ABB ZX1.5-R, Instruction Manual

Page: 36 / 48

36 ZX1.5-R I N S T R U C T I O N M A N U E L
Note on safety at work
Operation by trained specialists familiar
with the particular switchgear only.
6.1 Commissioning
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 supply 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 SF
6
also apply accordingly to nitrogen (N2)
• 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
- Power cables
- Control wiring
- Supply voltage and its polarity
- Remote controls
- External earth with connection to main
earthing bar (3.1)
- Switchroom equipment
- Switchroom condition
6.1.2 Initial start-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 the switchgear step by step
• Check measurements and functions
dependant on high voltage
• Look out for irregularities of any kind
6.2 Switching operations
6.2.1 Circuit breaker
(Figures 3/7, 6/1, 6/2, 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
• Closing and opening are effected by
operation of the devices fitted
• 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. Opening of the control cabinet
door can constitute intervention in the
interlock system (see sections 3.8 to 3.10).
• Observe the position indicator
Manual charging of the stored-energy spring
1. On failure of the charging motor,the charging
process can be performed or completed by
hand:
• Open control cabinet door (4.3)
• Insert charging lever (6.3) into recess (1.40)
and pump for approx. 25 strokes until the
charged condition is displayed
When the charged condition is reached, the
charging mecha nism automatically
disengages and further strokes of the
charging lever have no effect.
Key to the charging condition displays:
2. If the control voltage fails with the circuit
breaker closed, it is possible to open it using
the mechanical OFF push button (1.35).
Emergency operation of the mechanical ON
pushbutton for the circuit breaker operating
mechanism on failure of auxiliary voltage
(figure 6/6b)
Caution: Interlocks are cancelled during
this operation. Only open or close circuits
with the circuit breaker! The three position
switch must be in a limit position !
Release the fastening screws in the circuit breaker
cover and remove the cover. Use a suitable tool
to press the pin in the blocking magnet (2.41) to
the right and simultaneously move the slide
(2.42) to close the circuit breaker.
Note
On failure of the control voltage, there is
no maloper ation protection for the circuit
breaker and three-postion switch during
emergeny manual operation
6.2.2 Three-position switch
(Figures 3/7, 6/1, 6/3 and 6/5)
• The three position switch (2.1) is fitted with
a motor-operated mechanism. Opening and
closing are effected by selection on the
multifunction protection and switchbay
control unit or by means of the devices fitted
• Routine opening/closing operations
may only be performed with the control
cabinet door closed. Opening of the
control cabinet door can constitute
intervention in the interlock system (see
sections 3.8 to 3.10)
• Observe the switch position indication on the
electrical position indicators
• Sensors 2.28 to 2.31 or microswitches 2.37 to
2.40 on the three position switch operating
mechanism detect the switch positions
- Disconnector (-Q1) ON and OFF
- Earthing switch (-Q5) ON and OFF
Emergency manual operation
In place of motorised operation, the switching
process can also be initiated and completed
manually.
Caution!
Intervention in the interlock concept is
possible by opening the 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) can only be opened when the
circuit breaker is OFF.
• Prior to emergency manual operation, switch
off the mcbs for the circuit breaker release
circuit and for the operating mech anism of
the position switch
• Insert the crank (6.1) in the hollow shaft (2.26)
• A cam fitted at the crank prevent in cooperation
with a bolt which is routed at the operation
mechanism to run over the middle position
• Three-position switch operation
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.
Note
Always perform every switching operation right
up to the stop in the relevant limit position.
• Close flap (2.22) again
If the hand crank is withdrawn in an intermediate
position, the flap cannot be closed.
This intermediate position can be seen on the
one hand by the lack of a mechanical limit
position indication for the three position switch
and also by the electrical displays on the front
door.
The limit positions are only correctly indicated
when the switch is in a limit position, i.e. when
the contacts have full current carrying capacity.
The flap (2.22) can then be closed and the circuit
breaker switched on.
When the circuit breaker is open, the flap can
also be opened in an intermediate position
and the hand crank fitted to permit manual
completion of a switching operation.
The specific data for the relevant order are
also to be observed.
Note
When the flap (2.22) is open, the circuit breaker
is mechanically and electrically blocked in the
OFF position
• Close the control cabinet door
Emergency manual operation of the three position
switch in a riser panel on failure of auxiliary voltage
(optional mechanical interlock) (figure 6/6a)
Caution: Interlocks are cancelled during
this operation. Only open or close circuits
with the circuit breaker! The three position
switch must be in a limit position!
The flap (2.22) is released and access to the
emergency manual operation shaft provided by
pulling the interlock pin on the blocking
magnet (2.41).
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 tee-off earthing, a tie wire is
provided.
6.3 Observation of the display and monitoring
facilities
6.3.1 Gas monitoring
(Figures 6/1, 6/7)
All high voltage compartments in the switchgear
must have a sufficient insulating gas pressure
during operation. The minimum funcional level
for insulation is listed in section 2.1. This is
monitored by sensors (1.8) and (2.3).
