UniGear type ZS1 double level

Installation, service and maintenance instruction manual

Your safety first at all times!

This is why our instruction manual begins with the following recommendations:
Only install switchgear and/or switchboards in closed rooms suitable for electrical equipment. Ensure that installation, operation and maintenance are carried out by specialist electricians only. Fully comply with the legally recognized standards (IEC or local), the connection conditions of the local electrical utility and the applicable safety at work regulations. Observe the relevant information in the instruction manual for all actions involving switchgear and switchboards. Danger! Pay special attention to the hazard notes in the instruction manual marked with this warning symbol. Make sure that the specified data are not exceeded under switchgear or switchboard operating conditions. Keep the instruction manual accessible to all personnel involved in installation, operation and maintenance. The users personnel must act responsibly in all matters affecting safety at work and correct handling of the switchgear.

WARNING Always follow the instruction manual and respect the rules of good engineering practice ! Hazardous voltage can cause electrical shocks and burns. Disconnect power, then earth and short-circuit before proceeding with any work on this equipment.

If you have any further questions about this instruction manual, the members of our field organization will be pleased to provide the required information.

We reserve all rights to this publication. Misuse, and including in particular, duplication and making this manual - or extracts thereof available to third parties is prohibited. We do not accept any responsibility for the information provided, which is subject to alternation.

1/64

Contents
Page 1 Summary ........................................................... 3 1.1 General ............................................................... 3 1.2 Standards and specifications ............................. 3 1.3 Operating conditions ........................................... 3 1.3.1 Normal operating conditions ............................... 3 1.3.2 Special operating conditions .............................. 3 2 2.1 2.2 2.3 2.3.1 3 3.1 3.2 3.2.1 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 3.6 4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 5.2.1 5.3 5.4 5.4.1 5.5 5.6 5.6.1 5.6.2 Technical data ................................................... 4 Electrical data ..................................................... 4 Resistance to internal arc faults ......................... 4 Dimensions and weights..................................... 4 Dimensions and weights of 12/17.5 kV units ..... 5 Panel design and equipment ........................... 6 Basic structure and variants ............................... 6 Enclosure and partitioning .................................. 6 Ventilation of the panels ..................................... 7 Compartments in the panels .............................. 7 Busbar compartment .......................................... 7 Circuit-breaker compartment .............................. 8 Withdrawable parts ............................................. 8 Cable connection compartment ......................... 9 Control cabinet ................................................... 9 Interlock/protection against erroneous operation ............................................................. 9 Panel internal interlocking .................................. 9 Doors interlocking ............................................. 10 Interlocks between panels ................................ 10 Locking devices ................................................ 10 Control wiring plug connector coding ............. 10 Fast recovery .................................................... 10 Dispatch and storage ..................................... 22 Condition on delivery ........................................ 22 Packing ............................................................. 22 Transport ........................................................... 22 Delivery ............................................................. 22 Intermediate storage ........................................ 23 Assembly of the switchgear at site ................. 24 General site requirements ................................ 24 Foundations ...................................................... 24 Anchoring bolts and base iron fixing systems .. 24 Assembly of the switchgear panels .................. 25 Installation of the busbars and bushings .......... 26 Busbars and bushings for units 12/17.5 kV ...... 26 Installation of the top-mouted boxes ................ 26 Cable connection .............................................. 26 Power cables .................................................... 26 Control cables ................................................... 27 5.7 5.8 5.9 6 6.1 6.1.1 6.1.2 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 Page Earthing the switchgear .................................... 28 Laying the ring circuits ...................................... 28 Final erection work ........................................... 28

Operation of the switchgear .......................... 36 Commissioning ................................................. 36 Preparatory work .............................................. 36 Start-up ............................................................. 37 Switching operations ........................................ 37 Withdrawable circuit-breaker part ..................... 37 Circuit-breaker - type VD4 ................................ 39 Circuit-breaker - type VM1 ............................... 40 Circuit-breaker - type HD4 ............................... 42 Vacuum contactor - type V-Contact ................. 43 Withdrawable metering parts ............................ 43 Earthing switch - type EK6 ............................... 43 Earthing and short-circuiting with earthing module ................................................ 44 6.3 Test procedures ................................................ 44 6.3.1 Testing the off-circuit condition ......................... 44 6.3.2 Current and voltage tests ................................. 44 6.4 Service trucks ................................................... 45 7 7.1 7.1.1 7.2 7.3 7.4 7.4.1 7.4.2 7.5 7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.6 7.6.1 7.7 7.7.1 7.7.2 8 Maintenance .................................................... 54 General ............................................................. 54 Intervals for inspection, servicing and repairs . 54 Inspection ......................................................... 55 Servicing ........................................................... 55 Repair ............................................................... 56 Switchgear in general ....................................... 56 Replacement of complex functional groups ..... 57 Testing withdrawable parts ............................... 58 Motor-driven withdrawable parts ...................... 58 Checking correctness of dimensional settings ............................................................. 58 Checking auxiliary switch settings on withdrawable parts ............................................ 58 Checking the direction of rotation of the travel motors on motor-driven withdrawable parts ..... 59 Testing of interlock conditions .......................... 59 Tests on the panel ............................................ 60 Auxiliary switch settings on the earthing switch .................................................. 60 Spare parts, auxiliary materials, lubricants ...... 60 Spare parts ....................................................... 60 Auxiliary materials, lubricants ........................... 60 Product quality and enviromental protection ........................................................ 64

2/64

1.

Summary
UniGear is the new name of the ZS1 switchgear in release 1.2 (ZS1.2). The UniGear Double Level is a three-phase, metal-clad, air-insulated switchgear and all the units are factory-assembled, type-tested and suitable for indoor applications up to 17,5 kV. The units are designed as withdrawable modules on 2 levels and are fitted with a single busbar system. The withdrawable parts are equipped with circuitbreakers and contactors. Details of the technical design and configuration of individual switchgears, such as the technical data, detailed equipment lists for the individual panels and comprehensive circuit documentation etc., can be found in the relevant order documents.

1.1 General

1.2 Standards and specifications

UniGear switchgear panels comply with the standards and specifications for factory-assembled, metalclad and type tested high voltage switchgears to IEC publications 62271-200 and 60694. In addition, in accordance with IEC 60529, the switchgear panels have the following degrees of protection: IP 4X for the enclosure and IP 2X for the partitions. All other corresponding IEC publications, national or local safety at work regulations and safety regulations for production materials must followed during erection and operation of these systems. Above and beyond this, the order-related data from ABB must be taken into account.

1.3 Operating conditions

1.3.1 Normal operating conditions The switchgears are basically suitable for normal operating conditions for indoor switchgears and switchboards in accordance with IEC 60694. The following limit values, among others, apply: Ambient temperature: Maximum Maximum 24 h average Minimum (according to minus 5 indoor class) The maximum site altitude is 1000 m above sea 1.3.2 Special operating conditions Switchgears are suitable for operation in the climate of Wda type according to IEC 60 721-2-1. Special operating conditions must be discussed with the manufacturer in advance. For example: At site altitudes above 1000 m, the effects of the reduction in dielectric strength of the air on the insulation level must be taken into account (please refer to diagram in figure 1/1). Increased ambient temperatures must be compensated for in the design of the busbars and branch conductors as well as for the withdrawable parts, otherwise the current carrying capacity will be limited. Heat dissipation in the switchgear panel can be assisted by fitting additional ventilation facilities. Note on any special climatic operating conditions: When switchgears are operated in areas with high humidity and/or major rapid temperature fluctuations, there is a risk of dew deposits which must remain an exception 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 from the order documents. + 40 C + 35 C - 5 C level.

Figure 1/1: Curve for determination of the altitude factor k in relation to the altitude H.
3/64

2.

Technical data
Rated voltage Rated power frequency withstand voltage Rated lightning impulse withstand voltage Rated frequency Rated current of busbars Rated current of circuit-breaker branches Rated peak withstand current1) Rated short-circuit breaking current of circuit-breaker Rated short- time current 3 s
1)

2.1 Electrical data

kV kV kV Hz A A kA kA kA 1600 1600 125 50 50 12 28 75 50/60 1600 1600 100 40 40 17.5 38 95

1)

The short-circuit withstand capacity of the instrument transformers must be taken into account separately.

For individual switching device data, see the instruction manual for the relative switching device, as listed under 7.1.

2.2 Resistance to internal arc faults

The fault withstand capacity is as follows: 12 kV - 40 kA 1s - 50 kA 0.5s 17.5 kV - 40 kA 1s The switchgear units have been tested according to IEC 62271-200 Standards (appendix AA, class A, criteria 1 to 5). In individual cases, depending on the configuration of the switchgear panels and/or the switchroom conditions (e.g. low ceiling height), additional measures may be necessary to ensure compliance with criterion 5.

2.3 Dimensions and weights

4/64

2.3.1 Dimensions and weights of 12/17.5 kV units

Dimension Height Width - Feeder panels up to 1250 A (up to 31.5 kA)
1)

mm 2700

A B

750 (650 + 100) 900 (800 + 100) 900 (800 + 100) C 1976

- Feeder panels up to 1250 A (above 31.5 kA) - Feeder panels 1600 A Depth

1) Feeders equipped with contactor V-Contact are 750 mm wide up to the 50 kA short-time current.

Weights of 12/17.5 kV panels (including withdrawable circuit-breaker parts):

Rated current A ...1250 1600 Mass Kg 1300 1400

5/64

3.

Panel design and equipment

The basis for the UniGear double level panel is the CB compartment of the incoming/outgoing feeder panel with SF6 or vacuum circuit breaker using insertion technology. It is divided into busbar compartment B1, circuit-breaker compartment A1, cable compartment C1, busbar compartment B2, circuit-breaker compartment A2, cable compartment C2, control cabinet D, control cabinet d (available in deeper version on request) and gas exhaust duct E. Apart from this, there are variants for all operating needs. Pictures 3/1 and 3/2 show examples of possible configurations of a panel including electrical equipment. For busbar sectionalising, two panels are necessary, the coupling panel with the withdrawable circuitbreaker part and a bus riser panel (optional with busbar metering and earthing). In equipment without busbar sectionalising, a direct bar connection between the busbars will be established. Further details about installation and equipping the switchgear can be obtained from the order documents.

3.1 Basic structure and variants (Figures 3/1 to 3/3)

3.2 Enclosure and partitioning (Figure 3/3)

The enclosure and internal partitions of the panels are of 2mm thick high quality aluminium-zinc coated steel sheets. The six high voltage compartments (busbar compartments, circuit-breaker compartments and cable connection compartments) are equipped with secured pressure relief flaps. These open in case of internal arc fault. In order to premit the exhaust of the hot gases from high voltage compartments an additional channel has been added on the side of the panels. The additional panel is 100 mm width and it is placed within each panel and on both extremities of the switchboard (also in case of junction with UniGear single level panels). The front of the panel is closed off by pressure resistant doors which open to an angle of almost 180. Each circuit-breaker compartments have their own doors. The circuit-breaker compartments are equipped with inspection windows made of security glass. Neighbouring panels are partitioned from one another by the side walls of each panel and, as a result of the design, the air cushion remains between these walls when the panels are jointed together. The enclosure is completed pressure-relief flaps which, are made of sheet steel or expanded metal and below by means of floor-covering 17, made of sheet steel which cannot be magnetized. The pressurerelief flaps are secured with plastic screws. In the case of internal overpressure, the plastic screws are the point of rupture. Arc fault current limitation can be achieved by undelayed circuit-breaker release, carried out by auxiliary switches operated by the pressure wave. The switchgear can be equipped with the Fast recovery device: the auxiliary switches are mounted on the pressure sensors and operated by the sensor stroke pin (see chapter 3.6 - page 10/72) The necessary safety measures to counteract the effects of an internal arc fault must be ensured in relation to the ceiling height. In individual cases, this may require additional operator protection measures on the switchgear panels. The pressure relief duct is integrated in the design of the panel. The rear wall of the busbars of busbar compartment 84, intermediate wall 9, mounting plate 12 with shutters 12.1/12.2 and horizontal partition 20, form part of the internal partitioning. The internal partitioning makes safe access to the circuit-breaker and cable compartments possible even when the busbars are live. The low voltage compartment for the secondary equipment is completely protected from the high voltage area thanks to its steel-sheet casing. On the end sides, cover plates ensure good appearance and are mechanically and thermally arc fault proof should such an event occur in the end panel. Doors and cover plates are thoroughly cleaned and treated against corrosion before receiving a high quality double coating of paint. The finishing coat is in the standard RAL 7035 colour (special colours by agreement). Stoving completes the procedure and provides considerable insensitivity to impact and corrosion. The circuit-breaker compartment doors are pressure resistant and can either be fitted with screws or manual closing systems.

