Ug Zs1 Iom Man Rev.h 2012 06

Medium voltage products
UniGear ZS1
Installation, operation and maintenance instruction manual
Your safety first at all times! 1
1. Summary 2
1.1. Introduction 2
1.2. General 2
1.3. Standards and specifications 2
1.4. Operating conditions 2
2. Technical data 4
2.1. Electrical data 4
2.2. Resistance to internal arc faults 4
2.3. Dimensions and weights 5
3. Panel design and equipment 7
3.1. Basic structure and variants 7
3.2 Enclosure and partitioning 7
3.3. Compartments in the panels 11
3.4. Interlock/protection against incorrect operation 16
3.5. Circuit-breaker and contactor plug connector
coding 21
3.6. I
th
Limitors 22
3.7. Fast recovery device 23
4. Dispatch and storage 24
4.1. Condition on delivery 24
4.2. Packing 24
4.3. Transport 24
4.4. Delivery 25
4.5. Intermediate storage 25
4.6. Handling 25
5. Assembly of the switchgear at site 29
5.1. General 29
5.2. Foundations 29
5.3. Assembly of the switchgear panels 47
5.4. Procedure for setting-up the doors of UniGear
switchgear with adjustable hinges 48
5.5. Installation of the bushing 52
5.6. Fixing of the panels 53
5.7. Installation of the busbars 54
5.8. Installation of the top-mounted boxes 63
5.9. Pressure relief ducts 71
5.10. Cable connection 73
5.11. Earthing the switchgear 79
5.12. Installation of interconnecting bundles 79
5.13. Final erection work 79
6. Operation of the switchgear 80
6.1. Switching operations 80
6.2. Test procedure 91
6.3. Service trucks 92

