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Medium voltage products

UniSec

 

Installation manual 

Safety  

3

 

For your safety! 

3

 Skilled 

personnel 

3

 

Crucial information  

3

 Contact 

us! 

3

1.   Introduction 

4

 

1.1   General aspects 

4

 

1.2   Installation manual 

4

2.   Product information 

5

 

2.1   Unit dimensions 

5

 2.2 

 

Weights 

6

3.   Transport and storage 

7

 

3.1   Condition on delivery 

7

 

3.2   Unpacking at installation site 

7

 

3.3   Handling the units as far as the installation site  8

 

3.4   Temporary storage 

10

 

3.5   Delivery responsibilities 

10

4.  Assembly of the switchgear on site 

11

 

4.1   General warnings and cautions  

11

 4.2 

 

Preparations 

11

 

4.3   Dimensional foundation drawings 

11

 4.4 

 

Foundations 

15

 

4.5   Installation procedure for units 

15

 

4.6   Gas vent ducts  

26

 

4.7  Coupling the units with switch-disconnector 

 

 

to WBC-WBS units 

29

 

4.8  Coupling the units with switch-disconnector 

 

 

to WBC unit 24 kV 

30

5.   Cable connections 

31

 

5.1   Installing the cables 

31

 

5.2   Control cables 

37

 

5.3   Earthing the switchgear 

37

 

5.4   Final installation work 

38

A.  Tightening torques for steel screws and nuts/bolts  39

B.  Tools required for installation 

42

Содержание UniSec

Страница 1: ...orage 10 3 5 Delivery responsibilities 10 4 Assembly of the switchgear on site 11 4 1 General warnings and cautions 11 4 2 Preparations 11 4 3 Dimensional foundation drawings 11 4 4 Foundations 15 4 5 Installation procedure for units 15 4 6 Gas vent ducts 26 4 7 Coupling the units with switch disconnector to WBC WBS units 29 4 8 Coupling the units with switch disconnector to WBC unit 24 kV 30 5 Ca...

Страница 2: ......

Страница 3: ...use of the circuit breaker refer to the instruction booklet Skilled personnel All the installation putting into service running and mainte nance operations must be carried out by skilled personnel with in depth knowledge of the apparatus When carrying out any maintenance work the regulations in the country of installation must be strictly complied with Maintenance work must only be performed in a ...

Страница 4: ...dliness and simplicity of installation as well environmental sustainability were the driving forces in developing this switchgear UniSec is structured by placing standardized units side by side in a coordinated way Construction and testing are carried out in the factory 1 2 Installation manual This manual provides information on installation of UniSec units It contains details about product dimens...

Страница 5: ...he main dimensions and space requirements of the different units 2 Product information Front views of the various units Figure 1 SDC 375 Figure 2 SFC 500 Figure 5 SBC 750 Figure 3 WBC 600 Figure 4 WBC 750 Side view of the different units Figure 6 Without circuit breaker with a gas vent duct Figura 7 Without circuit breaker with gas vent filters ...

Страница 6: ...maximum weights of the different units Unit mm Weight kg 375 250 500 400 600 800 750 600 750 WBC 24 kV Table 1 Maximum weights of units Figure 8 With large auxiliary circuits compartment and VD4 circuit breaker without gas vent ducts Figure 9 With Vmax withdrawable circuit breaker without gas vent ducts Figure 10 WBC 24 kV ...

Страница 7: ...ctory assembled for each unit However the main busbar connections between different units must be carried out on site The main busbars and their accessories are packed separately for delivery 3 2 Unpacking at installation site Storage and inspection The UniSec switchgear must only be installed indoors It is therefore important to store the switchgear units in their trans port packing for as long a...

Страница 8: ...ecessary single units can be carried horizontally for example because of a low doorway In such cases the unit must be supported over a wide area CAUTION The packages should be placed on a level surface Lifting instructions Use the following tools for lifting Crane Fork lift truck and or Manual trolley jack NOTE It is also possible to move units on a flat floor to the installation site by using rol...

Страница 9: ...acity with spring catches b Keep an angle of at least 60 between the horizontal plane and the ropes leading to the crane hook Figure 21 Dimensions and angles Lifting by crane CAUTION Four lifting ropes of sufficient length must be used when lifting several units or a whole switchgear 4 units at the most or a maximum length of 2 m Figure 22 Lifting Operations after lifting a Dismantle the lifting h...