6/64

3.2.1 Ventilation of the panels (Figures 3/3, 6/20, 6/21) Openings in the outer enclosure are needed for the purpose of ventilation in the case of certain rated currents in the busbars and branch bars. For incoming air to the circuit-breaker compartment, the horizontal partition is provided with air-vents 20.2. IP4X degree of protection and safety in the case of any release of hot gas due to an arc fault are provided by flap 20.3 in the horizontal partition 20.

3.3 Compartments in the panels

3.3.1 Busbar compartments (Figures 3/3, 5/21 to 5/26, 5/29 to 5/34) The busbars have a flat cross-section made of copper and are laid in sections from panel to panel. According to the current rating, either single or double configuration is used. They are held by flat branch conductor 2 and, if installed, by busbar bushings 29. No special connection clamps are needed. Busbars and branch conductors for 17.5 kV are insulated by means of shrink-on sleeves. The bolt connections in the 17.5 and 24 kV busbar system are covered by insulating covers 58. The busbars for 12 kV units up to 1600 A are without any covers. By means of bushing plates 28 and busbar bushings 29, partitions can be created between panels. These partitions are necessary for higher rated short-time currents see the following table.

Rated voltage

Rated short-time withstand current 25 kA 31.5 kA

Partitions No 1) Every third panel 2) Every panel 3) Every panel 3)

12/17.5 kV 40 kA - 50 kA Marina application

1) In these panels, busbar bushings 29 and bushing plates 28 need not be mounted - the dynamic strength of the busbar system is sufficient. 2) In these panels, busbar bushings 29 and bushing plates 28 must be mounted in every third panel. 3) In these panels, busbar bushings 29 and bushing plates 28 must be mounted in every panel.

According to customer requirements, this separation into individual panels by means of busbar bushings 29 and bushing plates 28 can also be provided in switchgear panels where it is not technically necessary.

7/64

3.3.2 Circuit-breaker compartment (Figures 3/3, 3/8, 3/9, 3/10, 3/11, 5/20, 6/22) The circuit-breaker compartment contains all the necessary equipment for reciprocal operation of the withdrawable part and the panel. Like the busbar compartment, it is metallically partitioned on all sides. The tulip isolating contacts 5, together with the fixed isolating contacts, are located in mounting plate 12. The metal shutters 12.1/12.2, covering the insertion openings, are also included. The shutters are opened by means of actuating bars 13.16 of the withdrawable circuit-breaker part, using lever 38 when inserting into the service position, and are closed when the latter is removed. In the test/disconnected position of the withdrawable part, partitioning by separation is established in the main current circuit. Connection of the control wiring, required for test purposes, need not be interrupted when in the test/ disconnected position. In the test/disconnected position, the withdrawable part is still completely inside the panel with the door closed. The ON/OFF pushbutton located on the circuit-breaker, and the mechanical indicators for ON/ OFF and CHARGED/DISCHARGED can be observed through an inspection window. The switching operations are carried out with the doors closed. Installation of an additional mechanical switching device for manual operation of the circuit-breaker in the service position is also possible (see Fig. 3/14, 3/15). The socket 10.1 for the control wiring is mounted fixed in the circuit-breaker compartment. 3.3.3 Withdrawable parts (Figures 3/3, 3/9, 3/10, 3/12, 3/13, 3/16 to 3/19, 3/22, 3/25) 1. Withdrawable circuit-breaker parts The withdrawable circuit-breaker forms a complete module consisting of the VD4 type vacuum circuitbreaker, VM1 or SF6 type HD4 circuit-breaker, the withdrawable assembly 13.15, isolated contact arm 4.2 with contact system 4.3 and control wiring plug 10.2. The withdrawable assembly 13.15 and the circuit-breaker are coupled via a multi-pole control wiring plug connector 10.3. The withdrawable assembly establishes the mechanical connection between the panel and the circuitbreaker. The fixed part is connected to the panel by forking, which is form coded on both sides. The moving part with the circuit-breaker is moved manually or by a motor by means of a spindle, between the service or test/disconnected positions with the front doors closed. Service and test disconnected positions are set precisely by means of auxiliary switches, which register the final position reached and the angular position of the spindle. The earthing connection between the withdrawable part and the panel is established by its rollers and travel rails 42, which are bolted onto the panel. Withdrawable parts of the same design are interchangeable. In the case where the withdrawable parts have the same dimensions, but different circuit-breaker fittings, the control wiring plug coding prevents any erroneous connections between the withdrawable part and the panel. The coding is indicated in the order documents (see Fig. 3/25). 2. Withdrawable contactor parts (Figures 3/3, 3/20, 3/21) In place of the circuit-breaker type, the withdrawable part can also be fitted with the V-Contact type vacuum contactor. V-Contact is fitted with MV fuses 91.15 and can be used for rated voltage up to 12 kV. All the data mentioned in this chapter for circuit-breakers also apply to the contactors. 3. Other withdrawable parts The withdrawable part can also be fitted with the following trucks: metering voltage transformers truck with fuses; earthing truck without making capacity (for main busbar system and power cables); earthing truck with making capacity (for main busbar system and power cables); power cable testing truck; isolation truck; isolation truck with fuses.

8/64

3.3.4 Cable connection compartment (Figures 3/3, 5/18 to 5/20, 5/41, 5/42) The cable compartment contains current transformers 7, fixed and withdrawable voltage transformers 8, and earthing switch 6, according to individual operating requirements in each case. The cable compartment is constructed for installation of three current transformers. Should all three current transformers not be required, dummies will be installed in their place, using the same installation and connection procedures. The voltage transformers mounted fixed are connected on the primary side with flexible, fully- insulated cables which are inserted into the transformers. The EK6 type earthing switch can be used with either a manual or motor-operated mechanism. Its switching position will be indicated both mechanically and electrically by means of the auxiliary switch. Three surge arrestors can be mounted fixed, instead of the three-core cables. Cable connection of 12/17.5 kV units: In the 650 mm wide panel, up to three parallel plastic cables can be connected with single-core cable protection and push-on sealing ends with a maximum cross-section of 630 mm2. In the 800 mm wide panel, up to six parallel plastic cables can be connected with single-core cable protection and push-on sealing ends with a maximum cross-section of 630 mm2. Customer requests regarding connections to bars, three-core cables, special cables or sealing ends of different types must be considered during the order-planning stage.

3.3.5 Control cabinet (Figures 3/3, 3/7, 5/20, 5/39) The control cabinet is for all control and protection aspects, suitable for both conventional or microprocessor control technology. For details, see chapter 2.3. If the secondary devices are not intended for door installation, they are mounted on special metal strips.

3.4 Interlock/protection against erroneous operation

3.4.1 Panel internal interlocking (Figure 3/3, 3/18) To prevent hazardous situations and erroneous operation, there is a series of interlocks to protect both personnel and equipment: The withdrawable part can only be moved from the test/disconnected position (and back) when the circuit-breaker and earthing switch are off (i.e. the switch must be off beforehand.) In the intermediate position, the switch is mechanically interlocked. When the circuit-breakers have an electrical release, the interlock is also electrical. The circuit-breaker can only be switched on when the withdrawable part is in the test or service position. In the intermediate position, the switch is mechanically interlocked. When the circuitbreakers have an electrical release, the interlock is also electrical. In panels with digital control technology, prevention of malfunction of the switch can also be achieved by means of the panel software. In the service or test positions, the circuit-breaker can only be switched off manually when no control voltage is applied and it cannot be closed (electromechanical interlock). Connecting and disconnecting the control wiring plug 10.2 is only possible in the test/disconnected position of the withdrawable part.

9/64

 The earthing switch 6 can only be switched on if the withdrawable part is in the test/disconnected position or outside of the panel (mechanical interlock 1) ). If the earthing switch is on, the withdrawable part cannot be moved from the test/disconnected position to the service position (mechanical interlock). Details of other possible interlocks, e.g. in connection with a locking magnet on the withdrawable part and/or earthing switch drive, can be obtained from the relevant order documents. 3.4.2 Doors interlocking (Figure 3/4-1 to 3/4-8) The panels can be equipped with the following interlocks: The apparatus (circuit-breaker or contactor) cannot be racked-in if the apparatus compartment door is open (3/4-1 and 2). The apparatus compartment door cannot be opened if the apparatus (circuit-breaker or contactor) is in service or in an undefined position (3/4-3 and 4). 3.4.3 Interlocks between panels (Figure 3/1-6, 3/1-7, 3/2-6, 3/2-7) The busbar earthing switch can only be closed when all the withdrawable parts in the relative bus-bar section are in the test/disconnected position (electromechanical interlock). When the busbar earthing switch is closed, the withdrawable parts in the earthed busbar section cannot be moved from the test/disconnected position to the service position (electromechanical 2) interlock). 3.4.4 Locking devices (Figures 3/3, 6/13, 6/22) The shutters 12.1/12.2 can be secured independently of each other with padlocks when the withdrawable circuit-breaker part has been removed. Access to the operating-shaft 14.1 of the earthing switch can be restricted with a padlock. Access to the circuit-breaker racking slot can be restricted with a padlock. Access to the circuit-breaker compartment and the cable compartment from the backside of the panel can be restricted with a padlock.

3.5 Control wiring plug connector coding (Figure 3/25)

The control wiring plug connector coding allows withdrawable parts for switching devices to be assigned to particular panels. This ensures, for example, that withdrawable parts with different rated currents or different control wiring circuits can only be used in the panels they are intended for. Coding pins are fitted in the control wiring sockets 10.1 or control wiring plugs 10.2, and engage with the corresponding bores of the relevant plug 10.2 or socket 10.1 when the two parts are connected. The plug connector coding is order-related, and is noted in the relevant wiring documentation.

3.6 Fast recovery (Figure 3/5-1 to 3/5-4)

UniGear switchgears can optionally be equipped with Fast Recovery, a specific protection system. This system is based on pressure sensors 3/5-1, suitably located in the switchgear and directly connected to the shunt opening release installed in the circuit-breaker operating mechanism 3/5-2. The sensors detect the pressure rise front at the moment of an internal arc and promptly open the circuitbreaker. Thanks to the Fast recovery system, only the part involved in the fault is selectively excluded in under 100 ms (including the circuit-breaker opening time). Rapid elimination of the fault along with the metal segregation between compartments and the use of self-extinguishing materials drastically reduces any possible damage.

1) In the case of a motor operator, the mechanical interlock or the locking magnet is replaced by an electrical interlock of the earthing switch. The manual emergency switch is not locked!

2) The locking magnet is not installed in the case of a motor operator; busbar earthing switches or the withdrawable parts are electrically locked. The manual emergency switch is not locked!

10/64

Figures 3/1-1 to 3/1-8: examples of 12-17.5 kV panel variants.

Figure 3/1-1: Bustie/Feeder unit - 12 kV, 1250 A, 31.5 kA with fixed voltage transformers

Figure 3/1-2: Feeder/Feeder unit - 12 kV, 1250 A, 31.5 kA with fixed voltage transformers

Figure 3/1-3: Feeder unit - 12 kV, 1250 A, 31,5 kA with fixed voltage transformers

Figure 3/1-4: Riser/Feeder unit - 12 kV, 1250 A, 31.5 kA with withdrawable voltage transformer
11/64

Figure 3/1-5: Bustie/Feeder unit 12 kV, 1600 A, 40 kA, with fixed voltage transformer

Figure 3/1-6: Feeder/Feeder unit - 12 kV, 1600 A, 40 kA with fixed voltage transformer

Figure 3/1-7: Joint/Feeder unit - 12 kV, 1600 A, 40 kA, with withdrawable voltage transformers on Joint and with fixed voltage transformer on Feeder

Figure 3/1-8: Bus riser/Feeder - 12 kV, 1600A, 40 kA - with withdrawable voltage transformers on bus riser, fixed voltage transformer on Feeder and deeper low voltage upper box

12/64

1.1

1.2

D 84 A1 D1

B1 16 7 18 18.1 18.2 C1

12.1 12.2

5 5

13 18

6 8 14 14.1 14.2 84 3 2 8 B2 16 7 5 A2 D

12.1

13 21 C2 18 5 12.2

17 21 6

A1 B1 C1 A2 B2 C2 D D1

Upper busbar compartment Upper circuit-breaker compartment Upper cable compartment Lower busbar compartment Lower circuit-breaker compartment Lower cable compartment Control cabinet Control cabinet (available in deeper version on request)

1 1.1 1.2 2 3 5 6 7 8 12.1 12.2 13 14 14.1 14.2 16 17 18 18.1 18.2 21 84

Enclosure Pressure relief flap Control wiring duct Branch conductor Busbar Isolating bushing Earthing switch Current transformer Voltage transformer Top shutter Lower shutter Withdrawable part Earthing switch operating mechanism Operating shaft for earthing switch Slide Cable sealing end Floor cover split Spindle mechanism Spigot on spindle Hole in spindle for insertion lever Cable clamp Partition