7. Commissioning 94
7.1. Preparatory work 94
7.2. Measurements and tests 95
8. Maintenance 96
8.1. Maintenance strategies 96
8.2. Preventive maintenance 96
8.3. Inspection 97
8.4. Servicing 99
8.5. Repairs 101
8.6. Risk-Based maintenance 103
8.7. Spare parts, auxillary materials and lubricants 103
8.8. Operating accessories 104
9. Product quality and environmental protection 105
1
Your safety first at all times!
If you have any further questions about this instruction
manual, ABBs field service team will be pleased to provide
the required information.
We reserve all rights to this publication. Misuse, 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 change.
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.
That is why our instruction manual begins with the
following recommendations:
Only install switchgear in closed rooms suitable for electrical
equipment.
Ensure that installation, operation and maintenance is only
carried out by qualified competent electricians.
Fully comply with the legally recognized standards (IEC or
local), the connection conditions of the local electrical utility
and the relevant safety at work regulations.
Observe the relevant information in the instruction manual
for all actions involving switchgear.
Danger!
Pay special attention to the hazard notes in the instruction
manual marked with this warning symbol.
Make sure that the specified criteria are not exceeded
under switchgear operating conditions.
Ensure the instruction manual is accessible to all personnel
involved in installation, operation and maintenance.
The users personnel must act responsibly in all matters
relating to safety at work and correct handling of the
switchgear.
2
k 1,0
0,8
0,6
0,4
1000 2000 3000 4000 m 5000 H
1. Summary
1.1. Introduction
The instructions in this publication refer to UniGear ZS1
medium voltage switchgear with either withdrawable
apparatus or LBS.
For correct use of the apparatus, please read the manual
carefully.
Thanks to the advanced design of ABB switchgear, UniGear
ZS1 is suitable not only for many different applications, but
also allows for further technical and construction
modifications to suit any installation requirements.
Consequently, this manual may not include some specific
instructions concerning special apparatus configurations.
In these cases, it is therefore strongly recommended
to consult both this manual and the latest technical
documentation (circuit and wiring diagrams, foundation plans
and any protection selectivity studies).
1.2 General
UniGear ZS1 is three-phase, metal-enclosed, air-insulated,
LSC-2B switchgear and all the units are factory-assembled,
type-tested and suitable for indoor applications up to 24 kV.
The units are designed as withdrawable modules and are
fitted with a single busbar system. The withdrawable parts are
equipped with circuit-breakers and contactors.
Details of the technical design and configuration of individual
switchgear, 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.
Figure 1: Curve for determining the altitude factor k in relation to the altitude H
1.3 Standards and specifications
UniGear switchgear panels comply with the standards and
specifications for factory-assembled, metal-enclosed and type
tested high voltage switchgear to IEC publications 62271-200
(r. 2011) and 62271-1 (r. 2007). 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 be followed during erection and
operation of these systems. Above and beyond this, the
order-related data from ABB must be taken into account.
1.4. Operating conditions
1.4.1. Normal operating conditions
The switchgear is basically suitable for normal operating
conditions for indoor switchgear in accordance with IEC
60271-200. Among other considerations, the following limiting
values apply:
The normal operational altitude is up to 1000 m above sea
level.
The indoor ambient conditions are free of significant pollution,
such as dust, smoke, corrosive and/or flammable gases,
vapors or salt, etc.
1.4.2. Special operating conditions
The switchgear is suitable for operation in the WDa type of
climate according to IEC 60721-2-1.
Ambient temperature:
- Maximum +40 C
- Maximum 24 h average +35 C
- Minimum (according to minus 5 indoor class) -5 C
Ambient humidity:
Maximum 24 h average of relative humidity 95% RH
Maximum 24 h average of water vapour pressure 2.2 kPa
Maximum monthly average of relative humidity 90% RH
Maximum monthly average of water vapour pressure 1.8 kPa
3
Special operating conditions must be discussed with ABB 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 the diagram in Figure 1).
Increased ambient temperatures must be compensated
in the design of the busbars and branch conductors,
otherwise the current carrying capacity will be limited.
Note on special climatic operating conditions:
When switchgear is operated in areas with high humidity and/
or major rapid temperature fluctuations, there is a risk of dew
deposits which must be excluded under normal operating
conditions for indoor switchgear.
Preventive action (e.g. suitable ventilation and proper air
conditioning of the building or housing, use of dehumidifying
equipment, etc.) must be taken into consideration with ABB
to avoid this condensation phenomenon and any resulting
corrosion or other adverse effects.
4
2. Technical data
2.1 Electrical data
2.1.1 Main parameters for panels with circuit breakers
2.1.2 Main parameters for panels with switch-disconnectors NALF
2.2 Resistance to internal arc faults
The fault withstand capacity is as follows:
12 kV - 50 kA 1s
17.5 kV - 50 kA 1s
24 kV - 31,5 kA 1s
For individual switching device data, see the instruction manual for the relevant switching device, as listed under 8.2.
Rated voltage kV 12 17,5 24
Rated power frequency withstand voltage kV 1 min 28 38 50
Rated lighting impulse withstand voltage kV 75 95 125
Rated frequency Hz 50/60
Rated current of busbars A ...4000 ...2500
Rated current of branches A ...630 ...630
Rated breaking current of switch-disconnector
(power factor = 0.7)
A ...630 ...630
Rated short-time withstand current of
switch-disconnector 1s
1)
kA ...25 ...20
Rated short-circuit making current kA ...40 ...38
Rated peak withstand current kA ...62.5 ...62.5
Auxiliary voltage V
DC 24, 48, 110, 220;
AC 110, 230
Rated voltage kV 12 17.5 24*
Rated power frequency withstand voltage kV 1 min 28** 38** 50
Rated lightning impulse withstand voltage kV 75 95 125
Rated frequency Hz 50/60
Main busbar rated current A 4000 4000 3150
Circuit-breaker rated current A 4000 4000 3100
Peak current kA 125 125 80
Internal arc withstand current kA 1 s 50 50 31,5
Rated short time withstand current kA 3 s 50 50 31,5
* 27,6 kV with VD4 according to CSA C22.2 No 31-10 is available
** 42 kV (GB/DL)
VSC7/P VSC12/P
Rated voltage kV 7.2 12
Rated insulation voltage kV 7.2 12
Rated power frequency withstand voltage kV 1min 20
(3)
28
(3)
Rated lightning impulse withstand voltage kV 60 75
Rated frequency Hz 50/60 50/60
Rated short-time withstand current kA
(1)
50 50
Peak current kA 125 125
Internal arc withstand current
(2)
kA 1s 50 50
Maximum rated current of the contactor A 400 400
2.1.3 Main parameters for panels with vacuum contactor
(1) Limited by the fuses.
(2) The internal arc withstand values are guaranteed in the compartments on the supply side of the fuses (busbars and apparatus) by the structure of the switchgear and on the load side (feeder)
by the limiting properties of the fuses.
(3) VSC7/PG for 32 kV power frequency withstand voltage and VSC12/PG for 42 kV power frequency withstand voltage are available on request in a dedicated panel.
The switchgear units have been tested according to IEC
62271-200 standard (Annex A, accessibility type A, IAC
classification FLR) and also to PEHLA recommendation no.
4. 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.
5
1)
Height of the control cabinet is 705/1100 mm
2)
1000 mm on request.
3)
Deeper units are available on request
4)
Feeders equipped with the VSC contactor are 650 mm wide up to the 50 kA short-
time current and up to 12 kV rated voltage.
2.3.1 Dimensions and weights of 12/17.5 kV units with
circuit-breakers and contactors
Weight of 12/17.5 kV panels (including withdrawable
circuit-breaker parts):
2.3 Dimensions and weights
Dimension mm
Height A 2200/2595
1)
Width
- Feeder panels up to 1250 A (up to 31.5 kA)
4)

- Feeder panels up to 1250 A (above 31.5 kA)
- Feeder panels 1600 - 2000 A
- Feeder panels above 2000 A
B
650
800
800
2)
1000
Depth
C
3)
- up to 2500 A, 31.5 kA 1340
- 3150 A, 40 kA 1355
- 4000 A, 40 kA 1390
- 3150 A, 50 kA 1390
- 4000 A, 50 kA 1455
Height of the basic part of panel D 2100
E 1495
Rated current Mass
A Kg
...1250 800-850
1600 850-900
2000 850-900
2500 1200
3150 1200
4000 1400
6
2.3.2 Dimensions and weight of 24 kV units with circuit-
-breakers
Weight of 24 kV panels (including withdrawable circuit-
breaker parts):
Rated current Mass
A Kg
...1250 1000-1050
1600 1200
2000 1200
2500 1200
Dimension mm
Height A 2325/2720
1)
Width
B

