ABB ZX1.5-R Instruction Manual Download

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I N S T R U C T I O N M A N U E L

ZX1.5-R

Gas-insulated medium voltage
for railway application

Summary of Contents for ZX1.5-R

Page 1: ... Safety and reliability 20 footprint saving Easy operation Complete solution INSTRUCTION MANUEL ZX1 5 R Gas insulated medium voltage for railway application ...

Page 2: ......

Page 3: ...Summary 2 Technical data 3 Design and function of the switchgear system and its equipment 4 Despatch and storage 5 Erection of the switchgear at site 6 Commissioning operation 7 Maintenance disposal 8 Table of equipment designations used ...

Page 4: ...handling Paragraphs in this manual are marked in accordance with their significance The markings mean the following Hazard warning meaning in this manual that death or serious injury and considerable damage may occur if the actions described are not performed Important note meaning in this manual that injury and damage may occur if the actions described are not performed Attention is drawn to furt...

Page 5: ...llation and operation in particular Power installations exceeding AC 1kV DIN VDE 0101 Operation of electrical installations VDE 0105 Earthing systems for special power installations with rated voltages above 1 kV DIN VDE 0141 The accident prevention regulations issued by the appropriate professional bodies The safety guidelines for production materials The order related details provided by the swi...

Page 6: ...r insulation Pae Rated filling level for insulation Pre Motor and release data Charging motor Closing coil Opening coil Rated supply voltage DC Degree of protection IEC 60529 DIN VDE 0470 1 High voltage live part Control cabinet Ambient temperature Maximum temperature Maximum temperature of 24 hours mean Minimum value Opearting Altitude Dimensions Height for transport Depth 9 10 11 Width Height of...

Page 7: ...eak withstand current Rated short time current 4 s Motor data Motor power max 1 Motor running times max 1 Centre position to busbar Centre position to earth Rated supply voltage DC 2 line to earth line to line Across the isolating distance line to earth line to line Across the isolating distance kV kV kV A kA kA W s s V 27 5 2x27 5 95 140 118 200 325 220 2500 80 31 5 180 18 18 60 110 220 1 At rate...

Page 8: ...sure relief duct above F Pressure relief duct for busbar compartment G Pressure relief duct with absorber I Pressure relief chimney lateral E Pressure relief duct above F Pressure relief duct for busbar compartment G Pressure relief duct with absorber A Circuit breaker compartment B Busbar compartment C Cable termination compartment partitioned D Control cabinet Incoming feeder panel up to 4 cable...

Page 9: ...a pressure relief duct F see page 9 from the busbar compartments to a metering panel or sectionalizerpanel If the installation does not contain a metering panel or sectionalizer panel anoutgoing feeder panel can be used for pressure relief The panels can have optionally integrated pressure relief ducts with the opportunity for Conducting out of the switchroom in a manner suitable for the building ...

Page 10: ...rd the plasma gases are discharged through the lower pressure relief duct 3 6 to the side pressure relief chimney I refer to page 9 and into the upper pressure relief duct 1 9 Optionally in systems with pressure relief to the rear discharge is effected centrally via the pressure relief duct 3 6 into a sectionalizer panel busbar riser panel or metering panel There flap 3 15 opens Cable termination ...

Page 11: ...reaker compartment 1 0 The circuit breaker operating mechanism 1 2 is located outside the gas compartment and is therefore easily accessible It is connected to the breaker poles by a gas tight bushing Functions of the vacuum circuit breaker 1 1 Opening and closing on rated currents Short circuit breaking operations Earthing function in conjunction with three position switch 2 1 The earthing functi...

Page 12: ... the ZX1 5 R has microswitches on the operating mechanism base plate figure 6 2 for detection of the position of the three position switch 2 1 These are used to start and stop the relevant drive motor disconnector or earthing switch These microswitches are used to activate and deactivate the relevant mechanism motor function disconnector or earthing switch 5 pole sets of auxiliary switches are ava...