Страница 10: ...hout packing 1 Use a dry well ventilated place with climatic conditions in accordance with Table 3 2 Store the units upright 3 Do not stack units 4 Units with basic packing Open the packing at least partially 5 Units without packing Cover with non adherent protective sheeting Ensure there is sufficient air circulation Regularly check for any condensation until installation is started 2 Units with ...

Страница 11: ...le i e provided with lighting and electricity fitted with a padlock ventilation facilities and must also be dry All the necessary preparations such as wall openings ducts etc for laying the power and control cables as far as the switchgear must already have been completed Before proceeding with installation a Clean the installation site b Visibly trace the perimeter of all the units making up the ...

Страница 12: ...chgear The figures also Figure 27 375 mm wide units Figure 28 500 mm wide units show the switchgear fixing points There is one fixing point in each corner of the unit 4 per unit Units without cable entry have dimensions and fixing points according to the width of the unit 10 mm anchoring bolts can be used for fixing Figure 25 Minimum distances to installation room wall with gas absorbers Class ALF...

Страница 13: ...00 100 43 5 43 5 10 301 5 Ø12 5 753 230 1200 800 125 81 550 750 100 100 43 5 43 5 10 301 5 773 230 1300 800 125 81 25 Ø12 5 Figure 30 750 mm wide units Figure 31 750 mm wide for SBR unit Figure 32 600 mm width for units with withdrawable circuit breaker up to 17 5 kV Figure 33 750 mm width for unit with withdrawable circuit breaker at 24 kV ...

Страница 14: ...Medium voltage cable lengths RLC unit Details 190 mm width 375 mm width 500 mm width 600 mm width 750 mm width A mm B mm A mm B mm A mm B mm A mm B mm A mm B mm SDC Basic 915 210 915 275 SDC With CT 525 275 525 275 SDM Basic 525 1 275 1 SFC 292 mm fuse 600 200 600 230 SFC 442 mm fuse 450 200 450 230 SBC Basic 500 310 WBC Basic or with CT 600 150 2 600 165 DRC Basic 500 165 670 255 DRC With CT 530 ...

Страница 15: ...tal frame Figure 36 Switchgear erected on a floating floor If the switchgear only consists of a few units and no heavy units are included it can be installed on the concrete floor Figure 37 Switchgear installed on a concrete floor 4 5 Installation procedure for units 4 5 1 Assembly of the first two switchgear units WARNING Before positioning the different switchgear units check the floor levelling...

Страница 16: ...wo units com pletely together make sure that the lower joining plate of the right hand unit is in the upper position as shown in Figure 41 Figure 40 Two units side by side Figure 41 Outline of lower joining plate in upper position b Hammer the lower joining plate down so that the units are firmly fixed to each other at the back Figure 42 Installation of lower joining plate c Screw up the lower joi...

Страница 17: ...M6x12 screws so that they are fully tightened Insert a bolt M8x20 round headed with square neck with a nut M8 hexagonal nut with flange figure 45 to tighten the units and the joining plate Figure 45 Screws for the top joining plate Figure 46 Plates installed f Insert 5 bolts M10x20 hexagonal with flange and 5 nuts M10x20 hexagonal with flange into the LV and instrument compartment front upper part...

Страница 18: ...e operations for the remaining units Figure 47 Places for screws g Insert 8 bolts M10x20 hexagonal with flange and 8 nuts M10x20 hexagonal with flange into the cable compartment front lower part of the units but do not tighten them yet Figure 48 Screw positions h Use a screwdriver to trim the unit alignment Tighten all the bolts from the front NOTE Do not remove the roof frame for SBR functional u...

Страница 19: ...torques are indicated in the Tightening torques for steel screws and nuts bolts table NOTE It is important for the screws to be of the correct length Busbar spacer Busbar Busbar spacer 1 Odd numbered unit 2 Even numbered unit 3 Odd numbered unit 4 Even numbered unit 5 Odd numbered unit 4 5 5 Fixing the switchgear to the floor See Figures 35 36 and 37 Fixing to the metal frame a The switchgear must...

Страница 20: ...ce to the corresponding numbers of the components in Table 5 All unit types Part Name 1 Round headed socket screw M10x40 2 Round headed socket screw M10x45 3 Round headed socket screw M10x50 4 Round headed socket screw M10x60 5 Cheese head socket screw M10x65 6 Cheese head socket screw M10x70 7 Rubber cap for local terminal 8 Ring field control 9 Insulating terminal cover 10 Insert 11 Busbar 12 Co...