Figure 3/3: Example of UniGear Doble Level feeder unit

13/64

Figure 3/4-1: Circuit-breaker compartment door enabling device (A)

Figure 3/4-2: Circuit-breaker truck enabling slot (A)

Figure 3/4-3: Circuit-breaker compartment door locking device (B)

Figure 3/4-4: Circuit-breaker compartment door locking pin (B)

14/64

Resetting the auxiliary contacts

Figure 3/5-1: Pressure sensor

Figure 3/5-2: Shunt opening release

Compressed air system

Figure 3/5-3: Fast recovery system

1 Pressure reducer 2 Lever for opening the air valve 3 Manometer

Figure 3/5-4: Testing equipment

15/64

Figure 3/6:

Feeder unit (with deeper version of low voltage upper box)

Figure 3/7:

Low-voltage compartment, internal view

10.2

13.1

18.1

14

Figure 3/8:

Circuit-breaker compartment, open. Withdrawable part in service position

Figure 3/9:

Circuit-breaker compartment, open. Withdrawable part in disconnected position, control wiring plug connector open 10.2 Control wiring plug 13.1 Withdrawable part 14 Earthing switch operating mechanism 18.1 Square spigot

16/64

12.1

4.3 4.2

4.1 5 12.2

12.2

Figure 3/10: Withdrawable part during insertion into the service position, shutters not yet fully open 4.2 Contact arm, with insulating sleeve 4.3 Contact system 5 Isolation tulip 12.1 Top shutter 12.2 Lower shutter

Figure 3/11: View inside the circuit-breaker compartment, withdrawable part removed, shutters open 4.1 Isolating contact 5 Isolating tulip 12.2 Lower shutter

13.13 13.10

13.13

13.16

13.15

Figure 3/13: Figure 3/12: Withdrawable part with circuit-breaker, type VD4, operating mechanism side

13.15 Withdrawable assembly

Withdrawable part with VD4 type circuitbreaker, - pole side 13.10 Pole tube cover 13.13 Lifting eyebolts 13.16 Actuating bars
17/64

45.3

45.2

45.1

Figure 3/14: Push button for mechanical ON/OFF breaker operation with the door closed (on request). If the withdrawable part is in the service position, operation is carried out using the knob which swings a push rod extension out. 45.1 Mechanical pushbutton 45.2 Turning knob

Figure 3/15: View of the push rod extension swung out by the knob at the front, with the withdrawable circuit-breaker part in service position and the door open

45.3

Swivelling push rod

31.9 31.16 31.2 31.3 31.5 31.6 31.4

Figure 3/16: Withdrawable part with VM1 type circuitbreaker - operating mechanism side 31.2 Ready display 31.3 ON pushbutton 31.4 OFF pushbutton 31.5 Mechanical operating cycle counter 31.6 Mechanical switch position indicator 31.9 Catch for emergency manual operating lever 31.16 Front cover plate
18/64

Figure 3/17: Withdrawable part with VM1circuit-breaker pole side

10.2

90.4

90.5

90.1

90.2 90.3 90.7 90.6 13.15

Figure 3/18: HD4 type circuit-breaker - side view

10.2 Control wiring plug 13.15 Withdrawable assembly

Figure 3/19: Operating and signalling parts of HD4 circuitbreaker 90.1 Signalling device for state of SF6 pressure (on request) 90.2 Opening pushbutton 90.3 Closing pushbutton 90.4 Operation counter 90.5 Circuit-breaker open/closed indicator 90.6 Shaft for manual closing spring charging 90.7 Signalling device for closing springs charged/discharged

91.15

91.13

91.14

Figure 3/20: V-Contact type vacuum contactor - front view 91.13 Signalling device ON/OFF 91.14 Operating cycle counter

Figure 3/21: V-Contact type vacuum contactor - pole side

91.15 MV fuses
19/64

95.2

95.1

18.2

18.1

S9

S8

10.3

Figure 3/22: Withdrawable assembly for circuit-breaker, with auxiliary switches S8 Test position indicator S9 Service position indicator 10.3 Control wiring plug connector for withdrawable assemly 18.1 Square spigot 18.2 Hole in spindle for insertion lever spindle

Figure 3/23: Withdrawable part with metering unit 95.1 Voltage transformer 95.2 Cast resin tube (with fuse cartridge)

20/64

10.5

10.4

10.1

B5 (B5) B2 (B1) 47 45 43 10 42 11 1 12 2 13 3 14 4 15 5 16 6 17 7 18 8 19 9 20 B3 (B4) B6 (B6) 31 B4 (B3) 54 55 56 57 58 25 36 26 37 27 38 28 39 29 40 30 41 53 24 35 52 23 34 51 22 33 50 21 32 49 46 44 B1 (B2) 48

Coding:
(...) The corresponding coding

designation for the control wiring plug is given in brackets (10.2) The coding pins can be fitted in the control wiring socket (10.1) and/or in the control wiring plug (10.2).
Basic design:

The number of sockets is optional, but the basic assignment is 1, 8, 10, 20, 21, 31, 33 and 40. Sockets and pins can be mixed as required in the control wiring socket (10.1) and control wiring plug (10.2).

10.4

Circuit breakers and contactors

12-17,5kV 650mm 400A 630A 1250A 1600A V VD4 VD4 VM1 VM1 HD4 HD4 VD4 VD4 VM1 VM1 HD4 HD4 VD4 VD4 VM1 VM1 800mm 1000mm

Socket pin coding (apparatus)

B1 B2 B3 O O O O O B4 O O B5 B6

Plug hole coding (panel)

B1 B2 B3 O O O O O O B4 O B5 B6

Isolating trucks
12-17,5kV 650mm 400A 630A 1250A 1600A 17.12.32 800mm 1000mm

Socket pin coding (apparatus)

B1 B2 B3 B4 B5 B6

Plug hole coding (panel)

B1 B2 B3 B4 B5 B6

Figure 3/25: Control wiring plug connector coding, shown for a 58-pole connector 10.1 Control wiring socket 10.4 Centring striking tabs 10.5 Bore for actuating pin of the control wiring plug for controlling the auxiliary switch

21/64

4.

Dispatch and storage

4.1 Condition on delivery

At the time of dispatch, the UniGear Double Level panels are factory-assembled, the withdrawable parts are in the service position and the doors are closed. The factory-assembled panels are checked at the works for completeness in terms of the order and simultaneously subjected to routine testing (normally without AC voltage testing of the busbars) to IEC publication 62271-200, and are therefore tested for correct structure and function. The busbars are not assembled. The busbar material, fasteners and accessories are packed separately.

4.2 Packing
According to the kind of transport and country of destination, the panels remain unpacked or are welded in foil and packed in seaworthy crates. A drying agent is provided to protect them against moisture: Panels with basic packing or without packing. Panels with seaworthy or similar packing (including packing for containerised shipments): - Sealed in polyethylene sheeting - Transport drying agent bags included - Moisture indicator included - When aluminium composite sheeting is used, an inspection window is fitted for checking. Observe the directions for use of the drying agent bags. The following applies: - Coloured indicator blue: contents dry - Coloured indicator pink: contents moist (relative humidity above 40%).

4.3 Transport (Figure 4/1)

The transport units normally comprise individual panels and, in exceptional cases, small groups of panels. The panels are each fitted with four lifting lugs. Transport panels upright. Take the high centre of gravity into account. Only ever carry out loading operations when it has been ensured that all precautionary measures to protect personnel and materials have been taken and use the following: Crane Fork-lift truck and/or Manual trolley 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.

4.4 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 damage (e.g. also for moisture and its detrimental effects). In case of doubt, the packing must be opened and then properly resealed, putting in new drying agent bags, when intermediate storage is necessary. If any quantities are short, or defects or transport damage are noted, these must be: - documented on the respective shipping document. - notified to the relevant carrier or forwarding agent immediately in accordance with the relative liability regulations. Note: Always take photographs to document any major damage.

22/64

4.5 Intermediate storage

Optimum intermediate storage, where it is necessary, without any negative consequences depends on compliance with a number of minimum conditions for the panels and assembly materials. 1. Panels with basic packing or without packing: A dry well-ventilated store room with a climate in accordance with IEC 60694. The room temperature must not fall below 5 C. There must not be any other negative environmental influences. Store the panels upright. Do not stack panels. Panels with basic packing: - Open the packing, at least partially. Panels without packing: - Loosely cover with protective sheeting. - Ensure that there is sufficient air circulation. Check regularly for any condensation until installation is started. 2. Panels with seaworthy or similar packing with internal protective sheeting: Store the transport units: - protected from the weather, - in a dry place, - safe from any damage. Check the packing for damage. Check the drying agent (also see section 4.2): on arrival of the consignment, - subsequently at regular intervals. When the maximum storage period, starting from the date of packing, has been exceeded: Note: Do not walk on the roof of the panels (rupture points in pressure relief devices!). the protective function of the packing can no longer be guaranteed, take suitable action if intermediate storage is to continue.

1.5

Figure 4/1:

Handling by crane 1.5 Lifting eyebolt

23/64

5.

Assembly of the switchgear at site

Always use protection gloves during assembly of the switchgear at site.

In order to obtain an optimum installation sequence and ensure high quality standards, site installation of the switchgear should only be carried out by specially trained and skilled personnel, or at least by personnel supervised and monitored by responsible persons.

5.1 General site requirements

On commencement of installation on site, the switch-room must be completely finished, provided with lighting and the electricity supply, lockable, dry and with facilities for ventilation. All the necessary preparations, such as wall openings, ducts, etc., for laying the power and control cables up to the switchgear must already be complete. The ceiling height must also be checked considering the top-mounted pressure relief duct. Compliance with the conditions for indoor switchgear according to IEC 60694, including the conditions for the minus 5 indoor temperature class must be ensured.

5.2 Foundations (Figures 5/1 to 5/14)

The switchgear must preferably be erected on a floor frame set into the switchroom floor or on a raised false floor. The structural data guideline listed below is to facilitate a rough calculation of the space required and for preliminary planning of the room design for a switchgear project. When the final construction documents are compiled, the binding data supplied by ABB must always be taken into account! Dimension chart of structural data (also see figures 5/1 to 5/14)
Rated voltage Panel width Aisle width 1) Door width Door height
2)

kV FT G mm mm mm mm 650 1350 850 2400

12/17.5 kV 800 1500 1000 2400

1)

Assembly opening in celing: Width Length Ceiling load

3)

mm mm kg/m2

1000 1500 1200

1000 1500 1400

2)

3)

Pay attention to appropriate national standards. Applies to low voltage compartments of standard height. Approximate numbers depending on the type of panels.

5.2.1 Anchoring bolts and base irons fixing systems (Figure 5/5 to 5/7, 5/9 to 5/14) Before installation, through holes must be drilled underneath each unit of the switchboard. A general foundation drawing is given in figures 5/9 to 5/14: The switchboard can be fixed either to the floor or to special base irons (supplied on request): For floor fixing, put the expansion and anchoring bolts in the fixing holes. Special bolt blocks are supplied for base iron fixing. The base irons must be fixed and buried in concrete. Four fixing holes are drilled in each unit base. Before positioning the different switchboard units, check both the levelness of the floor, with particular attention to longitudinal levelling (maximum planarity 2/1000). Fixing with anchoring 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.

24/64

 Drill the floor at the foreseen fixing points, referring to the slab drilling drawings. To make the holes, use a hammer drill with a = 16 mm bit. Insert the expansion anchoring bolts in the holes. Fixing with base irons to concrete floor: The base irons, which can be supplied on request, must be installed in the slab before finishing the floor: Rest the irons on the floor and line them up so that they are parallel and are spaced from each other as shown in the foundation drawing. Level the base irons both longitudinally and transversally. Fix the base irons in this position with expansion anchor bolts, using the holes provided in the base irons. Complete the flooring so that the base irons extend out by at least 0.5 mm from the finished floor surface. Fixing to a floating 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. Drill the floor at the foreseen fixing points, referring to our slab drilling drawings. To make the holes, use a drill with a suitable bit for the type of fixing to be made (through or threaded hole).

5.3

Assembly of the switchgear panels (Figures 3/3, 5/15 to 5/41)

Use screws of tensile class 8.8. The tightening torques for the busbar screw connections with dished washer are as follows:
Recommended tightening torque Lubricant Thread M6 M8 M10 M12 M16
1)

1) 2)

Nm

3)

Without 10.5 26 50 86 200

Oil or grease 4.5 10 20 40 80

2) 3)

The rated tightening torques for fasteners without lubrication are based on a coefficient of friction for the thread of 0.14 (the actual values are subject to an unavoidable range, in part not inconsiderable). Rated tightening torques for fasteners with lubrication in accordance with DIN 43 673 Standard . Thread and head contact surface lubricated.