800
2)
1000
- Feeder panels up to 1250 A
- Feeder panels above 1250 A
Depth C
4)
1700
Height of the basic part of panel D 2200
E 1620
1)
Height of the control cabinet is 705/1100 mm.
2)
1000 mm on request.
3)
Dimension must be veried according to relevant order documentation.
4)
Deeper units are available on request
Height A 2200/2595
1)

Width
- Outgoing and incoming panels with
switch-disconnector
B
800
630 A
4)
Depth C 1300/1340
2)

Height of basic part of panel D 2100
E 1495
2.3.3 Dimensions and weight of panels with the switch-
-disconnector NALF 12 and 17,5 kV
2.3.4 Dimensions and weight of panels with the NALF
switch-disconnector 24 kV
1)
Height of control cabinet is 705/1100 mm.
2)
The depth of panel with the switch-disconnector in combination with HD4 circuit breaker
panels is recommended to be 1340 mm,
in other cases 1300 mm always take into account note 3)
3)
The dimensions must be veried according to the relevant order documentation.
4)
Max. current of LBS panel limited by coordinated fuses.
Weight of 12/17,5 kV panel (including the switch-disconnector):
Outgoing and incoming panels of width 800 mm......ca 750 kg
1)
Height of control cabinet is 705 /1100mm
2)
The depth of panel with the switch-disconnector in combination with HD4 circuit breaker
panels is recommended to be 1560 mm, in other cases 1520 mm always take into
account the note 3)
3)
The dimensions must be veried according to the relevant order documentation.
4)
Max. current of LBS panel limited by coordinated fuses.
Weight of 24 kV panel (including the switch-disconnector):
Outgoing and incoming panels of width 1000 mm.....ca 950 kg
Dimension mm
Height A 2325/2720
1)
Width
B 1000
- Outgoing and incoming panels with
Depth C 1520/1560
2)
Height of basic part of panel D 2200
E 1620
7
3.1 Basic structure and variants
The basis for the UniGear panel is the incoming/outgoing
feeder panel with SF
6
or vacuum circuit-breaker using insertion
technology. It is divided into busbar compartment I., circuit-
breaker compartment II., cable compartment III. and control
cabinet IV. for the secondary equipment. Apart from this, there
are variants for all operating needs.
For busbar sectionalising, two panels are necessary, the
coupling panel with the withdrawable circuit-breaker 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.
The UniGear switchgear also includes the variant of incoming/
outgoing panel with the NALF switch-disconnector with the
stationary mounting of the switch-disconnector. The panel
is divided into busbar compartment A, switch-disconnector
compartment including cables B and control cabinet for the
secondary equipment D.
Further details about installation and switchgear equipment can
be obtained from the relevant order documents.
3.2 Enclosure and partitioning
The enclosure and internal partitions of the panels are of 2
mm thick high quality AlZn sheets. The three high voltage
compartments (busbar compartment, circuit-breaker
compartment and cable connection compartment) are equipped
with top-mounted and secured pressure relief aps. These open
in the case of overpressure due to an internal arc fault.
The front of the panel is closed off by pressure resistant doors
which open to an angle of 130.
Cable and circuit-breaker compartments have their own doors,
both compartments can be 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 on the roof by top-mounted
pressure relief aps which, according to the rated branch
conductor current, are made of sheet steel or expanded metal
and at the base by means of oor-covering 17 (Figures 2, 3),
made of Al sheet.
The pressure-relief aps are secured with steel screws on one
longitudinal side and on the other longitudinal side with plastic
screws. In the case of internal overpressure, the plastic screws
are the rupture point.
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 following systems:
I
th
limiter: the auxiliary switches 11.5 (gure 34) are operated by
the pressure relief aps.
Fast recovery device: the auxiliary switches are mounted on
the pressure sensors and operated by the sensor stroke pin (see
chapter 3.7).
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. These measures
include:
1. Mounting a pressure relief duct 50 (gure 123) on the top
of the switchgear, with further channels leading out of the
switchgear room in a form appropriate for the design of the
building. The shock wave and arc discharge are channelled off in
ducts.
2. Mounting a pressure relief duct with blow-out apertures
located above the duct at the ends of the switchgear and
pointing towards the centre of the switchgear (diverter duct).
The shock wave and arc discharge then emerge in an extremely
attenuated form and in a location which is not critical for the
operating personnel.
The rear wall of the 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 (Figures 2, 3).
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 a 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 nishing coat is in the standard RAL 7035 color
(special colors by agreement). Stoving completes the procedure
and provides considerable resistance to impact and corrosion.
The circuit-breaker compartment and cable connection
compartment doors are pressure resistant and can either be
tted with screws or manual closing systems. (central handle)
3.2.1 Ventilation of the panels