If the gas pressure falls below the alarm level for
insulation, a LED on the multifunction protection
and switchbay control unit signals that the gas
should be topped up. With conventional panel
control, the issue of the signal is optional and
dependent on the individual project.
Note
If a panel is isolated for a relatively long period
(several weeks), mcb (F116) for the auxiliary
voltage supply to the must remain on. Only in
this way monitoring of the insulating gas is
ensured. With conventional panel control, the
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.
6.4 Test procedures
6.4.1 Testing for the off-circuit condition
The panels are fitted with the low impedance,
capacitive voltage indicator system for testing
of the off-circuit condition.
For details, see VDE 0682 Part 415, or IEC 61243
Part 5.
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!
Note
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)!
Testing for the off-circuit condition is performed
with a plug in display unit at corresponding pairs
of measuring sockets (1.6) and optional at (4.5)
(Front side).
Use of the display unit
• Perform a functional test on the display unit
immediately before and after use, e.g. with
interface tester. The display must be clearly
visible
• The presence of operating voltage is indicated
by a signal
• Observe the individual operating instructions
for the display unit for the relevant switchgear
Interface testing
• Perform interface testing as a functional test
on all coupling components, e.g. with interface
tester
• The interface test is a repeat test to IEC 61243
Part 5 or VDE 0682 Part 415
6.4.2 Testing for the in-line condition
Testing for the in-line condition, e.g. when there
is more than one incoming feeder, can be performed
with a suitable line comparator at measuring
sockets (1.6 and 4.5 respectively) on the capacitive
voltage indication system.
Test procedure:
• Only use line 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 line
• Connect the measuring leads precisely assigned
to the corresponding main conductor sections
• Always follow the details in the operating
instructions for the line comparator
6.4.3 High voltage tests
(Figures 3/7, 6/1, 6/6)
The test plugs available for high voltage tests,
shown in figure 6/6, are suitable for the following
applications up to and including 27.5 kV rated
voltage.
Optional test cables can be used for high voltage
tests.
On account of the sensor technology used and
the multifunction protection and switchbay
control unit, the test voltage must not exceed
the following levels:
• Insulation testing of the switchgear at the
relevant power frequency withstand voltage
(The voltage value in site shall not exceed
80% of the following value)
- 27.5 kV switchgear: 95 kV
Performance of voltage test plugs
• Isolate the switchgear area in accordance
with the safety rules according to VDE 0105/EN
50110 and secure it to prevent reconnection
• Verify the off-circuit condition with a suitable
hand-held display unit at measuring sockets
(1.6) or (4.5) on the capacitive voltage indicator
system
• Unscrew surge arresters where fitted and close
off the exposed sockets with insulating cable
dummy plugs
• Close off empty cable sockets with insulating
cable dummy plugs
• Check the test plug to ensure that the surface
is clean and dry, and clean it if necessary
• Grease the insulating part of the test plugs in
accordance with the instructions
• Unscrew cable dummy plug (1.5) in the relevant
test socket (1.4) and remove it
• Connect an earthing lead to the test plug,
following the instructions on safety at work
in figure 6/7
• Insert the test plug into the prepared test 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 (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 the mechanical OFF button to
open the circuit-breaker (see also Section 3.10)
6.4.4 Protection tests by primary current injection
(Figures 6/1 and 6/7)
In testing of protection functions by primary
current injection, the primary current is conducted
into the panel via the test sockets. Current test
plugs, which are to be fitted as described below,
are inserted in the test sockets.
• Observe the manufacturers instructions for
current test plugs
• Isolate the relevant area of the switchgear in
accordance with the safety regulations of
VDE 0105/EN 50110 and secure it to prevent
reconnection
• Check the off-circuit condition with a suitable
(hand-held) indicator unit at the measuring
sockets (1.6 or 4.5) of the capacitive voltage
indicator system
• Check the test plugs to verify that the surface
is clean and dry, and clean them if necessary
• Unscrew and remove the cable blanking plug
(1.5) in the relevant test socket (1.4)
• Insert the test plugs into the empty test sockets
and screw them tight
• Assemble the test apparatus in accordance with
the directions from the protection test equipment
manufacturer and perform the protection test
• As soon at the test is complete, remove the
current testing plug and replace it with an
insulating blanking plug
Note
Voltage may only be applied to the OFF
release coil of the circuit breaker (shunt
release OFF) for a period of 1000 ms. If this
period is exceeded, the coil will be burn out.
For this reason, the protection testing system
must be shut down by the OFF release
disconnected.
Caution!
If the circuit breaker is to be included in
the test, it must be taken into account
that earthing via the circuit-breaker is
cancelled when the breaker is opened !
To prevent this, the release coil is to be
disconnected prior to testing.
6.4.5 Maintenance earthing
• Earthing of the busbar with the bus tie/riser,
as described in section 3.10
• Earthing with an earthing and short-circuiting set
Handling during earthing with an earthing and
short-circuiting set:
(Figures 6/1 and 6/7)
The plugs shown in figure 6/7 in conjunction with
corresponding short-circuiting and earthing cable
sets are to be used for maintenance earthing.