Any tightening torques which deviate from those in the general table (e.g. for contact systems or device terminals) must be taken into account as stated in the detailed technical documentation. It is recommended that the threads and head contact surfaces of bolts should be lightly oiled or greased, so as to achieve a precise rated tightening torque. The individual installation stages are as follows: Remove withdrawable parts 13 from the switchgear panels and store them with suitable protection. Dismantle lifting eyebolts 1.5. Transport the switchgear panels to the prepared installation point following the sequence shown on the switchgear plan. Remove vertical partitions 9 in front of the busbar compartments by releasing the fixing screws. Release the fixing screws and draw out horizontal partition 20 below the withdrawable part travel rails. Release and remove floor cover 17. Remove covers 43.2 and 43.3 from the vertical control wiring ducts at the front right and left of the panel.

25/64

5.4 Installation of the busbars and bushings (Figures 3/3, 5/22 to 5/24)
Access to busbars is possible from the back of the panel, after dismounting of the back plate of the busbar compartment (this is valid for upper and lower busbar compartments). Install bushings 29 (for switchgears with busbar barriers only). Clean the insulation on the busbar sections with a soft, dry cloth, and check for insulation damage. Remove greasy or adhesive dirt as described in section 7.3. Busbar connections: The silver plated surfaces of the connections must be cleaned with a metal-free non-woven cleaning cloth and thinly and evenly coated with vaselin grease. The non-silver plated surfaces of the connections are either brushed with a wire brush, preserving the grease film, or cleaned with a metal-free non-woven cleaning cloth and evenly greased with a thin coat of vaselin grease. Prepare insulating covers 58 and lids 58.5 to suit the relevant busbar connections and thread them onto the busbar. (For insulated busbars only). Install the busbars panel by panel. Screw on the individual busbar elements one above the other (depending on the system layout) and in line with the flat branch conductor. Use the hexagonal socket head screws 163 provided. See the table above for the tightening torque. Use two dished washers for each screw. Bolt one holder 58.1 to each end of the busbars to support insulating cover 58. The screws for holder 58.1 must be tightened with a lower torque. (For insulated busbars only). Position insulating covers 58 and lids 58.5 over the relevant bolted joint, and slide the lid onto the cover until it clicks into place. (For insulated busbars only). Note: The connection of busbars is carried out with so called stabilized 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 according to the table in sect. 5.3. We recommend only inspecting tightness of busbar connections during repairs - see sect. 7.4.1.

5.4.1 Busbars and bushings for units 12/17.5 kV (Figures 5/21 to 5/24) Busbars are made of copper and have a flat cross-section for rated current up to 1600 A. Branch conductors always have a flat cross-section. 12/17.5 kV bushings are made of epoxy resin castings and are arranged as a single casting for all three phases (see fig 5/22). For 12 kV, the busbars are bare (without insulation) and without insulating covers up to 1600 A. For 17.5 kV, the busbars are insulated and fitted with covers over the whole current range.

5.5 Pressure relief ducts (Figure 3/1-1, 5/5 to 5/7, 5/17)

The pressure relief duct is integrated in the design of the panel. The screw fixing material is contained in the pressure relief duct set of bags. Rivet nuts are already provided in the metal sheets.

5.6 Cable connection

5.6.1 Power cables (Figures 5/18, 5/19, 5/41) The standard method for entry of power cables in the switchgear is shown in Fig. 5/18 and 5/19. The cables are conveyed from below rear through floor covering 17, which is divided at the cable entry point. The cables go through rubber reducer rings 17.2, which can be adapted to the required cable diameter in a range from 27 to 62 mm. Cables are fastened in the panel by means of cable clamps mounted on cable strips, which are part of the panel floor covering. The clamps make it possible to fasten cables with diameters between 35 and 54 mm.

26/64

Cable sealing ends are mounted on the cable cores according to the manufacturers instructions. It is possible to use cable sealing ends of different manufactures (e.g. Pirelli, Raychem etc.), but it is necessary to keep the length of the cable ends, including cable sealing ends, which is given by the distance of cable connecting bars 23 from the panel floor covering. These bars have different versions, which differ in their number of parallel cables and the values of rated and short-circuit currents. See Fig. 5/41, 5/42. The bars are equipped with holes for M16 screws. If M12 screws are used for cable connections, special washers with the diameter for M12 screws are supplied. In all cases, the earthing of cable screens is carried out on the strip-holding cable clamps. The cable strip is connected to the earth potential. Three fixed mounted surge arresters can also be installed here. But in both these cases the number of parallel cables must be reduced see the table. Connection of cables in typical panels:
Rated voltage (kV) Panel width (mm ) 650 12/17.5 800 1000 24 800 1000
1)

Max. number of parallel cables in phase 3

1)

Max. cross section of cables (mm2)

Range of cable clamp (mm)

Range of reducer ring (mm)

6 2)

630 35 - 54 27 - 62

3 6

1)

500

2)

2)

In the case where there are removable voltage transformers on the truck, or surge arresters are used, the number of parallel cables is reduced to a max. of 2 per phase. In the case where there are removable voltage transformers on the truck, or surge arresters are used, the number of parallel cables is reduced to a max. of 4 per phase.

Important note! Connection with single-core plastic insulated cables is presumed in the typical panels. In the case of any atypical cable connections or of special cables (e.g. three-core cables, cables with paper or special insulation etc.), an agreement must be reached between the customer and manufacturer. Mounting procedure for power cables: Power cables must be inserted, cut to length and stripped. Reducer rings 17.2 must be adapted to the cable diameter and fitted onto the cable. Cable sealing ends 16 must be prepared and mounted on cable cores according to manufacturers instructions. Cable eyes must be connected to the prepared connections bars 23 with strain relief. Earthing of cables must be connected. Individual parts of the floor covering must be mounted. Reducer rings 17.2 must be moved down so that nuts in the rings fit into the corresponding recesses in the floor coverings. In this way, the cable passages are sealed. Cables must be fastened in the prepared cable clamps 21 (the maximum tightening torque applicable to the clamp screws is 9 2 Nm). 5.6.2 Control cables (Figures 3/3, 5/1, 5/20) The control cables are conveyed into the panel through the control wiring duct 1.2 on the left-hand panel side and through the wiring duct placed in the intermediate 100mm width panel. Mounting procedure: Insert the cables into the control wiring duct 1.2 on the left-hand side (Fig. 3/3). The duct is covered by covers 43.1, 43.2 (Fig. 5/20). Connect control cables to the terminal strip according to the circuit diagram. Make the control wiring connections to adjacent panels using bushing 24 (Fig. 5/15).

27/64

5.7 Earthing the switchgear (Figures 3/3, 5/19)

Connect main earthing bar 19 with connections 19.1 provided in every panel. Protection wiring connection of the floor frame or the erected raised false floor respectively, should be made. Connect the earthing conductor coming from the earth electrode, preferably via a removable bolted connection for testing purposes, to the main earthing bar 19 of the switchgear.

5.8 Laying the ring circuits

The ring circuits are supplied rolled up in a bundle in the control cabinet. They are marked and fitted with ferrules at both ends. Openings are provided in the side walls of the control cabinet for these lines to be looped through from panel to panel.

5.9 Final erection work

Check painted areas of the switchgear for possible damage, touching up where required (see also section 7.4.1). Check bolt connections and tighten where required, in particular all those carried out during on-site erection of the busbars and earthing system. Clean the switchgear thoroughly. Remove all foreign bodies from the panels. Correctly replace all coverings, etc. removed during erection and connection. In the enclosure, any remaining openings must be closed if they are no longer needed. Check the isolating contacts and interlocking mechanisms for smooth motion, and grease again with vaselin where necessary (see section 7.4.1). Withdrawable circuit-breaker parts must be inserted and the control wirings connected. Panels doors must be properly closed.

28/64

Structural data

Top view

Figure 5/1:

Structural guideline data for foundation frame on concrete floor - UniGear Double Level -12/17.5 kV, panel depth 1976 mm G P Control cables entrance Power cables entrance

29/64

Figure 5/9-1: 12-17.5 kV - 650 mm wide units - anchoring bolt fixing system

Figure 5/9-2: 12-17.5 kV - 650 mm wide units - base iron fixing system

Figure 5/10-1: 12-17.5 kV - 800 mm wide units - anchoring

30/64

bolt fixing system

Figure 5/10-2: 12-17.5 kV - 800 mm wide units - base iron fixing system

Figure 5/14-1: anchoring bolts on concrete floor

Figure 5/14-2: base irons on concrete floor

Figure 5/14-3: through hole on metal structure

Figure 5/14-4: threaded hole on metal structure

31/64

1.11

28

1.9

1.5

1.3

1.3 1.5 1.9 1.11 28

Main earthing bar Lifting huck Threaded bush, for switchgear assembly Bore, for control wiring bushing 24 Bushing plate

Figure 5/15: For bolting the switchgear panels together, through holes are provided on the left-hand side and threaded bushes on the right-hand side, near the front and rear edges of the side walls, and through holes on both sides in the central part of the walls

50

50

26

Figure 5/16: End panel of a switchboard with bolted-on cover plate 26 Cover plate
32/64

Figure 5/17: Schematic diagram of the pressure relief duct. The components are assembled panel by panel and bolted together with overlaps at the panel joints. 50 pressure relief duct 1) If the switchgear is equipped with a pressure relief duct, the pressure relief flap for the cable connection compartment is fixed to the rear side of the panel and will open to the front (into the duct) in case of an arc fault.

19.2 23 19

17

21

39

Figure 5/18: View max. 17 23

into the cable connection compartment, six parallel cables possible Floor cover, split Cable connec

Figure 5/19: Partial view of the cable compartment, prepared here for connection of triple cables 19 Main earthing bar 19.2 Earthing connection pin 21 Cable clamp 39 Mounting rail, conncted to earth potential

1.8

20

43.1

Figure 5/20: View 1.8 20 43.1

into the high voltage area at the front Central catch Horizontal partition, removable Duct cover for external control cables

Figure 5/21: View into the busbar compartment, shown without insulating covers 2 Branch conductor 3 Busbar
33/64

a) Bushings with busbar supports with double D-shaped conductor

b) Bushings with busbar supports with single flat conductor

28

L1
9.3

L2

L3

29 2

Figure 5/22: Panels - 12/17.5 kV - Arrangement of the bushing plate and busbar bushing on the right-hand panel side wall. View of the inside 2 Branch conductor 3 Busbar section 9.3 Partition 28 Bushing plate 29 Busbar bushing

Rated busbar current

1250 A 2500 A 2500 A

Rated branch current

Figure 5/24: Pannels 12/17.5 kV Busbar junctions

2 3 3.2 3.3 3.4 58

34/64

Branch conductor Busbar section Spacer plate, 5 mm thick Spacer plate, 15 mm thick M 10 Bolt Insulating cover

23

23

21 21

17.2

17.2

In A 630 1000 1250 1600

with mm 750

Ith kA 31,5

max. number of cables in one phase

A mm

B mm

C mm

3/6 900 40-50

575

1320

90

Figure 5/41: Dimensions of power cable connection of UniGear Double Level 12/17.5 kV panels

17.2 Reducer ring 21 Cable clamp 23 Cable connection bar

35/64

6.

Operation of the switchgear

Note on safety at work The relative work and operating procedures must be carried out carefully by trained specialists familiar with the installation, taking into account all the relative safety regulations according to the IEC and other relevant professional bodies, as well as any local and work regulations and instructions. Note: Do not walk on the top surfaces of the switchgear panels (rupture points for pressure relief).

6.1 Commissioning
6.1.1 Preparatory work (Figures 3/13, 3/23) In preparation for commissioning, the following work must be carried out prior to connection with the high voltage power supply: Check the general condition of the switchgear for any damage or defects. Visually inspect the switching devices, withdrawable parts, isolating contacts, insulating parts, etc. Check connection of the main earthing bar to the installation earthing conductor (following the appropriate safety regulations). Check the paintwork for damage and, where necessary, touch up as described in section 7.4. Remove all residues of materials, foreign bodies and tools from the switchgear. Clean the switchgear, rubbing down insulating parts with a soft, dry, clean, non-fraying cloth. Remove any greasy or sticky dirt as described in section 7.3. Correctly remount all covers etc. removed during assembly and testing procedures. Transport caps 13.9 on vacuum circuit-breakers - if still fitted - must be removed. Pole tube lids 13.10 on vacuum circuit-breakers may be fitted in certain systems and on certain circuitbreakers. Check that they are fitted correctly. Lifting eyebolts 13.13 on high current vacuum circuit-breakers must be removed if still fitted. Preparatory works for SF6 circuit-breakers: - Clean the insulating parts with clean dry cloth. - Check that the upper and lower terminals are clean and free of any deformation caused by shocks received during transport and storage. - It is advisable to check the SF6 gas pressure. Perform AC voltage testing of the main circuits according to IEC 60298 where necessary. Pay special attention to voltage transformers and cables, etc. during this procedure. A testing and earthing module 142 can be used to make the connections (see section 6.3.2). Switch the auxiliary and control voltage on. Carry out testing operations on switching devices manually or by electrical control, and simultaneously observe the relative 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. On motorized withdrawable parts, check the direction of rotation of the travel motor in accordance with section 7.5.4. For any other matters regarding operation of the withdrawable circuit-breaker part and testing facilities for the withdrawable part, see section 7.5. Instruct local operators regarding the basic details of regular handling of the switchgear. Check readiness for operation and switching status of electrical systems upstream and downstream of the switchgear.