Openings in the outer enclosure are needed for 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 is provided by flap 20.3 in the
horizontal partition 20. For outgoing air, the pressure relief
flaps 1.1 incorporate vents which provide the IP4X degree
of protection (Figure 2, 3).
In cases of higher ambient temperature (>40 C) and/or
increased frequency (60 Hz) it necessary to apply the rating.
It is necessary to use forced fan ventilation in 3600 A and
4000 A panels for 12/17.5 kV rated voltage and in 3150 A
panels for 24 kV rated voltage. Please refer to figure 169 and
170.
3. Panel design and equipment
8
Instructions for switching of cooling fans:
INCOMER 12/17.5 kV 4000 A, ambient temperature max. 40C
Current
FAN 1
Circuit Breaker
FAN 2
Current transformers
Note
< 3200 A No No both fans are stopped
=> 3200 A Yes Yes both fans start operation
INCOMER 12/17.5 kV 3600 A, ambient temperature max. 40C
Current
FAN 1
Circuit Breaker
Note
< 3200 A No fan is stopped
=> 3200 A Yes fan starts operation
INCOMER 24 kV 2500 A, ambient temperature max. 40C
Current
FAN 1
Circuit Breaker
Note
INCOMER 24 kV 3150 A, ambient temperature max. 40C
Current
FAN 1
Circuit Breaker
Note
12.1
15.1
10
1.2
13
12.2
19
20.2
18
14
21
20
1.1
1
2
3
84
5
12
7
6
17
8
18
18.1
18.2
14
14.1
14.2
20.2
A
B
D
C 16
1.2
9
20.3
9
A Busbar compartment
B Circuit-breaker compartment
C Cable compartment
D Low voltage compartment
1 Enclosure
1.1 Pressure relief flap
1.2 Control wiring duct
2 Branch conductor
3 Busbar
5 Isolating bushing
6 Earthing switch
7 Current transformer
8 Voltage transformer
9 Partition removable
10 Control wiring plug connector
12 Mounting plate
12.1 Top shutter
12.2 Lower shutter
13 Withdrawable part
14 Earthing switch operating mechanism
14.1 Operating shaft for earthing switch
14.2 Slide
15.1 Terminal rack
16 Cable sealing end
17 Floor cover split
18 Spindle mechanism
18.1 Spigot on spindle
18.2 Hole in spindle for insertion lever
19 Main earthing bar
20 Horizontal partition, removable
20.2 Ventilation grid
20.3 Back flap
21 Cable clamp
84 Partition
Figure 2: Example of UniGear feeder unit
10
A Busbar compartment
B Switch-disconnector and cable compartment
D Low voltage control cabinet
1 Enclosure
1.1 Pressure relief flaps
1.2 Control wire duct
2 Branch conductor
3 Busbar
15.1 Terminal rack
16 Cable sealing end
17 Floor cover - split
21 Cable clamp
84 Partition
200 Switch-disconnector
200.1 Position indicator of switch-disconnector
201 Operating mechanism of switch-disconnector
201.1 Operating shaft of switch-disconnector
201.2 Slide
202 Fuse or link
203 Insulator or current transformer
204 Bushing
205 Insulating partition wall
205.1 Movable insulating plate
207 Earthing switch
207.1 Position indicator of earthing switch
207.2 Interlocking of earthing switch
208 Operating mechanism of earthing switch
208.1 Operating shaft for earthing switch
208.2 Slide
Figure 3: Example of panel with 12 kV switch-disconnector with fuses and earthing switch
11
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.
Top-mounted boxes with busbar earthing switches, or busbar
voltage transformers can be placed above the units.
3.3 Compartments in the panels
3.3.1 Busbar compartment
The busbars 3 (Fig. 2, 3) have a flat cross-section made of
copper and are laid in sections from panel to panel. For higher
rated currents (3150, 3600 and 4000 A), the busbars have
a open D-shaped cross-section. According to the current
rating, either single or double configuration is used. They are
held in place by the flat branch conductor 2 (Fig. 2, 3) and,
if installed, by busbar bushings 29 (section 5.5). No special
connection clamps are needed.
Busbars and branch conductors for 17.5 and 24 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 (section 5.7). The busbars for 12 kV units
up to 2500 A do not have covers. Open D-shaped busbars
3150, 3600 and 4000 A are insulated and the connections are
covered.
By means of bushing plates 28 and busbar bushings 29
(section 5.5), 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
Partitions
25 kA
Every lateral panel; from 12 panels addi-
tional partiton in the middle; from 21 pa-
nels 2 additional partitions in each third
12/17.5 kV 31.5 kA Every lateral panel and every third panel
40 kA, 50 kA Every panel
24 kV
25 kA
Every lateral panel; from 12 panels addi-
tional partiton in the middle; from 21 pa-
nels 2 additional partitions in each third
31.5 kA Every panel
Marine / Seismic
version
All ratings Every panel
12
3.3.2 Circuit-breaker compartment
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 (Figure 2). The
metal shutters 12.1/12.2 (Fig. 4), covering the insertion
openings, are also included. The shutters are opened by the
actuating bars of the withdrawable circuit-breaker part, using
the lever 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. If the circuit breaker
is in service position.
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. 7, 8).
The socket 10.1 for the control wiring is mounted in the
circuit-breaker compartment (Fig. 4).
10.2
13.1
18.1
10.1
12.1
43.3
12.2
42
14/14.1
Figure 4: View into the circuit-breaker compartment

10.1 Control wiring socket
12.1 Top shutter
12.2 Lower shutter
14.1 Drive shaft
42 Right-hand travel rail
43.3 Duct cover, top right
Figure 5: Circuit-breaker compartment, open.