The short-circuit withstand capability of the
cable set must correspond to the conditions of the
switch-gear installation.
Caution!
Observe the notes in Section 3.8 on the interlock
dependencies for all work with earthing and
short-circuiting 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 (1.6) or (4.5) on the
capacitive voltage indicator system
• Unscrew surge arresters where fitted and
close off the exposed sockets with insulating
cable dummy plugs
• Close off empty cable sockets with insulating
cable dummy plugs
• 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
• Unscrew cable dummy plugs (1.5) in the relevant
test socket (1.4) and remove it
• Insert the test plugs into the prepared test
sockets and screw them tight
6.5 Safety note on operation of the voltage
transformers
The screws marked in figure 5/13 establish 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 transformers!
Releasing earthing screw "N" is only
permissible when the voltage transformers
are off-circuit on the primary side (for test
purposes)!
The relevant switchgear section is to be isolated
and earthed before the isolating system for the
voltage transformers is operated! (The 5 VDE
safety rules are to be observed.)
Always use original earthing screws!
6.6 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 in Germany
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 62271 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
• Fulfillment 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 transmis sion)
Circuit breaker compartment
Circuit breaker
Circuit breaker operating mechanism
Pressure relief disk, above
Test socket
Blind plug
Measuring sockets for capacitive voltage
indicator
Plug-in cable socket
Pressure sensor for circuit breaker
compartment
Pressure relief duct (optional)
Absorber (optional)
Drying agent bag, circuit breaker
compartment
Bushing circuit breaker compartment /
busbar compartment
Filling valve for circuit breaker compartment
Protection cover for current transformer
terminal board
Cover for metering cables
Handling bracket (to be removed after
handling)
Edge protection
Socket head screw M 8x25
Hexagon nut M 8
Dished washer8
Centre of gravity
ON-release shaft
OFF-release shaft
Cam
Mechanical interlock circuit breakerr/
three-position switch
Lever
Clamping piece
Clamping screw
Tee-off conductor, bus-coupler
Tee-off conductor bus-riser
Front plate
On push button
OFF push button
Operating cycle counter
Mechanical position indicator
Rating plate
Charging condition indicator
Recess for charging lever (6.3)
Terminal board for current transformer
Auxiliary switch
Busbar compartment
Three-position switch
Three-position switch operating
mechanism
Pressure sensor for busbar compartment
Busbar
Plug-in busbar connector
Tee-off conductor, metering panel
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.14
1.16
1.17
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 10x50
Guide pin
Hexagon nut M 10
Dished washer 10
Socket head bolt M 10
Bus connector
Flap
Bore for padlock
Central gas connector for busbar
compartment
Drive motor for three-position switch
Hollow shaft (emergency manual
operation shaft)
Mechanical switch position indicator
Sensor, disconnector ON
Sensor, disconnector OFF
Sensor, earthing switch ON
Sensor, earthing switch OFF
Bore for padlock
Contact ring
Manual drive for isolating device
Tie wire
Auxiliary switch
Microswitch, disconnector on
Microswitch, disconnector off
Microswitch, earthing switch off
Microswitch, earthing switch on
Blocking magnet
Slide (mechanical operation circuit
breaker ON)
Cable termination compartment
Main earthing bar
Panel / panel connecting link
Cable mounting (optional)
Cable plug
Pressure relief flap, optional
Lower pressure relief duct
High voltage cable
Parallel connector PB50,
GCE 0909125P0100
Floor plate splitted
Reducer ring
Cable mounting
Supporting section, at earth potential
Rear panel compartment
Supporting section, at earth potential
Pressure relief flap, optional
Socket for fully insulated bar
Fully insulated bar
Venti lator
Control cabinet
Central unit of the Bay Control and
Protection Unit
HMI of the Bay Control and Protection Unit
Control cabinet door
Door-lock
Measuring sockets for capacitive
voltage indicator, optional
Light-emitting diode (LED)
LC-Display of the Bay Control and
Protection Unit
Closing lever
Double bit lock or security lock
Measuring facilities
Current transformer
Plug-in voltage transformer
Block-current transformer
Terminal board for current transformer
Accessories
Hand crank
Double bit key
Charging lever for emergency manual
operation
Test plug for high voltage tests, optional
Test plug for current tests, optional
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
2.24
2.25
2.26
2.27
2.28
2.29
2.30
2.31
2.32
2.33
2.34
2.35
2.36
2.37
2.38
2.39
2.40
2.41
2.42
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
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)
Fixing angle bracket
Connecting link
Transverse bracket for two panel frame,
(this one for panel depth 1300 mm)
Connecting angle
Screwed connection for foundation frame
Socket head bolt M 8x25
Socket head bolt M 10x25
Socket head bolt M 8x25
Socket head bolt M 8x25, frame height 40 mm
Socket head bolt M 8 x 35, frame height
50 mm
Partition plate
Dished washer8
Dished washer 10
Washer8
Nut M10
Fixing dowel 7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15
7.20
7.21
7.22
7.23
7.30