36/64

Depending on allocation of responsibilities, it may also be necessary to check the following equipment in areas adjacent to the switchgear: power cables auxiliary cables auxiliary power source remote control system complete earthing system switchroom equipment switchroom conditions 6.1.2 Start-up Comply with all relevant safety regulations. Ensure that the circuit-breakers in the system are in the OFF position. Remove any existing earthing and short circuiting connections in the critical switching area. Energize the feeder cables. Connect the switchgear step by step, observing the signals and indicators. Check that relative conductors are in phase, where necessary, when there are several incoming feeder cables and switchgear sections (also see section 6.3.2). Carry out all measurements and check all functions which depend on high voltage power supply being connected. Watch out for irregularities of any kind.

6.2

Switching operations
Carry out switching operations with the front doors closed. 6.2.1 Withdrawable circuit-breaker part (Figures 3/18, 3/22, 6/1, 6/5 to 6/12) Manual insertion from the test/disconnected position to the service position: Connect control wiring plug 10.2 Close the front door. Ensure that the circuit-breaker is in the OFF position. Fit hand crank 121 on square spigot 18.1 of the spindle mechanism 18, after opening the hole for them by turning slide 121.1. Turn the crank clockwise (approx. 20 turns at 12 - 17.5 kV and 30 at 24 kV) until the stop is reached and the withdrawable part is in the service position. Observe the position indicator. Remove hand crank 121. It must be considered that the spring loaded pin head 18.2 will lie completely on the rear side of the panel door when the hand crank is moved from square spigot 18.1 of spindle mechanism 18. This ensures that the rear part of the pin head has been shifted onto the hexagonal cap of the spindle and prevents unintentional wrenching of the spindle during panel service. Wrenching may lead to the circuit-breaker blocking. Note: The withdrawable part must not be stopped in any intermediate position in the travel range between the service and test/disconnected position!

37/64

Manual withdrawal from the service position into the test/disconnected position: Ensure that the circuit-breaker is in the OFF position. Reverse the procedure described above for insertion into the service position. Important note Insertion and withdrawal of circuit-breakers (and other withdrawable parts) must be gradual, in order to avoid any shocks which could deform the mechanical interlock. If the operations are prevented, do not force the interlocks and check that the operating sequence is correct. The force normally applicable to the insertion/withdrawing lever is 260 N. In any case, the maximum applicable force must never exceed 400 N. Please also refer to the technical documentation of the circuit-breakers for installation operations. Caution: the insertion and withdrawal must always be carried out with the circuit-breaker open! Do not use force to move withdrawable parts with locking magnet YO in the event of an auxiliary voltage drop. If this occurs, they are locked along the whole travel range between the service and test positions. To remove the interlock, consult the technical documentation of the circuit-breakers. Motorized movement of the withdrawable part: Briefly operate the electrical control for insertion or withdrawal (the withdrawable part then automatically moves into the opposite position). Observe the position indicator. Note When the drive motor is faulty, the withdrawable part can be moved using the emergency manual operation. If the drive motor fails during movement of the withdrawable part, the withdrawable part must be moved into a limit position using emergency manual operation. Emergency manual operation is carried out with hand crank 121 on spindle mechanism 18, in a similar way to operation of a withdrawable circuit-breaker part with manual systems. To disengage the motorized withdrawable part, consult section 7.5.1. Switch off the auxiliary power (m.c.b.), since the motor would otherwise be braked electrically. Turn hand crank 121 in the required direction. When the withdrawable part moves, the motor turns. In this case, the motor functions like a generator, i.e. it can lead to reserve voltages in the terminals. The motor fuse must not be changed from the specified type and rated value, otherwise the behaviour of the permanent magnet motor could be irreversibly impaired!

Caution In emergency manual operation of a motorized withdrawable circuit-breaker part, the interlock with the earthing switch is not effective! Withdrawal from the test/disconnected position onto the service truck: Open the door of the circuit-breaker compartment. Release control wiring plug 10.2 and place it in the storage position on the withdrawable part. Position service truck 124 with guide pins 124.2 of the adjustable bench top at the correct height facing the panel front, and allow catch 124.3 to engage. Move sliding handles 13.11 inwards against the springs to release withdrawable part 13, draw the withdrawable part out onto the service truck and secure it in the catches on the truck. Press release lever 124.4 (at the front underneath the bench top) and release the service truck from the switchgear panel. Secure the position of the shutters with padlock 130 (Fig. 6/22). Insertion from the service truck into the test/disconnected position: Carry out the procedure described above for withdrawal in reverse order.

38/64

6.2.2 Circuit-breaker - type VD4 Instructions for operating the circuit-breaker Safety indications The VD4 circuit-breakers guarantee a minimum IP2X degree of protection when installed in the following conditions: fixed version, installed behind metallic grid withdrawable version, installed in switchgear. Under these conditions the operator is totally guaranteed against accidental contact with moving parts. Should mechanical operations be carried out on the circuit-breaker outside the switchgear, be very careful of the moving parts. If the operations are prevented, do not force the mechanical interlocks and check that the operating sequence is correct. Racking the circuit-breaker in and out of the switchgear must be done gradually to avoid shocks which may deform the mechanical interlocks. Circuit-breaker closing and opening operations 2 5 4 Circuit-breaker operation can be either manual or electrical a) Manual spring charging operation To manually charge the closing springs, it is necessary to repeatedly activate the charging lever (2) (maximum rotation angle of the lever: about 90) until the yellow signalling device (7) appears which indicates completion of charging. The maximum forces which can normally be applied to the lever are <150 N for the EL1operating mechanism and <200 N for the EL2 operating mechanism. For the type of operating mechanism, please refer to the rating plate in fig. 5/42. b) Electrical spring charging operation On request, the circuit-breaker can be fitted with the following accessories for electrical operation: geared motor for automatic closing spring charging shunt closing release shunt opening release. 6 7 Figure 5/42: VD4 Circuit-breaker. The geared motor automatically recharges the springs after each closing operation until the yellow signalling device (7) appears. If the power is cut off during charging, the geared motor stops and automatically starts recharging the springs again when the power returns. In any case, it is always possible to complete the recharging operation manually. c) Circuit-breaker closing The operation can only be carried out with the closing springs completely charged. For manual closing, press the pushbutton (5). When there is a shunt closing release, the operation can also be carried out remotely by means of a special control circuit. Closing having taken place is indicated by the signalling device (6). d) Circuit-breaker opening For manual opening, press the pushbutton (4). When there is a shunt opening release, the operation can also be carried out remotely by means of a special control circuit. Opening having taken place is indicated by the signalling device (6). For further details, please refer to specific manual N. 647654.
39/64

6.2.3 Circuit-breaker - type VM1 Operation of the circuit-breaker drive Magnetic actuator The magnetic actuator used in the VM1 circuit-breakers generates the run required to operate the moving contacts of the interrupters and integrates all the functions of a traditional operating mechanism. The magnetic actuator is a bistable system where end-of-run positions of the moving armature are reached by means of magnetic fields generated by two coils (one for closing and one for opening). The moving armature is kept in position by permanent magnets. The circuit-breaker operations are obtained by means of energisation of the opening or closing coil respectively. The magnetic field generated by each coil attracts the moving armature and thereby moves it from one of the latching points of the permanent magnets to the other. The capacitors which allow circuit-breaker operation, for a maximum time of two minutes, even in the case of a drop in the auxiliary voltage, are provided in the control circuit. In case of emergency, the circuit-breaker can in any case be opened by means of a special crank handle which acts directly on the moving armature of the drive. Compared to a traditional operating mechanism, the magnetic actuator has few moving parts and greatly reduced wear even after a high number of closing and opening cycles. These characteristics therefore make it practically maintenance-free. Opening and closing operations The opening and closing operations can either be remotely controlled by means of the special inputs provided in the control module, or locally by pressing the pushbuttons (8 - 9) (fig. 5/43). During the operations, the moving anchor of the actuator acts directly on the moving contact by means of the kinematics. Reclosing function Thanks to the short duration of capacitor recharging, the drive is suitable for multiple reclosing operations with O-0.3s-CO-15s-CO cycle. Control module The control module is available in the standard version and in the complete version. Functions of the control module - standard version All the conditions for controlling the opening and closing commands given to the magnetic actuator are managed by a microprocessor: 8 9 the power supply voltage must be applied to the AC/DC converter. the capacitor must be sufficiently charged for the next operation: Figure 5/43: VM1 Circuit-breaker. Circuit-breaker position Open Closed Operations Closes and Opens Opens

the closing coil can only be activated when the circuit-breaker is open the opening coil can only be activated when the circuit-breaker is closed closing is disabled when an opening command is active at the same time de-activation of the opening or closing coil takes place when the relative limit position has been reached. WRONG POSITION (auto trip) function: if the final CLOSED (or OPEN) position is not reached within 70 ms during a closing (or opening) operation, an opening operation is immediately started to guarantee reaching a defined safe position in any case. The anti-pumping function ensures that only one closing-opening cycle is carried out when a closing command followed by an opening command is active. The active closing command must be cancelled and reset for the next closing operation. Activation of the input for the closing command can be locked by means of an external locking signal. The input for the lock on closing command must be energised to be able to close the circuit-breaker (without power it inhibits closing).
40/64

Additional functions of the control module - complete version When the FULL OPTION control module is requested, the following functions are also available: Undervoltage function: controls circuit-breaker opening if the voltage applied drops below the limit of tolerance (established by the Standards). The rated voltage value to be monitored is set in the factory in conformity with the order specifications. To prevent the function intervening when the voltage drops below the specified level (e.g. in the case of motor starting), it is possible to set a trip time. If no voltage is applied to the undervoltage function input, it is impossible to close the circuit-breaker. The undervoltage function can be disabled. In this case, it is possible to open and close the circuitbreaker without applying voltage to the input of the function. Monitoring function of the actuator closing and opening coil. This function serves to monitor the continuity of the closing and opening coils of the magnetic actuator to detect any faults. If a fault is detected, the luminous READY signal on front of the circuit-breaker turns off and the READY/NOT READY signalling contacts are activated. Additional safety opening command function. The second input of the control module for the opening function is designed so that an opening command is carried out directly even in the case of a fault in the microprocessor. READY signalling The luminous signal and relative READY/NOT READY contacts signal: capacitor charged detection of the correct CLOSED and OPEN positions by the position sensors watchdog (function only present on the FULL OPTION control module) If the luminous READY signal is off or flashing, please refer to the following table to find the cause. Truck locking magnet (compulsory device) The locking magnet is inserted in withdrawable circuit-breakers with manual movement and prevents traverse of the withdrawable truck when there is no power supply voltage. It is always provided as part of the safety interlock against withdraval of the circuit-breaker if closed for any fault.

Meaning of the signals according to the charging state of the capacitor/s

Circuit-breaker closed Ready signal: lit Ready contact: closed Not Ready contact: open Ready signal: flashing Ready contact: closed Not Ready contact: open Ready signal: flashing Ready contact: closed Not Ready contact: open Ready signal: off Ready contact: open Not Ready contact: closed Circuit-breaker open Ready signal: lit Ready contact: closed Not Ready contact: open Ready signal: flashing Ready contact: closed Not Ready contact: open Ready signal: off Ready contact: open Not Ready contact: closed Ready signal off: Ready contact: open Not Ready contact: closed Insufficient energy for opening Sufficient energy for one opening Sufficient energy for a C-O cycle Capacity of the capacitor/s Sufficient energy for an O-C-O cycle

Meaning of the signals according to the state of continuity of the coils

Circuit-breaker closed Ready signal: flashing Ready contact: closed Not Ready contact: open Ready signal: off Ready contact: open Not Ready contact: closed Circuit-breaker open Ready signal: off Ready contact: open Not Ready Contact: closed Ready signal off: Ready contact: open Not Ready contact: closed No continuity in the opening coil State of the coils No continuity in the closing coil

For further details, please refer to specific manual N. 1VCD 600182.