Withdrawable part in test position, control wiring plug connector open
10.2 Control wiring plug
13.1 Withdrawable part
18.1 Square spigot
Figure 6: Withdrawable part with VD4 type circuit-breaker, pole
side
13
2. Withdrawable contactors
In place of the circuit-breaker type, the withdrawable part can
also be fitted with the VSC type vacuum contactor.

VSC is fitted with MV fuses 91.15 (Fig. 154) and can be used
for rated voltage up to 12 kV.

All the data stated in this chapter for circuit-breakers also
applies 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.
shutter lifting truck.
3.3.3 Withdrawable parts
1. Withdrawable circuit-breakers
The withdrawable circuit-breaker forms a complete module
consisting of the vacuum circuit-breakers type VD4 or VM1,
SF6 circuit-breaker type HD4 the withdrawable assembly
13.15, isolated contact arm 4.2 with contact system 4.3 and
control wiring plug 10.2 (Fig. 7, 164).
The withdrawable assembly 13.15 and the circuit-breaker are
coupled via a multi-pole control wiring plug connector 10.3
(Fig 9, 10).
The withdrawable assembly establishes the mechanical
connection between the panel and the circuit-breaker. The
fixed part is connected to the panel by a forked connection,
which is form coded on both sides. The moving part with the
circuit-breaker is moved either 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 (Fig.
4), which are bolted onto the panel.
Withdrawable parts of the same design and electrical
parameters are interchangeable. In the case where the
withdrawable parts have the same dimensions, but different
electrical parameters, the control wiring plug coding prevents
any incorrect connections between the withdrawable part and
the panel.
45.2
45.1
45.3
Figure 7: 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 8: 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
13.15
18.2 18.1 S9 S8 10.3
91.14
91.13
Figure 9: Withdrawable part with circuit-breaker, type VD4, operating
mechanism side
13.15 Withdrawable assembly
Figure 11: VSC type vacuum contactor - front view
91.13 Signalling device ON/OFF
91.14 Operating cycle counter
Figure 12: VSC type vacuum contactor - pole side
91.15 MV fuses
91.15
14
Figure 10: 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
15
3.3.4 Cable connection compartment
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
(Figure 2).
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 fixed voltage transformers are connected on the primary
side with flexible, fully-insulated cables which are connected
to the transformers.
The removable voltage transformers are fitted with HRC fuses.
The earthing switch can be used with either a manual or
motor-operated mechanism. Its switching position will be
indicated both mechanically by indication on the shaft and
electrically by means of the auxiliary switch.
Three fixed surge arrestors can be mounted instead of one
position of single-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 mm
2
.
In the 800 or 1000 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 mm
2
.
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.
Cable connection of 24 kV units:
In the 800 mm wide panel, up to three parallel plastic cables
2
.
In the 1000 mm wide panel, up to six parallel plastic cables
2
.
For more information regarding cable connection, see chapter
5.10.
3.3.5 Control cabinet
The height of the control cabinet is 705/1100 mm. For details,
see chapter 2.3.
If the secondary devices are not intended for door installation,
they are mounted on DIN RAILS that enable any subsequent
changes to the wiring. In the lower part of the control cabinet,
there are three rows of DIN RAILS on the swivelling DIN RAILS
holder and, below these, there is an easily accessible auxiliary
switch for the control wiring plug.
Secondary wiring inside the panel is in a duct on the right
side of the panel. The left side of the panel is for the external
wiring. The ducts are covered with steel sheet 43.1, 43.2 (Fig.
76). There are holes for sliding in the ring conductors at the
side of the control cabinet.
3.3.6 Switch-disconnector and cable compartment in the
panel with switch-disconnector
The switch-disconnector and cable compartment is merged.
The stationary switch-disconnector is connected to busbars.
The interconnection to the busbar compartment is carried
out by bushings, which secures the separation of busbar
compartment from all other switchgear compartments.
The switch-disconnector and cable compartment is also
separated from other compartments by metal partitions.
The switch-disconnector can optionally contain an integrated
earthing switch. The switching positions of the integrated
earthing switch type E can be indicated by an auxiliary switch.
The closing and opening of the switch-disconnector
is performed manually by a lever with the door closed.
On request, the device can be also mounted for the
motor operation of the switch-disconnector. The switch-
disconnector can therefore be operated both locally and
remotely.
The earthing switch is always operated locally by the
operating lever.
The switchgear is constructed for the use of single-core
cables as standard. The cable compartment usually contains
supporting insulators for the fastening of cables. On request
the cable compartment can contain the instrument current
transformers instead of the supporting insulators. If all three
current transformers are not required, the relevant insulators
are installed instead of them.
Cable connection in the panels for 12 kV, 17,5 kV and 24 kV:
In the panel with switch-disconnector 1 plastic single-core
cable can be connected on each phase with a cross-section
up to 240 mm2 as standard.
Important notice:
In the case of any non standard cable connections an
agreement must be reached between the customer and ABB
during the technical preparation stage of the order.