Страница 21: ... 800 A end unit Figure 53 12 17 5 kV 630 A middle unit Figure 54 12 17 5 kV 630 A end unit Figure 55 12 17 5 kV 630 A end unit Units with 24 kV 630 A switch disconnector Figure 56 24 kV 630 A middle unit Figure 57 24 kV 630 A end unit Figure 58 24 kV 630 A end unit Units with 12 17 5 kV 800 A switch disconnector Figure 60 12 17 5 kV 800 A end unit FIgure 59 12 17 5 kV 800 A middle unit ...

Страница 22: ...ly the nuts must be installed under the busbars DRS DRC 12 17 5 kV 630 A end or isolating units Figure 62 DRS DRC 12 17 5 kV 630 A end or isolating units DRS DRC 24 kV 630 A end or isolating units Figure 63 DRS DRC 12 17 5 kV 630 A end or isolating units Figure 64 DRS DRC 24 kV 630 A end or isolating units Figure 65 DRS DRC 24 kV 630 A end or isolating units DRS DRC 12 17 5 kV 800 A end or isolati...

Страница 23: ...0 A middle unit DRC 12 17 5 kV 630 A middle unit DRC 24 kV 630 A middle unit Figure 69 24 kV 630 A middle unit DRC 12 17 5 kV 800 A middle unit Figure 70 12 17 5 kV 800 A middle unit For the SBR unit up to 24 kV 630 A Units with insulators Figure 71 Busbar exit on the left Figure 72 Busbar exit on the right ...

Страница 24: ...ransformers and Combisensors Figure 73 Busbar exit on the left Figure 74 Busbar exit on the right Figure 75 630 A middle unit Figure 76 1250 A middle unit WBC WBS 630 A middle unit WBC WBS 1250 A middle unit Figure 77 630 A end unit Figure 78 1250 A end unit WBC WBS 630 A end unit WBC WBS 1250 A end unit ...

Страница 25: ... unit with WBC WBS to unit with 12 17 5 kV 630 A switch disconnector Figure 79 12 17 5 kV 630 A middle unit Figure 80 12 17 5 kV 630 A end unit Panel for coupling unit with WBC WBS to unit with 12 17 5 kV 800 A switch disconnector Figure 81 12 17 5 kV 800 A middle unit Figure 82 12 17 5 kV 800 A end unit ...

Страница 26: ... is positioned as shown in Figure 83 Figure 83 Installation of fire protection plate and double roof plate Make sure that the bent edges of the double roof plate are completely under the plate 4 Install the roof joining plate with six screws Torx screws M6x12 Figure 84 Outline of roof joining 4 6 Gas vent ducts 4 6 1 Installation of the gas vent ducts The gas vent ducts are usually already install...

Страница 27: ...rew 3 additional screws Torx M6x12 in the bottom plate as shown in Figure 88 Figure 88 Additional screws for the bottom plate e Mount the horizontal duct onto the vertical duct as shown in Figure 89 Insert the screws and nuts in it as shown in Figure 90 4 Torx M6x12 screws support bar and 2 M6 hexagonal nuts Figure 89 Installation of the horizontal duct Figure 90 Screws and nuts for the horizontal...

Страница 28: ...as vent duct additional duct and end plate Figure 95 shows an additional duct and end plate Connecting these parts can be done in the same way as in the previous stages An additional duct is used in the end unit to direct any gas due to arc faults out of the switchgear room The switchboard is always provided with an additional duct 1 metre long On request an additional duct with a maximum length o...

Страница 29: ...29 Figure 96 Figure 97 4 7 Coupling the units with switch disconnector to WBC WBS units Units up to 17 5 kV ...

Страница 30: ...30 4 8 Coupling the units with switch disconnector to WBC unit 24 kV Figure 98 Figure 99 ...

Страница 31: ...lamps cable guide splines fairleads and the floor sheet a Unscrew the eight bolts on the floor and remove the bottom plates Figure 102 Dismantling completed 5 Cable connections 5 1 Installing the cables NOTE The clamping screws are optional NOTE The position of the medium voltage cables are positioned L1 L2 and L3 front to back 5 1 1 Installing the cables Parts Figure 100 Parts 1 Floor sheet 2 Fai...