41/64

6.2.4 Circuit-breaker - type HD4

Instructions for circuit-breaker operation Safety indications

HD4 circuit-breakers ensure a minimum degree of protection IP2X if installed under the following conditions: fixed version, with protection netting withdrawable version, installed in a switchboard. Under these conditions, the operator is fully guaranteed against accidental contact with moving parts. Should any mechanical operations be carried out on the circuit-breaker outside the switchboard or with the protection netting removed, be very careful of any moving parts. If the operations are prevented, do not force the mechanical interlocks and check that the operation sequence is correct. The racking-in and racking-out operations of the circuit-breaker must be carried out gradually to prevent any impacts which might deform the mechanical interlocks. 2 7 Operating and signalling parts Circuit-breaker closing and opening operations (fig. 5/44) Circuit-breaker operation can be manual or electrical. a) Manual operation for spring charging To manually charge the closing springs, it is necessary fully insert the charging lever into the seat (6) and turn it clockwise until the yellow indicator (7) appears. The force which can normally be applied to the charging lever fitted is 130 N. In any case, the maximum force which can be applied must not exceed 170 N. b) Electrical operation for spring charging On request the circuit-breaker can be fitted with the following accessories for electrical operation: geared motor for automatic charging of the closing springs shunt closing release shunt opening release. The geared motor automatically recharges the springs after each closing operation until the yellow indicator (7) appears. Should there be no voltage during charging, the geared motor stops and then starts recharging the springs automatically when the voltage is on again. It is, however, always possible to complete the charging operation manually.

Figure 5/44: HD4 Circuit-breaker.

c) Circuit-breaker closing This operation can only be carried out with the closing springs completely charged. For manual closing, push the push button (3). When there is a shunt closing release, the operation can also be carried out with remote control by means of a control circuit. The indicator (4) shows that closing has been accomplished. In case of earthing truck with making capacity, activate the key lock (in the closed position) and remove the key. This is to prevent accidental opening operations during any maintenance work on the installation. d) Circuit-breaker opening For manual opening, push the push button (2).

When there is a shunt opening release, the operation can also be carried out with remote control by means of a control circuit. The indicator (4) shows that opening has been accomplished.
For further details, please refer to specific manual N. 647016.
42/64

6.2.5 Vacuum contactor - type V-Contact The V-Contact type vacuum contactor is ideal for controlling users in a.c. requiring a high number of operations. The contactors basically consist of a moulded resin monoblock, where the vacuum interrupters, moving apparatus, control electromagnet, multivoltage control feeder and auxiliary accessories are housed. The monoblock is also the support for assembly of the fuse-holder frame. Closing of the main contacts is carried out by means of the control electromagnet. Opening is carried out by means of a special opposing spring. The contactor can be equipped with electrical or mechanical latching. The fuses are positioned in special supports to be connected in series between the contactor and the user. The supports can house fuses in compliance with DIN or BS standards. For details, please refer to manual 647011.

Figure 5/45: V-Contact vacuum contactor.

6.2.6 Withdrawable metering parts (Figures 3/1-3, 3/1-4, 3/1-7, 3/1-8, 3/23) Handling of the withdrawable metering part in the metering panel is as described in section 6.2.1, without, however, the switching operations and interlocking functions. Withdrawable metering parts in incoming and outgoing feeder panels are put into the cable compartment using a ramp. They reach their service position immediately and engage in the panel earthing by means of the two locking pins at the sides. The voltage transformers used correspond to the type used in the metering panel, and therefore HRC fuses can also be used along with the voltage transformers. 6.2.7 Earthing switch - type EK6 (Figures 3/1, 3/3, 6/9, 6/12, 6/13, 6/14, 6/24) The earthing switch - type EK6 - has a snap closing mechanism which is independent of the rotation of the drive shaft. An earthing switch 6 allocated to a circuit-breaker is only enabled for switching when withdrawable part 13 is in the test/disconnected position or removed from the switchgear panel. Only turn earthing switches on when the doors are closed. Manual opening and closing: Press slide 14.2 onto the operating lever recess socket downwards. (When the switch is closed, it is already in this position!) Caution! If the operation is prevented, do not force the interlock and check that the operation sequence is correct. Fit operating lever 122 onto hexagonal shaft 14.1,which is now released for operation. Note Put operating lever 122 in pointed upwards or downwards on the hexagonal shaft so that there is sufficient room for movement of the operating lever even if space is limited at the sides. Turn the lever clockwise through approx. 180 until the 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 operating lever 122. Slide 14.2 remains open if the earthing switch is in the closed position. Make sure that the operating lever 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 mechanism can also be fitted with a locking magnet. The earthing switch for the lower cable compartment is provided with a special operating lever with the hexagon bush rotated of 90 with respect to the standard lever, in order to permit the 180 rotation of the hexagonal shaft which is placed at floor level.

43/64

6.2.8 Earthing and short-circuiting with earthing module (Figures 6/17 to 6/19) Isolate the area to be earthed and secure it against reconnection. Carefully follow all safety regulations. Remove the withdrawable circuit-breaker part from the relative switchgear panel. Secure the shutter in front of the live contact pins by means of the padlock. Screw on the earthing module 142 actuating bars 142.1 as follows: - To the top position for opening of bottom shutter. - To the bottom position for opening of top shutter. Further screw on the earthing module 142 insulating plate 142.5 with 3 removable bushings as follows: - Contact arms 142.2 in the bottom position for earthing of cable output feeder. - Contact arms 142.2 in the top position for earthing of busbars. Insert the earthing module 142 into the test/disconnected position and then move it into the service position with the hand crank 121 (for procedure - see sect. 6.2.1). Using a high voltage tester, check that contact pins 142.7 of the earthing module are definitely offcircuit. Withdraw the earthing module back into the test/disconnected position (see sect. 6.2.1). Mount a complete short circuit link 142.8 on the earthing module 142. Connect one end of earthing cable 133.1 under one of three screws M12, with which short circuit link 142.8 is connected to contact pins 142.7. Connect the second end of this cable to the earthing terminal 19.3 in the panel. Insert the earthing module 142 with short-circuit link 142.8 mounted and earthing cable 133.1 returned from the test/disconnected position into the service position in the panel with hand crank 121. For safety reasons, insert the module only with the circuit- breaker compartment door closed and with door catches 1.8 locked (see Fig. 5/20). Display earthing warning label on the switchgear panel door. Secure neighbouring areas to prevent inadvertent contact with live parts (e.g. feeder cables). The procedure for removing earthing is the same, only in reverse order.

6.3 Test procedure

6.3.1 Testing the off-circuit condition (Fig. 3/10, 3/11, 6/16, 6/17) In switchgear panels which are not equipped with capacitive voltage indication, checking the off-circuit condition is carried out with a HV tester on the isolating contacts 4.1 in the isolating tulips 5, after the corresponding upper shutter 12.1 or lower shutter 12.2 has been opened. Shutter opening can be carried out by means of module 129 - see Fig. 6/17. If the panels are equipped with capacitive voltage indication 125, checking the off-circuit condition can be carried out by means of this device. In this case, proceed according to the manufacturers instructions or the indicators. (Optionally, switchgear can be equipped with various types of indicators coming from various manufacturers). In case of any doubt about correct operation of capacitive voltage indication, the off-circuit condition must be checked using a HV tester. Checking the off-circuit condition must always be carried out in compliance with the relevant safety regulations and local operating conditions! 6.3.2 Current and voltage tests (Figures 6/4 , 6/16, 6/18, 6/19, 6/20) The testing and earthing module 142 is available for carrying out current and voltage tests. It is also suitable for supplying primary current to any current transformers which may be fitted during measurements in the protection circuit and, for example, for application of a test voltage during insulating tests. 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 contact pins 142.7. For AC voltage tests, ball 142.4 is required on the contact pin. The bore in the ball is used for connection of the voltage supply. For current tests, for example of small connected generators, the short-circuit bridge 142.8 must be fixed onto the contact pins. Note: With voltage tests at power frequency withstand voltage and/or impulse voltage, carry out the following procedure: Disconnect any voltage transformers and capacitive dividers and cover them with an insulating plate.
44/64

6.4

Service trucks
Instead of earthing, short-circuiting and testing with module 142 (see Fig. 6/18, 6/19 and chapters 6.2.9, 6.3.1, 6.3.2), it is possible to use the service trucks. These trucks are divided into four different types: Earthing truck without making capacity These trucks carry out the same function as the earthing switches without making capacity. Therefore they do not have any capacity to earth the live circuits under fault conditions. They are used to ensure fixed additional earthing, as required by the plant service and maintenance procedures, as at further guarantee for personnel. The use of these trucks foresees removal of the switching device from the switchgear (circuit-breaker or contactor) and its replacement with the truck. The units preset for use of earthing trucks are fitted with a key lock which, if activated, prevents their racking-in. This truck is available in two versions: main busbar system earthing; power cable earthing. During the racking-in phase, the main busbar earthing truck only lifts the top shutter and earths the contacts connected to the top branches (and therefore to the main busbar system) by means of the switchgear structure. During the racking-in phase, the power cable earthing truck only lifts the bottom shutter and earths the contacts connected to the bottom branches (and therefore to the power cables) by means of the switchgear structure. These trucks can also be used in the bus-tie units. In this case, they earth the two sides of the main busbar system. Earthing truck with making capacity These trucks carry out the same function as the earthing switches with making capacity. They consist of circuit-breakers only fitted with top (main busbar earthing) or bottom (power cable earthing) terminals. The contacts without terminals are short-circuited by means of a copper bar and connected to earth by means of the apparatus truck. They keep all the characteristics of the circuit-breakers, such as full making capacity and opening of the live circuits under fault conditions. They are used to ensure extremely efficacious earthing on circuits stressed by a fault. They allow opening and closing operations to be carried out rapidly with remote electric control. The use of these trucks foresees removal of the switching device from the switchgear (circuit-breaker or contactor) and its replacement with the truck. The units preset for use of earthing trucks are fitted with a key lock which, if activated, prevents their racking-in. This truck is available in two versions: main busbar system earthing; power cable earthing. During the racking-in phase, the main busbar earthing truck only lifts the top shutter and presets the contacts connected to the top branches (and therefore the main busbar system) for closing to earth by means of a control. During the racking-in phase, the power cable earthing truck only lifts the bottom shutter and presets the contact connected to the bottom branches (and therefore to the power cables) for closing to earth by means of the control. These trucks can also be used in bus-tie units. In this case, they earth the two sides of the main busbar system. Power cable test truck These trucks allow the insulation tests to be carried out on the power cables without accessing the feeder unit or disconnecting the cables from the switchgear. The use of this trucks foresees removal of the switching device from the switchgear (circuit-breaker or contactor) and its replacement with the truck. During the racking-in phase, the truck only lifts the bottom shutter and, by means of the connectors it is fitted with, allows connection of the test apparatus cables. This truck can only be used in the incoming/outgoing units.

45/64

Isolation truck The isolation truck allows the switchgear top and bottom contacts to be connected directly. Connection is made extremely safe by using the poles of the HD4 circuit-breakers to insulate the connection bars from the external environment. In the incoming/outgoing units, it connects the main busbar system to the power cables, whereas in the bus-tie units, to the two sides of the busbar system. This truck is used in the UniGear switchgears to make incoming/outgoing units without circuit-breakers in radial networks, to make cable connections between two switchgears placed in front of each other, and for constructing interconnection units and creating bus-tie-riser units with double insulation (in this case, both the units are made from bus-ties, the first fitted with a circuit-breaker and the other with an isolation truck). 1.17

1.18 145

Figure 6/1:

Operation of the door screw 1.18 Door screw 145 Double bit screw

Figure 6/2:

Operation of the door catch 1.17 Door catch

46 13.2

13.4

90

13.8 13.5

128 13.11 Figure 6/3:

Operation and communication via digital control system 46 REF542 Bay control and protection unit

Figure 6/4:

Manual operation of withdrawable part with VD4 circuit-breaker 13.2 Mechanical OFF push-button 13.4 Mechanical switch position indicator 13.5 Mechanical operating cycle counter 13.8 Charging condition indicator 13.11 Sliding handle, connected with the catch on the withdrawable assembly 128 Charging lever

46/64

145

121.1

121

Figure 6/5:

Before inserting the hand crank, it is necessary to open the hole for it - turn the slide by means of the key 121.1 Slide 145 Double bit key

Figure 6/6:

Movement of the withdrawable part between the test/disconnected position and the service position, clockwise up to the stop to the to the service position and anti-clockwise for the test/ disconnected position 121 Hand crank

32 10.2 45.2 10.1

45.1

Figure 6/7:

Control wiring plug connector blocked to prevent disconnection with the withdrawable part in the service position 10.1 10.2 32 Control wiring socket Control wiring plug Interlock

Figure 6/8:

Handling of the mechanical circuit-breaker operation in the switchgear panel door (nonstandard equipment) with the withdrawable part in the service position 45.1 45.2 Mechanical pushbutton Knob
47/64

13 13.11 13.12 124.4

124
Figure 6/9:

13

13.11

124

124.1

Service truck engaged with the switchgear panel. Withdrawable part released for withdrawal with the handles slid inwards 13 Withdrawable part 13.11 Sliding handle 124 Service truck

Figure 6/10: Withdrawable part standing on service truck and secured in the catches

13 Withdrawable part 13.11 Sliding handle 13.12 Catch (connected to sliding handle 13.11) 124 Service truck 124.1 Height adjuster 124.4 Release lever for catch pin (124.3)

10.1

12.1 43.3 124.2 124.3 12.2 42

124.1

14/ 14.1

Figure 6/11: Positioning the service truck with the guide pins on the adjustable height bench top at the correct height for approach to the switchgear panel, and engaging the catch

124.1 Height adjuster 124.2 Guide pin 124.3 Catch pin

48/64

Figure 6/12: View 10.1 12.1 12.2 14 14.1 42 43.3

into the circuit-breaker compartment Control wiring socket Top shutter Lower shutter Earthing switch operating mechanism Drive shaft Right-hand travel rail Duct cover, top right

14.1 122

14.2

Figure 6/13: Preparation for operation of branch earthing switch - press the slide downwards.