Page 13: ...ded to protect the operators and the switchgear itself Note If the operating mechanism for the three position switch fail during a switching operation when the switch is in an intermediate position the electrical interlock between the VD4 X R circuit breaker and the UX2TE R three position switch established by the REO 517 is effective The VD4 X R circuitbreaker could however be closed mechanically...

Page 14: ...ionalizers risers permit earthing ofa busbar section without additional equipment 3 10 1 Electrical earthing of a busbar section using the sectionalizer riser Operating sequence Circuit breaker in the sectionalizer panel OFF All disconnectors in the busbar section to be earthed OFF apart from the disconnector Q11 or Q12 between the busbar section to be earthed and the sectionalizer breaker Secure ...

Page 15: ...to the conductors in the connection area is possible without releasing the cable connection Access is effected via the test sockets 1 4 Surge arresters must be removed during voltage tests The empty sockets must be closed with insulating blanking plugs during testing Voltage transformers must be isolated from the test circuit prior to testing Voltage tests Close and insulate free cable sockets wit...

Page 16: ...oor Figure 3 4 Panel top pressure relief disk on the circuit breaker compartment Shown before installation of a pressure relief duct or plasma Figure 3 5 Panel top pressure relief disk on the circuit breaker compartment Shown with plasma deflector assembled 1 3 Figure 3 3 Figure 3 4 Figure 3 5 1 15 ...

Page 17: ...in busbar connector 3 0 Cable termination compartment 3 1 Main earthing bar 3 4 Cable plug 3 6 Lower pressure relief duct 3 7 High voltage cable 4 0 Control cabinet 4 3 Control cabinet door 4 4 Door lock 5 3 Block current transformer Insulating gas Q0 Circuit breaker Q1 Tee off disconnector Q5 Tee off earthing switch T1 Current transformer C1 Capacitive voltage divider Insulating gas Q0 Circuit br...

Page 18: ...ion Unit 4 2 HMI of the Bay Control and Protection Unit 4 3 Control cabinet door 4 4 Door lock 4 5 Measuring sockets for capacitive voltage indicator optional Insulating gas Q0 Circuit breaker Q1 Tee off disconnector Q5 Tee off earthing switch T1 Current transformer C1 Capacitive voltage divider C2 Capacitive voltage divider optional Insulating gas Q0 Circuit breaker Q1 Tee off disconnector Q5 Tee...

Page 19: ...tor Q5 Tee off earthing switch T1 Current transformer T5 Voltage transformer C1 Capacitive voltage divider ZX1 5 R Figure 3 9 Outgoing feeder panel double pole 2000 A with 4 cables per pole and voltage transformer Isolating system 2 9 is only to be operated when the feeder is off circuit Alwaysperform switching operations up to the limit positions and lock the isolating system Figure 3 10 Outgoing...

Page 20: ...e off earthing switch T1 Current transformer T5 Voltage transformer C1 Capacitive voltage divider C2 Capacitive voltage divider optional ZX1 5 R Figure 3 11 Outgoing feeder panel double pole 2500 A with 4 cables per pole and busbar voltage transformer shown with pressure relief duct Figure 3 11 ...

Page 21: ...ENT Channel Channel Channel Channel Channel Channel Channel Channel L2 L2 L2 3 12 Circuit diagram for panel with conventional metrology Transformation rating accoring to order documentation X 80 Figure 3 12 Conventional current and voltage transformers Figure 3 12 ...

Page 22: ...nsport Figure 4 1 Note Do not walk on the tops of the panels pressure relief system The transport units are normally individual panels Always handle the panel in the upright position Take account of the weight of the transport units when selecting the handling equipment Due to the high centre of gravity of the panel blocks there is a risk that the transport units may tip over Take all precautions ...

Page 23: ...rdance with VDE 0670 Part 1000 IEC 62271 1 Room temperature not falling below 25 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 seaw...

Page 24: ...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 Ventilate well if leakage occurs 5 2 2 Perform the following work to prepare silicone insulating parts for assembly Inspect the sillicone insulating parts ...