Страница 32: ...o consideration the installation of the cable terminations and cable terminals b Adapt the fairleads to the cable diameter and fit them onto the cable Figure 103 Cables and reducer rings c Prepare the cable insulating ends and mount them on the cable cores according to the manufacturer s instructions d Connect the cables to the cable terminals as shown in Figure 104 In a switch fuse combination th...

Страница 33: ... Tighten to the correct torque See the tight ening torques table at the end of the manual 5 1 2 Installing the cables in the RLC unit RLC unit cable compartment Figure 109 Cable compartment Open the RLC cable compartment 1 Unscrew at the top of the RLC front cover lift it and remove the front RLC cover Figure 110 RLC front cover Figure 108 Cables ready ...

Страница 34: ...bottom of the RLC unit according to the cable diameter and fix the cables in the centre of the RLC unit to the locking part Figure 114 RLC unit cable locking parts 2 Unscrew the top and back part of the RLC side cover lift it and remove the RLC side cover Figure 111 RLC cover 3 Unscrew lift and remove the two metal sheets Figure 112 RLC transversal part ...

Страница 35: ...terminal connections 3 Connect the cable earthing screen beside the plastic locking devices Figure 118 RLC unit earthing cable terminals Close the RLC unit cable compartment Carry out the same operations in reverse order to open the RLC unit cable compartment 5 1 3 Installing the WBC unit cables a Open cable door A by unscrewing knurled screws A1 Figure 119 b If necessary remove the lower front co...

Страница 36: ...Figure 121 e Connect the MV cables H using the H1 bolts Figure 122 NOTA If there is more space the circuit breaker compartment plate can be dismantled f Re assembly of all components Figure 123 Cable connections Panels Width Max number of cable Max cross section of cables mm2 SDC 375 2 300 500 2 300 1 630 750 2 300 SFC 375 1 95 500 1 95 SBC 750 2 300 1 630 SBR 750 1 300 DRC 375 2 300 500 1 630 WBC...

Страница 37: ...the lower front part of the unit These busbars must be connected together as shown in chapter 5 3 1 The station earthing system must be connected to the end unit of the switchgear If the switchgear consists of more than 8 units it is advisable to connect the station earthing system to both end units The external station earthing connection point inside the unit is shown in Figure 128 All the appar...

Страница 38: ...ear thoroughly Remove all foreign objects from the units Correctly replace all coverings etc removed during the installation and connection operations Any remaining openings in the switchgear housing must be closed if they are no longer needed Check that the isolating contacts and interlocking mecha nisms operate correctly and if necessary grease them again with Isoflex Topas NCA 52 Insert any wit...

Страница 39: ...is specified in the table of joint types Nuts and bolts Max tightening torque Nm Type Steel class 8 8 M4 3 M5 5 M6 9 M8 22 M10 45 M12 75 M16 185 Cheese head socket screws Max tightening torque Nm Type Steel class 8 8 M4 2 M5 4 M6 8 M8 12 M10 35 M12 50 M16 110 Socket head screws and round headed Torx Max tightening torque Nm Type Steel class 8 8 Steel class 10 9 M4 2 2 M5 4 4 M6 8 8 M8 12 12 M10 30...

Страница 40: ...6 56 nominal max 3 5 20 70 2 Bolts mounted on electrical pliers min 8 nominal 9 max 10 3 Cable connection nut min 18 35 65 170 nominal 20 40 70 180 max 22 45 75 190 4 Busbar connections min 18 35 65 170 nominal 20 40 70 180 max 22 45 75 190 5 Bolts mounted on the circuit breaker min nominal 30 40 max ...

Страница 41: ...d on the mandolin CT min nominal 35 max 7 Bolts mounted on the post insulator min 25 nominal 9 20 30 max 31 8 Bolts mounted on the connection and switching busbar min 56 nominal 35 60 max 70 9 Bolts for mounting CT min nominal 40 max 10 GSec and busbar min nominal 35 max ...

Страница 42: ...42 B Tools required for installation Torx wrench TX30 Torx wrench Allen wrenches 5 mm 6 mm 8 mm Socket wrenches 10 mm 15 mm 17 mm 19 mm Ring spanner 13 mm ...

Страница 43: ......

Страница 44: ...www abb com contacts More product information www abb com productguide For more information please contact The data and illustrations are not binding We reserve the right to make changes in the course of technical development of the product Copyright 2012 ABB All rights reserved ...

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