Figure 6/14: Preparation for operation of branch earthing switch - operating lever prepared for switching on/off

14.1 14.2

Hexagonal shaft of earthing switch operating mechanism Slide

122

Operating lever

90

90.8
Figure 6/15: Manual charging of HD4 circuit-breaker springs.

125
Figure 6/16: Voltage indicator, placed on door of control cabinet. It is possible to use various types of indicators from various manufacturers.

90 SF6 circuit-breaker type HD4 90.8 Charging lever

125

Voltage indicator
49/64

135

19.3 12.1 133.1 142

Note The drawing represents the hearting of the power cable through circuit-breaker compartment and it is applicable on double level, too.

Figure 6/17: Shutter operating module, side view- actuating bars must be bolted in the top position (for operation of the bottom shutters) or in the bottom position (for operation of the top shutters), as required (example version) 129 Shutter operating module 129.1 Actuating bars (one pair), removable

Figure 6/18: Earthing at the bottom pins 12.1 19.3 133.1 135 142 Shutter Earthing Earthing Warning Earthing terminal cable label module

50/64

133.1

Figure 6/19: Testing and earthing module with:

- Actuating bars, removable -

- top position for bottom shutter - bottom position for top shutter Contact arms, removable - bottom position for cable area - top position for busbar area Insulating plate with alternative mounting positions for cable or busbar earthing (turn through 180o for busbar earthing) Contact systems, replaceable for different contact pin diameters on the switchgear Ball handles, removable, for voltage tests Short-circuiting connection - can be replaced with ball handles Earthing cable Testing and earthing module with manual mechanism Actuating bars (1 pair) Contact arms (3 pcs.) Contact systems Ball handles (3 pcs.) Insulating plate with 3 removable bushinghs Bushings Contact pin Short-circuiting connection, complete

133.1 142 142.1 142.2 142.3 142.4 142.5 142.6 142.7 142.8

51/64

31.28 130 38
Figure 6/23: Manual emergency - off operation of the VM1 vacuum circuit-breaker with magnetic actuator 31.28 Emergency manual operating lever (for switching off VM1 type circuit-breaker)

Figure 6/22: Lower shutter secured with padlock to prevent unauthorized operation

38 130

Lever for shutter operation Padlock (customer component)

Note: During operation with the emergency operation lever 31.28, a mechanical resistance must be overcome following tension of the auxiliary spring 31.29 and at the end of the turning movement

52/64

145 128

147

31.29

31.28

122

121 90.8

Figure 6/24: Operating accessories

31.28 31.29 90.8 121 122 128 145 147

Emergency manual operating lever (for switching off VM1 type circuit-breaker) Auxiliary spring to secure the opening capacity (for VM1 type circuit-breaker) Charging lever (for HD4 type circuit-breaker) Hand crank (for moving the withdrawable part inside the panel) Operating lever (for earthing switch) Charging lever (for HD4 type circuit-breaker) Double bit key (for using the central catch and screw type door catch) Hand crank (for using the central catch or screw type door catch)

53/64

7.

Maintenance

7.1 General
Maintenance serves to preserve trouble-free operation and achieve the longest possible working life of the switchgear. It comprises the following closely related activities: Inspection: Servicing: Repair: Note: When carrying out all maintenance work, the regulations in the country of installation must be strictly complied with. Maintenance work may only be performed in a careful manner by trained personnel familiar with the characteristics of the individual switchgear, in accordance with all relevant IEC safety regulations and those of other technical authorities, and with other overriding instructions. It is recommended that ABB service personnel be called in to perform the servicing and repair work detailed below. The inspection and servicing intervals for some of the equipment/components (e.g. parts subjects to wear) are determined by fixed criteria, such as switching frequency, length of service and number of short-circuit breaking operations. On the other hand, for other parts the length of the intervals may depend, for example, on the different modes of operation in individual cases, the degree of loading, and also environmental influences (including pollution and aggressive air). The following operating instructions must also be followed, together with this instruction manual in the individual cases concerned: Vacuum circuit-breaker: type VD4 Vacuum circuit-breaker: type VD4- high-current Vacuum circuit-breaker with magnetic actuator mechanism: type VM1 SF6 circuit-breaker: type HD4 Vacuum contactor: type V-Contact 647654 BA 359/10E 1VCD 600182 647016 647011 Determination of the actual condition Measures to preserve the specified condition Measures to restore the specified condition

If necessary, further details can be taken from the technical documentation for the switchgear installation (including, for example, any special operating conditions agreed on). 7.1.1 Intervals for inspection, servicing and repairs Time intervals for maintenance work to be carried out always depend on the operating conditions of the switchgear, and mainly on the mode of operation, the number of rated and short-circuit current switching operations, ambient temperature, pollution etc. We recommend carrying out the maintenance work at the following intervals:
Activity performed According to section Time interval in years According to number of switching operations Inspection Servicing Repair
1) 2) 3)

7.2 7.3 7.4

4 1) 4 2) As required 10 000 3) As required

Under more demanding service conditions, we recommend shortening this interval appropriatel also sect. 7.1 and 7.2. According to results of inspection. See the instruction manual of the circuit-breakers.

54/64

7.2 Inspection
Where necessary, the working area must be isolated and secured against reconnection in accordance with the Safety Regulations specified by IEC and appropriate national standards before inspection. Correct condition of the switchgear should be monitored by regular inspections. Under normal operating conditions, inspection should be carried out once every four years by specially trained professional electricians. Under abnormal operating conditions (including adverse climatic conditions) and/or special environmental stresses (heavy pollution and aggressive atmosphere, among others), inspection may be necessary at shorter intervals. Inspection is primarily to carry out a visual check for grime, corrosion and moisture: - Effects of high temperature on the main circuits, - Traces of partial discharge on the insulating material parts, - Traces of leakage current on the insulating material parts, - Surfaces of the contact systems. However, inspection must also to include correct mechanical/electrical operation of the following parts: switching devices, actuating, interlocking, protection and signalling devices.

Caution: instrument transformer circuit. With regard to the switching devices, their separate Instruction manual should be followed. Check all switchgear accessories and auxiliary devices (e.g. storage batteries). No partial discharge must occur on the surfaces of equipment at operating voltage. This can, for example, be detected by characteristic noises, a clearly perceptible smell of ozone, or visible glowing in the dark. Visually checking the contact system. We recommend to turn the contact system alternately in order to clean the inner contact points of the contact system. The contact points should be cleaned if signs of overheating (discoloured surface) are visible (see section 7.4). If any irregular conditions are detected, then relative repair measures must be taken.

7.3 Servicing
If, during the course of an inspection in accordance with section 7.2, the need for cleaning measures has been established, proceed as follows: Where necessary, the working area must be switched off and secured against reconnection in accordance with the Safety Regulations specified by IEC and appropriate national standards before cleaning. Clean the surfaces in general: - Weakly adhering dry dust deposits: with a soft dry cloth. - More strongly adherent grime: with mildly alkaline household cleanser or with ETHANOL F 25 M. Clean insulating surfaces and conductive components with ETHANOL F 25 M. Wipe down after cleaning, using clean water, and dry properly. Should partial discharges occur as a result of condensation, application of a thin silicone film on the surface concerned is often effective as a temporary remedy. It is advisable to ask the ABB after-sales service department for advice regarding permanent solutions to this type of unusual problem.

55/64

7.4 Repair
7.4.1 Switchgear in general Repair of surface damage: 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 entire area. Then immediately apply an anti-rust primer and, after an appropriate hardening time, apply the top coat. Only use suitable and compatible paint products. Apply the top coat in standard RAL 7035 colour, or the relevant special colour. Carefully remove any white rust on aluminium/zinc surfaces with a wire brush or cleaning pad, e.g. Scotch-Brite, and clean loosely adhering particles with a dry, non-fraying cloth. Next treat the cleaned parts with zinc spray or zinc powder paint and, finally, treat with aluminium spray for colour matching. Carefully remove any white rust from passivated operating parts and rust formation on phosphatised parts with a wire brush or metal-free cleaning pad, e.g. Scotch-Brite, and clean with a dry cloth. Then grease evenly (vaseline). Switchgear in general: Follow the maintenance instructions in the manuals for individual equipment components. Check that the bolt connections at the contact points in the busbar system and the earth connections are tight, and that the contact system functions correctly. Where necessary, grease slide plates and bearings in the panel again or thoroughly clean them. Then grease them again with vaseline lubricant. Top 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 vaseline lubricant. Remove the contact system for thorough cleaning as described below (Figures 7/1, 7/3): - Slide in the two inner ring tension springs 4.4 facing the breaker pole to a position beside the other two outer ring tension springs, thus releasing contact system 4.3, and remove the contact system - The contact pin of the contact system and the slot on the contact arm must be cleaned and greased. Fit contact system back to front on the thin end of arbor 127 and slide it forwards onto the thicker part of the shank. - Fit arbor 127 onto the relative contact arm 4.2, slide the contact system 4.3 over onto the contact arm, and withdraw the arbor. - Check that all contact fingers and ring tension springs have a perfect fit. Note: The set installation position of contact arms 4.2 must not be changed by undue use of force Replacement of the contact pins when the surface is damaged: (Figure 3/11) After any required replacement of contact pins 4.1, the latter should be retightened using the socket head bolts.
Thread M10 M20 Rated tightening torque ungreased 46 Nm 250 Nm

56/64

7.4.2 Replacement of complex functional groups (Figures 3/3, 3/11, 7/3 to 7/11) Precise matching of functions for control, interlocking and signalling only permits replacement of individual components to a limited extent. The following assemblies are prefabricated and tested at the works, maintaining high quality standards. In the case of faults, they must therefore be completely replaced. 1. Withdrawable assembly: Disconnect plug connector 10.3. Remove interlock rod 13.91 with pin 13.27 from the withdrawable assembly. For motor-operated withdrawable assemblies, remove the two socket head bolts (M4), which are accessible from below the assembly. Remove the circuit-breaker from the withdrawable assembly (4 x M12 bolts). Mount the circuit-breaker on a new withdrawable assembly in the reverse order, using new circlips and special pliers for pin 13.27. Check the setting of interlocking rod 13.91. - Turn spindle 18 anti-clockwise to the stop for the disconnected position: The distance between lever 13.26 and cam 13.25 must be 21 mm. The distance between roller 13.24 and angle lever 13.92 must be 0.5 mm. - Turn spindle 18 clockwise to the stop for the service position: The distance between lever 13.26 and cam 13.25 must be 21 mm. The distance between roller 13.24 and angle lever 13.92 must be 0.5 mm. - Loosen bolts 13.91.2 or 13.92.1 for any necessary adjustment. Note: The auxiliary switches of the interchangeable groups are adjusted at the works. When final installation of the earthing switch and operator takes place on site, it may be necessary to carry out further precise adjustment of the auxiliary switch. In this case, the following should be taken into account: There must be a run-on of 0.5 mm in the fully operated position before the plunger reaches the stop (for safety reasons). Auxiliary limit switch 11.4 for earthing switch ON must be operated immediately after the dead centre position of the toggle spring mechanism has been reached in the closing process and the automatic quick-closing process has started. Auxiliary limit switch 11.3 for earthing switch OFF must a) be operated on earthing switches with manual mechanisms during the opening movement of slide 14.2 before half of the hexagonal shaft has become visible, or 1 mm before the tab of the slide makes contact with the armature of the de-energised locking magnet. b) be operated on earthing switches with motor operator (no slide 14.2 fitted) immediately after the toggle spring mechanism has passed the dead centre position during rotation to the OFF position.