Page 25: ...nels Figures 5 1 to 5 6 Note Do not walk on the top of the panels rupture point for pressure relief system 5 4 1 Preparatory work Before joining up the panels check the gas pressure in each gas compartment witha temperature compensated pressure gauge GCE0905091P101 The indication must be in the green area of the scale on the measuring instrument If there is any deviation from the specified pressur...

Page 26: ...to the foundation frame Figure 5 18b Dismantle connecting link 3 2 for the main earthing bar 3 1 in the cable compartment and lead it through to the adjacent panel Bolt the connecting link to the main earthing bar with bolts 2 20 and one dished washer at each of the bolt head and nut ends Check the bolted connection between main earthing bar 3 1 and the connecting link 3 2 in the previously erecte...

Page 27: ...tchgear assembly Figure 5 2a Switchgear assembly see figures 5 1 to 5 4 for details Multifunction protection and switch bay control unit not shown completely Figure 5 2b Switchgear assembly insulating part On assembly of the busbar the conical surface A is to be evenly lubricated with assembly paste No areas must be left unlubricated Figure 5 2a Figure 5 1 Figure 5 2b ...

Page 28: ...st be checked 1250 A 1 contact ring 1250 A 2 contact rings L1 L3 Protective caps removed L2 Insulating part 2 14 and bus connector 2 21 fitted Figure 5 3 Switchgear assembly Earthing bar connection Figure 5 4 Switchgear assembly Panel panel connection Figure 5 5 Busbar connection Figure 5 6 Assembly of the busbar connection shown for 1250 A Figure 5 3 Figure 5 5 Figure 5 6 Figure 5 4 ...

Page 29: ...ltage transformer Figure 5 8 Insertion area for voltage transformer top view Figure 5 9 Insertion area during assembly Figure 5 10 Insertion area fiual position Figure 5 7 Figure 5 8 Figure 5 9 Figure 5 10 Note Don t step on the bersting plate If necessary protect during assembly with sheet plate ...

Page 30: ...gure 5 13 Earthing screws for the voltage transformer terminals as delivered here for voltage transformer with 2 secondary terminals Figure 5 14 Plug connector for single core XLPE cableK Cable earthing conductor to be connected to switchgear earth Refer to the mounting instruction of the supplier Figure 5 15 Cable termination compartment single core cable panel side wall cut out Figure 5 11 Figur...

Page 31: ...e Front Openning of foundation frame Layout of foundation frame Channel Steel 1 When the optional 500mm deep low voltage compartment is used these dimensions increase by 100 mm Tolerance conditions for laying of the frame as follows Evenness tolerance 1 mm per meter Straightness tolerance max 1mm per metre but max 2mm for the entire length of the frame ...

Page 32: ...forcement plate below the transformers and screwed to the hexagon pins evenly across the diagonal up to the mechanical stop max tightening torque 15 Nm Where possible wipe off any surplus grease which emerges 32 ZX1 5 R INSTRUCTION MANUEL Connect the wiring for the secondary connections and the earthing of the voltage transformer in accordance with the circuit diagrams Check that all terminal scre...

Page 33: ...amage to the paintwork touching up with a suitable paint if necessary see Section 7 3 3 Properly refit any cladding and covers of operating mechanisms cable ducts etc Removed during the erection work Remove all tools and other foreign bodies from the switchgear Check the general condition of the switchgear Check that the areas adjacent to the switchgear are in the proper condition ...

Page 34: ...tart up Comply with all relevant safety regulations Ensure that the switchgear circuit breakers are in the OFF position Close the disconnector for the relevant busbar system Cancel any existing short circuiting and earthing connections in the critical switching area Check that corresponding conductor sections are in line where relevant with several incoming feeders and switchgear sections Energise...

Page 35: ...control cabinet door Switch the three position switch on or off manually This requires the following actions Open the control cabinet door Switch the circuit breaker off With the mechanical interlock between circuit breaker and three position switch option opening flap 2 22 on the three position switch operating mechanism activates a mechanical interlock between the two devices Note The flap 2 22 ...

Page 36: ... details in the order documents are to be observed Details on the gas system of the ZX1 5 R switchgear can be found in instruction manual 6 3 2 Electrical mechanical display monitoring 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...

