop 10 1 3 Truck on service trolley Truck is not parallel with the rails adjust the height on the service trolley 10 2 Truck cannot be locked in cubicle 10 2 1 Earth switch is at the open position Close earth switch...

Page 53: ...tactor from SERVICE to TEST ISOLATED position Replace the racking blocking coil as described at 9 4 3 4 10 4 4 Contactor on Open contactor 10 5 Vacuum contactor cannot be closed 10 5 1 Racking operation not completed mechanical and electrical block Rotate handle fully to stop 10 5 2 Secondary control plug damaged Check secondary control plug for damage 10 5 3 No control supply available Check cont...

Page 54: ...s the excellence level is proved by quality certificates according to ISO 9001 and by the EMS according to ISO 14001 End of life of product ABB is committed to complying with the relevant legal and other requirements for environment protection according to the ISO 14001 standard The duty of the company is to facilitate subsequent recycling or disposal at the end of product life During disposal of ...

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Page 56: ...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 2018 ABB All rights reserved Specifications subject to change without notice ...

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