3.4.1 Panel internal interlocking
To prevent hazardous situations and incorrect 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 circuit-breakers have an electrical
release, the interlock is also electrical.
If required, prevention of malfunction of the switch can also
be achieved by means of the control terminal (i.e. Relion
).
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
(Fig. 141) is only possible in the test/disconnected position
of the withdrawable part.
The earthing switch 6 (Fig. 2) 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).
Optionally there can be interlocking on shutters to prevent
manual opening. If it is applied then a shutter device must
be specified.
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 Door interlocking
The panels are equipped with the following interlocks:
The apparatus (circuit-breaker or contactor) cannot be
racked-in if the apparatus compartment door is open.
2)
The apparatus compartment door cannot be opened if the
apparatus (circuit-breaker or contactor) is in service or in an
undefined position.
The earthing switch cannot be operated if the cable
compartment door is open.
The cable compartment door cannot be opened if the
earthing switch is open.
Note:
When the interlocking for circuit-breaker is used then it is
necessary to use the OFF push button on the door to provide
emergency switching OFF.

3.4.3 Interlocks between panels
The busbar earthing switch can only be closed when all the
withdrawable parts in the relative busbar section are in the
test/disconnected position (electromechanical interlock)
1)
.
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 interlock)
1)
.
3.4.4 Locking devices
The shutters 12.1/12.2 (Fig. 4) 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 (Fig. 2) 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 can be restricted with a padlock.
3.4 Interlock/protection against
incorrect operation
16
WARNING
1) 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!
2) This interlock is not available for motor-
operated withdrawable apparatus as a
mechanical device.
Standard safety interlocks (mandatory)
Type Description Condition to be fulfilled
1
A Apparatus racking-in/out Apparatus in OFF position
B Apparatus closing Defined truck position
2
A Apparatus racking-in Apparatus multi-contact plug plugged
B Apparatus multi-contact plug unplugging Truck in test position
3
A Earthing switch closing Truck in test position
B Apparatus racking-in Earthing switch in OFF position
4
A Apparatus compartment door opening Truck in test position
B Apparatus racking-in Apparatus compartment door closed
5
A Feeder compartment door opening Earthing switch in OFF position
B Earthing switch opening Cable compartment door closed
Note: Apparatus are circuit-breakers and contactors.
Keys (on request)
6 Apparatus racking-in lock Can only be removed with the truck in the racked-out position
7 Earthing switch closing lock Can only be removed with the earthing switch open
8 Earthing switch opening lock Can only be removed with the earthing closed
9 Insertion of the apparatus raking-in/out crank lever Can always be removed
10 Insertion of the earthing switch operating lever Can always be removed
Padlocks
11 Apparatus compartment door opening
12 Cable compartment door opening
13 Insertion of the apparatus raking-in/out crank lever
14 Insertion of the earthing switch operating lever
15 Shutters opening or closing
Locking magnets (on request)
16 Apparatus racking-in/out Magnet energized
17 Earthing switch ON/OFF Magnet energized

Accessory devices
20 Shutters fail-safe
The device locks the shutters in the closed position when the
apparatus is removed from the compartment. The operator cannot
open the shutters manually. The shutters can only be operated by
the apparatus truck or the service trucks (please see the dedicated
chapter at page 28).
21 Apparatus-switchgear unit compatibility matrix
The apparatus multi-contact plug and relative switchgear unit socket
are equipped with a mechanical matrix, that disables apparatus
racking-in into a switchgear unit with an inappropriate rated current.
22 Circuit-breaker mechanical operating mechanism
The apparatus compartment is equipped with a mechanical device,
that enables circuit-breaker closing and/or opening directly by means
of the front operating mechanism pushbuttons, keeping the door
closed. The controls can be operated with the circuit-breakers in the
operation and racked-out position.
3.4.5 Types of interlocks
17
18
A
A
Figure 13: Circuit-breaker compartment door enabling device (A)
Figure 14: Circuit-breaker truck enabling slot (A)
B
Figure 15: Circuit-breaker compartment door locking device (B)
C
C1
C2
Pin ON
Pin OFF
D
Figure 17: Cable compartment door enabling device (C)
Figure 18: Cable compartment door enabling slot (C1) and earthing switch enabling pin (C2)
Figure 19: Cables compartment door locking pin (D)
C2
19
B
Figure 16: Circuit-breaker compartment door locking pin (B)
200.1
200
205.1
205
Figure 20: Switch-disconnector compartment - open position. Insulat-
ing plate in the isolating distance of switch-disconnector