57/64

7.5 Testing withdrawable parts (Figures 7/3, 7/4)

When functional tests are carried out on withdrawable parts, compliance with the conditions listed below should also be checked. 7.5.1 Motor-driven withdrawable parts (not standard) Carry out testing of motor-driven withdrawable parts in the same way as for manually operated withdrawable parts: Switch off the auxiliary power (m.c.b.), since the motor could otherwise be braked electrically. Turn hand crank 121 (fig. 6/24) in the required direction. Ensure that the spindle nut is correctly lubricated. Note When the withdrawable part moves, the motor turns. The motor functions like a generator in these cases, i.e. it can lead to reverse voltages in the terminals. 7.5.2 Checking correctness of dimensional settings (Figures 7/3, 7/9, 7/10) 1. The distance between lever 13.26 operated by tie-rod 13.91 and plastic cam 13.25 should be 21 mm. If adjustment is required, loosen the two bolts 13.91.1 and 13.91.2. Deviations from the specified value can have the following effects: Dimensions too large, locking system for the drive spindle deactivated. Dimensions too small, proper action of the electrical interlock no longer guaranteed. 2. The distance between roller 13.24 and angle lever 13.92 should be 0.5 mm when the circuitbreaker is closed. If adjustment is required, loosen the two bolts 13.91.2 and 13.92.1. 7.5.3 Checking auxiliary switch settings on withdrawable parts (Figures 3/22, 7/3) Compliance with the interlock conditions in the test/disconnected and service position areas is ensured by position signalling switches S8 and S9 located in the withdrawable assembly and factory-set. During testing operations, the withdrawable part must be moved by hand with the crank fitted and with the motor power switched off. 1. Settings in the area of the test/disconnected position: Move the withdrawable part out of the test/disconnected position towards the service position with a few turns of the crank. Slowly move the withdrawable part back to the stop. Auxiliary switch S8 must then switch over just before the stop is reached. Slowly insert the withdrawable part from the test/disconnected position towards the service position until auxiliary switch S8 just operates. In this position, it must still just be possible to move closing push-rod 13.2.1. For this test, the function of the locking magnet Y0 must be deactivated manually. This condition ensures that the electrical interlock takes effect before the mechanical interlock in the motion sequence involved. 2. Settings in the area of the service position: Move the withdrawable part out of the limit position towards the test/disconnected position with a few turns of the crank. Slowly move the withdrawable part forward again to the stop. Auxiliary switch S9 must then switch over just before the stop is reached.

58/64

7.5.4 Checking the direction of rotation of the travel motors on motor-driven withdrawable parts Move the withdrawable part by hand into a central position between the test/disconnected position and the service position. Remove the hand crank. Switch the auxiliary voltage for the travel motor on. Use the local electrical controls to check that the withdrawable part moves in the correct direction. Caution: Do not allow the withdrawable part to run up against a lock when the travel direction is incorrect! Switch the motor power off immediately (the travel process functions electrically by a seal-in system with limit position switch-off). There may be a danger of injury when the door is open! 7.5.5 Testing interlock conditions (Figures 3/9, 3/22, 6/6 to 6/8, 7/7) 1. The withdrawable part must only be movable from the test/disconnected position into the service position when the circuit-breaker is open and the earthing switch is open. Check the following conditions individually: With the circuit-breaker closed, insertion of the withdrawable part towards the service position must be locked after only half a turn of the crank in the clockwise direction, and it must not be possible to switch on the travel motor on motor-operated withdrawable parts. With the earthing switch closed, insertion of the withdrawable part towards the service position must be locked after only two clockwise turns of the crank, and it must not be possible to switch on the travel motor on motor-operated parts. Use no force! Also see the note in chapter 6.2.1! 2. The withdrawable part must only be movable from the service position into the test/disconnected position with the circuit-breaker open. Check this condition as follows: With the circuit-breaker closed, withdrawal movement of the withdrawable part must be locked after only half a turn of the crank in anti-clockwise direction, and it must not be possible to switch on the travel motor on motor-operated withdrawable parts. 3. Closing of the circuit-breaker must only be possible when the withdrawable part is in the defined test/disconnected position or service position. The control wiring plug 10.2 must previously have been inserted. Check this condition as follows: It must not be possible to close the circuit-breaker with the withdrawable part in any position between the test/disconnected position and the service position. Enabling of switching when the withdrawable part moves into the service position is carried out electrically by operation of auxiliary switch S9 in the withdrawable assembly, and slightly earlier mechanically - this corresponds to a position approximately half a turn of the crank before the stop. For movement into the test/disconnected position, the same enabling conditions apply in the same way, in this case by means of auxiliary switch S8 in the withdrawable assembly. 4. It must only be possible to open the circuit-breaker (manually) when the withdrawable part is in the service position or test/disconnected position and the control voltage has failed. Check this condition. 5. Withdrawable parts with order-related locking magnet Y0 may not be moved in case of control power failure, or when there is no control power. Do not forcibly move locked withdrawable parts! The locking magnet Y0 is only present on manually operated withdrawable parts. Releasing the locking magnet Y0: Remove front plate 13.17. Disengage locking magnet Y0 by pulling the magnet armature, While doing so, turn crank 121 about one half turn (either direction of rotation is permissible). The locking magnet is only active in the test position and service position. In intermediate positions it has no effect. 6. Disconnection of the control wiring plug 10.2 as well as later insertion must be locked in the withdrawable part service position.

59/64

Check this condition: 7. Operation of the earthing switch must only be possible when withdrawable part 13 is in the test/ disconnected position or the removed position (subject to any additional electro-magnetic interlocks in individual cases). Check this condition: With the withdrawable part in the test/disconnected position, it must be possible to press slide 14.2, in front of the earthing switch operating shaft 14.1, downwards to the opening position. The earthing switch can then be operated. With the slide pressed down, it must also be impossible to start the travel motor on motor-driven withdrawable parts. If the slide is pressed down slightly when the travel motor is running, the motor must then automatically switch off immediately. The selected travel direction is continued by pressing the button. It is only possible to press slide 14.2 down fully with a running travel motor when the latter is in the start-up phase. When the withdrawable part is moved inwards towards the service position, pressing down of slide 14.2 must be locked after only one and a half clockwise turns on the crank.

7.6 Tests on the panel

7.6.1 Auxiliary switch settings on the earthing switch (Figures 7/7, 7/8) 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.Auxiliary limit switch 11.4 (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 automatic rapid closing process has started. 3. Auxiliary limit switch 11.3 (Q8S1) for earthing switch OFF must a) be operated on earthing switches with manual mechanisms during the opening movement of the slide 14.2 before half of the hexagonal shaft has become visible, or 1 mm before the tab of the slide makes contact with the armature of the de-energised locking magnet. b) be operated on earthing switches with motor operators (no slide 14.2 fitted) immediately after the toggle spring mechanism has passed the dead centre position during rotation to the OFF position. Note: Check the direction of rotation of the motor after repair work. Do not allow the motor to run up against a lock if the direction of rotation is incorrect (also see section 7.5.4).

7.7 Spare parts, auxiliary materials, lubricants

7.7.1 Spare parts A spare parts list is available on request for procurement of spare parts. It basically includes moving parts and parts subject to wear. When parts are required, the serial number of the relative switchgear or switching device should always be quoted. 7.7.2 Auxiliary materials, lubricants Lubricant: Vaseline Halogen-free cleansers: ETHANOL F 25 M (for general cleaning) Touch-up paint: Standard colour RAL 7035

60/64

127.1
Figure 7/1:

127

4.3

4.6

4.2

(4.5)

4.3

4.4

127

Fit the contact system back-to-front on the thin end of the arbor and slide it onto the thicker shank area 4.3 Contact system 127 Arbor 127.1 Journal

Figure 7/2:

Slide the contact system over from the arbor onto the isolating contact arm and allow it to engage there 4.2 4.3 4.4 4.5 127 Contact arm Contact system Internal tension spring Hexagon socket head screw Arbor

10.3

Y1 13.2.1 13.26 13.24 13.2.1 13.25 13.26

13.3 13.92

Figure 7/3:

Motorized withdrawable part with VD4 type circuit-breaker in an intermediate position close to the test/disconnected position, with fitted crank for manual operation and circuit-breaker front panel removed 10.3 Control wiring plug connector of withdrawable assembly 13.2.1 ON push rod 13.24 Roller 13.26 Lever 13.92 Angle lever

Figure 7/4:

Detailed view of the opening and closing mechanism (VD4 type circuit-breaker) 13.2.1 13.25 13.26 Y1 ON push rod Plastic cam Lever Blocking magnet

61/64

31.9

31.6

31.15

31.16

31.26

31.27 31.10

31.26 31.6 31.5

Figure 7/5:

View of the magnetic actuator mechanism with auxiliary systems, front plate removed (VM1 type circuit-breaker) 31.5 Mechanical operating cycle counter 31.6 Mechanical switch position indicator 31.9 Catch for emergency manual operation lever 31.10 Actuator 31.26 Storage capacitor 31.27 Circuit-breaker control unit

Figure 7/6:

VM1 type circuit-breaker, switch position indicator 31.6 Mechanical switch position indicator 31.15 Sensor for VM1 circuit-breaker OFF signal 31.16 Sensor for VM1 circuit-breaker ON signal 31.26 Storage capacitor

11.3

14.1 14.2 14.3 11.4

Figure 7/7:

Manual earthing switch mechanism with auxiliary switches, side cover removed 11.3 11.4 14.1 14.2 14.3 Auxiliary switch Q8S1 - earthing switch Auxiliary switch Q8S2 - earthing switch Drive shaft (earthing switch) Slide Cam plate, adjustable OFF ON

62/64

13.25

13.25

13.26

13.26

13.91

13.91 13.90 13.91.1 13.24

max. 0.5

13.91.1 13.24
max. 0.5

13.91.2 13.92.1 13.27

13.91.2 13.92.1 13.27

13.92

13.92

Figure 7/9:

Detail in the area of a withdrawable part with VD4 type circuit-breaker with travel motor, viewed from the left-hand side 13.24 13.25 13.26 13.27 13.90 13.91 13.91.1 13.91.2 13.92 13.92.1 Roller Plastic cam Lever Pin Travel motor Tie-rod Bolt Bolt Angle lever Bolt

Figure 7/10: Mechanical interlock, withdrawable assembly/ VD4 type circuit-breaker, with manually operated withdrawable part

13.24 Roller 13.25 Plastic cam 13.26 Lever 13.27 Pin 13.91 Tie- rod 13.91.1 Bolt 13.91.2 Bolt 13.92 Angle lever 13.92.1 Bolt

41.1 41.3 41.2

0.1 +0.4

35.5
Figure 7/11: Mechanical interlock between the withdrawable assembly and the VM1 type circuit-breaker, setting the side lock

35.5 41.1 41.2 41.3

Circuit-breaker in closed position Pawl in the withdrawable assembly Link to the actuator Side blocker Screw
63/64

8. Product quality and environmental protection

The UniGear Double Level type panels are produced in compliance with the requirements of international standards for the quality management system and environmental management system. In these fields, the excellent level is proved by quality certificates according to ISO 9001 and by the EMS according to ISO 14 001. End of life of product The ABB company is committed to complying with the relevant legal and other requirements for environment protection according to the ISO 14 001 standard. The duty of company is to facilitate 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. We 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 as dielectric (transformer oil) SF6 gas Packing material wood Packing material foil RECOMMENDED METHOD OF DISPOSAL Separation and recycling Recycling or disposal Separation of metal material and the disposal of rest Disposal Draining from equipment and further recycling or disposal Discharging from equipment and further recycling or disposal Recycling or disposal Recycling or disposal

64/64

ABB Power Techmologies S.p.A. Unit Operativa Sace Via Friuli, 4 I-24044 Dalmine Tel: +39 035 395111 Fax: +39 035 395874 E-mail: sacetms.tipm@it.abb.com Internet://www.abb.com

ABB s.r.o. Org. unit EJF Vidensk 117, 619 00 Brno Czech Republic Tel: +420 5 4715 2413, 1111 Fax: +420 5 4715 2190 E-mail: info.ejf@cz.abb.com Internet://www.abb.com

1VCD003415 - Rev.-, en - Instruction Manual - 2006.01 (UniGear Double Level)

The data and illustrations are not binding. We reserve the right to make changes in the course of technical development of the product.