Page 37: ... the duration of those tests Short circuit the measuring sockets 1 6 or 4 5 in the panels concerned for the duration of the testing process at test voltages up to rated power frequency withstand voltage 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 accom plished by using th...

Page 38: ...h the earthing connections to the relevant cable terminals in the terminal box shown illustration shows condition as delivered The wiring and in particular the earthing of the secondary terminals is to be implemented in accordance with the circuit diagrams Releasing the earthing screw on the N terminal leads to potentially lethal high voltage at the terminal during operation of the voltage transfo...

Page 39: ...Hollow shaft emergency manual operation shaft 2 27 Mechanical switch position indicator 2 3 Pressure sensor for busbar compartment 2 36 Auxiliary switch 2 37 Microswitch disconnector on 2 38 Microswitch disconnector off 2 39 Microswitch earthing switch off 2 40 Microswitch earthing switch on 1 14 Filling valve for circuit breaker compartment 1 2 Circuit breaker operating mechanism 1 33 Front plate...

Page 40: ...t test plugs the following must be ensured The safety regulations of VDE 0105 are followed e g the section of the switchgear concerned De energised Is secured to prevent reconnection The off circuit conditions has been verified and It is earthed The occurrence of high voltage by secondary injection from the voltage transformers must be avoided Before and during fitting and removal of the test plug...

Page 41: ...ng cycles of the circuit breaker and 1 000 operating cycles of the three position switch Attention is also drawn to instruction manual 1YHA000118 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...

Page 42: ...rection is necessary tie wire 2 35 is to be adjusted Release clamping screw 1 30 on clamping piece 1 29 Align flap 2 22 in such a way that the two bores 2 23 are in alignment Fasten tie wire 2 35 with clamping screw 1 30 in such away that the abovementioned distance of 2 1 mm is achieved The tie wire must not be tensioned 7 3 3 Touch up of surfaces Sheet steel parts painted Remove rust e g with a ...

Page 43: ...s Isoflex Topas NB 52 Assembly paste for insulating part cast resin plug connections Silicone paste for greasing of o rings Cleaning agent for busbar insulating parts busbar sockets and cable sockets Cable cleanser MAB Paintwork Paint in standard colour RAL 7035 1 kg box Spray tin Coupling piece with hose connection for gas connector optional Part no Orderref GCE0990253P0103 GCEA901004P0102 GCE099...

Page 44: ... standard Density sensor for circuit breaker compartment Density sensor for busbar compartment Sensor to detect switch position circuit breaker OFF Sensor to detect switch position circuit breaker ON Sensor to detect the charging condition of the stored energy spring for the circuit breaker Sensor to detect switch position three position switch earthing switch OFF Sensor to detect switch position ...

Page 45: ...7 1 18 1 19 1 20 1 21 1 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 1 35 1 36 1 37 1 38 1 39 1 40 1 41 1 42 2 0 2 1 2 2 2 3 2 4 2 5 2 6 Support Plug in socket for voltage transformer Isolating system for voltage transformer Tee off conductor Pressure relief disk for busbar compartment Drying agent bag busbar compartment Busbar socket Insulating part O Ring Socket head bolt M 10x...

Page 46: ...s optional Test plug for current tests optional 3 15 3 16 3 17 3 18 4 0 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 5 0 5 1 5 2 5 3 5 4 6 0 6 1 6 2 6 3 6 4 6 5 Foundation frame Longitudinal bracket this one for panel width 600 mm Longitudinal bracket internal this one for panel width 600 mm Transverse bracket left this one for panel depth 1300 mm Transverse bracket right this one for panel depth 1300 mm F...

Page 47: ...stant that enables customers to connect to the broadest range of electrification solutions in one place Easy to find what you need by search Get all information about our products applications selection guides installation manuals service certificates and engineering tools etc Saving documents locally updating automatically Receive your expected messages Online customer service You can use ABB Con...

Page 48: ...rict 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 1YHA000326_EN REV A 06 2021 XM LDZ All rights reserved Specifications subject to change without notice ...

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