200 Switch-disconnector
200.1 Position indicator of switch-disconnector
205 Insulation partition wall
205.1 Movable insulation plate
20
In panels with digital control techniques the protection
against incorrect operation is basically carried out by the
panel software. But the earthing switch is operated locally
by the operating lever 215. The mechanical interlocking
between the switch-disconnector and earthing switch is still
in operation.
Details of other possible interlocks, e.g. in connection
with a locking magnet on the switch-disconnector, can be
obtained from the relevant order documents.
Figure 21: Preparation for the operation of earthing switch in panel with the
switch-disconnector
Operating lever prepared for the OFF operation
215 Operating lever
215
3.4.6 Internal interlocking of panel with switch-
-disconnector
To prevent hazardous situations and incorrect operation,
there is a series of interlocks to protect both personnel and
equipment:
The switch-disconnector can only be switched on if the
earthing switch is off. The earthing switch can only be
switched on if the switch-disconnector is off. The switch-
-disconnector and earthing switch are mutually mechanically
interlocked.
The door of the lower HV cable part of the panel can
only be opened if the earthing switch is on. During the
closing of the earthing switch the insulating plate 205.1
is automatically inserted in the isolating distance of
switch-disconnector, which increases safety. This plate
is automatically removed again during the opening of the
earthing switch.
The earthing switch can only be operated if the cable
compartment door is closed.
If the control voltage is not connected, the switch-
-disconnector can be open and closed only manually. The
manual operation of switch-disconnector and earthing
switch can be prevented if the slides 201.2 and 208.1 of
the operating openings are locked up.
WARNING
The door of the upper HV part of the
panel can only be opened if the off-circuit
condition of the switch-disconnector is
verified. This means that the off-circuit
condition must be unconditionally verified
both on the upper and lower contacts of the
switch-disconnector.
Sample for coding
Control Code B1 B2 B3 B4 B5 B6
wiring Pin x x
Socket Hole
Control Hole x x
wiring Pin
Plug Code B1 B2 B3 B4 B5* B6
* B5 is used in special cases only
47
45 49 46
48
43
10 21
44
42
11 22
32
1
12 23
33
2
13 24
34
3
14 25
35
4
15 26
36
5
16 27
37
6
17 28
38
7
18 29
39
8
19 30
40
9
20 31
41
50
51
52
53
54
55
56
57
58
B3
(B4)
B6
(B6)
B4
(B3)
B1
(B2)
B5
(B5)
B2
(B1)
10.4 10.5
10.4
Coding:
(...) In brackets is stated
the corresponding coding
designation for the
control wiring plug (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:
Number of sockets optional,
but always with the basic assignment:
1, 8, 10, 20, 21, 31, 33, 40.
Sockets and pins can be
mixed in the control wiring
socket (10.1) and control
wiring plug (10.2) as required
10.1
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).
Figure 22: Control wiring plug connector coding, shown for a 58-pole connector

10.4 Centring striking tabs
10.5 Bore for actuating pin of the control wiring plug for controlling the auxiliary switch
21
3.5 Circuit-breaker and contactor plug
connector coding
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.
49.2
B) IT IS VALID FOR MICROSWITCH OF TYPE M1S 6610
4
1
,
5
-
0
+
0
,
5
49.2
A) IT IS VALID FOR MICROSWITCH OF TYPE CROUZET
-
0
+
0
,
5
5
5
PANEL
11.5
11.5
PANEL
11.5
Figure 23: Auxiliary Ith limiter switch. It may be necessary to move the aux-
iliary switches into their service position when the lifting eyebolts have been
removed

11.5 Ith

limiter
It is necessary to adjust the centre of the switch knob of the
auxiliary switch to the centre of the pressure relief flaps hole.
Correct value of the adjustment of the auxiliary switches
height in the pressed position according to the particular type
of the switch is indicated on figure A) or B).
22
3.6 I
th
Limitors
It is additional safety feature on the top of each unit. The
microswitch generates an immediate fault signal when the
overpressure flap is opened. Reaction time is less then 15 ms.
The signal from the microswitch can be sent directly to trigger
the circuit-breaker OFF.
23
3.7 Fast recovery device
UniGear switchgear can optionally be equipped with Fast
Recovery, a specific protection system.
This system is based on pressure sensors (Fig. 24), suitably
located in the switchgear and directly connected to the shunt
opening release installed in the circuit-breaker operating
mechanism (Fig. 25).
Figure 24: Pressure sensor Figure 25: Shunt opening release
Resetting the auxiliary contacts
Figure 26: Fast recovery system
Compressed air system
1
2
3
Figure 27: Testing equipment
1 Pressure reducer
2 Lever for opening the air valve
3 Manometer
The sensors detect the pressure rise front at the moment of
an internal arc and promptly open the circuit-breaker.
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.
4.1 Condition on delivery
At the time of dispatch, the UniGear panels are factory
assembled, the withdrawable parts are in the test position and
the doors are closed.
The factory-assembled panels are checked 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
Available packing methods:
Polythene foil - storage time 1/2 year in clean and dry
environment
OSB boards - storage time 1/2 year in outdoor environment
according to IEC
Wood boxes - storage time 1 year in outdoor environment
according to IEC
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
4. Dispatch and storage
4.3 Transport
The transport units normally comprise individual panels and,
in exceptional cases, small groups of panels. The panels are
each fitted with four lifting eyebolts.
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;
Suspend the unit using ALL four eyebolts!
For detailed information on switchgear handling, please refer
to chapter 4.6.
24
Figure 28: Handling by crane
1.5 lifting eyebolt
1.5
25
4.4 Delivery
The responsibilities of the customer when the switchgear
arrives at site include, but are not limited to, the following:
Checking the delivery for completeness and damage
(e.g. also for moisture and its detrimental effects). In
case of doubt, the packing must be opened and then
properly resealed, inserting 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.
4.5 Intermediate storage
Optimum intermediate storage, where this 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 delivery;
- subsequently at regular intervals;
When the maximum storage period, starting from the date
of packing, has been exceeded:
- the protective function of the packing can no longer be
guaranteed;
- take suitable action if intermediate storage is to continue.
4.6 Handling
4.6.1 Switchgear
The switchgear sections are usually fixed to wooden pallets.
Handling should be carried out by overhead or mobile cranes.
Otherwise, use rollers or fork lift trucks.
Weights and dimensions of each section are listed in the
shipping documents and in the plant drawings.
4.6.1.1 Handling with overhead crane or mobile crane and
unpacking
Handling the switchgear in the wood packing
The switchgear must be lifted by crane and circular slings 1
(figure 29). The slings must be inserted according to the lifting
symbols marked on the crate.
Weight and lifting opening angle must be taken into account
when choosing the circular slings.
Figure 29: Handling the switchgear in the wooden crate
Switchgear handling
Unpacking

Remove the nails and crate lid and sides;
Open the compartment door and loosen the bolts fixing the
switchgear to the pallet;
Lift the cubicles by the crane following the instructions
below;
Remove the pallet;
Position the unloading shims;
Put the switchgear on the loading shims using the crane.
WARNING
Do not walk on the roof of the panels
(rupture points in pressure relief devices!).
The pressure relief devices and/or Ith
Limiters could be damaged.
WARNING
Only use a suitable balanced lifting system.
Should an accidental fault cause a leakage
of SF6, ventilate the room and carefully
follow the safety procedures prescribed in
the IEC 1634 Standards.
26
After unpacking, lift the unit groups by crane (figure 28). Use
the eyebolts (1.5) and the safety ropes.
After installation of the panels, remove the eyebolts used for
lifting.
4.6.1.2 Handling by rollers
Lift the switchgear section by overhead or mobile crane or
using jacks; remove the wooden pallet loosening the screws
fixing it to the switchgear section base.
Put a sturdy metal sheet between the rollers and the unit base
and place the switchgear on the sliding rollers.
4.6.1.3 Handling by transpallet or fork lift trucks
To guarantee stability, the switchgear must not be lifted too
high. Check the alignment of the forks.
Sliding rollers
Metal sheet
4.6.2 Apparatus
The apparatus can be handled by cranes, fork lift
trucks or using the truck provided by ABB.
For each piece of apparatus follow the instructions
below.
Figure 30: Handling by rollers
Figure 31: Lifting switchgear packed in a wooden crate
Figure 32: Switchgear handling
WARNING
Only use rollers on a level floor.
Move the switchgear section avoiding any
possible tilting.
WARNING
Only use transpallets or fork lift trucks on a
level floor.
Move the switchgear section avoiding any
tilting.
WARNING
While handling do not put any stress on
the insulating parts and on the apparatus
terminals.
Before handling the apparatus, make sure
that the operating mechanism springs are
discharged and that the apparatus is in the
open position.
27
4.6.2.1 Handling by crane
Circuit-breakers
Hook the lifting bolts to the relevant supports (figure 33).
While handling, pay the utmost attention not to put any stress
on the insulating parts or on the circuit-breaker terminals
(figure 34).
Before putting into service, remove all the lifting eyebolts.
Contactor
Insert the lifting bar (1) centering it with the contactor;
Hook the bracket (2) to the lifting bar (1);
Hook the bracket (2) by the spring catch and lift the
contactor;
To remove the lifting equipment proceed in reverse order.
Figure 33: Correct handling
2
2
1
4.6.2.2 Handling by fork-lift trucks
Handling by fork-lift trucks can be carried out only after the
apparatus has been positioned on a sturdy support.
While handling, pay the utmost attention not to put any stress
on the insulating parts or on the circuit-breaker terminals.
Figure 34: Wrong handling
Figure 35: Mounting the lifting equipment
Figure 36: Handling by fork-lift trucks
WARNING
Do not insert the truck forks straight
underneath the apparatus but put the
apparatus on a sturdy support.
28
(*)
(**)
3
4
3
4
1
4.6.2.3 Handling by service truck
For handling and inserting the apparatus into the switchgear,
use the service truck (Figure 37).
Figure 37:
(*) Handling direction for horizontal locking pin entry.
(**) Handling direction for exit of the horizontal locking pins.
2
2
In order to handle the circuit-breaker with the relevant truck,
follow the instructions below (figure 37):
hook the lifting bolts to the circuit-breaker supports and
align it above the truck (1):
press the handles (2) towards the circuit-breaker centre (*)
to insert the horizontal check pins (3);
put the circuit-breaker on the truck;
push the circuit-breaker towards the circuit-breaker
compartment and insert the truck into the guides until the
handles (2) are released (**) outwards and the horizontal
locking pins go into the slots (4), locking the circuit-breaker.
When moving the switchgear on cylinders always put the
cylinders collinear (in parallel) with the front side of the
switchgear!
Always keep the switchgear in the vertical position!
Do not try to open the cable or the circuit-breaker
compartment doors, close the earthing switch or withdraw the
circuit breaker if an auxiliary voltage is not connected to the
switchgear!
Do not step on the pressure relief flaps!
Further warnings:
WARNING
Do not use the service truck for any
purpose other than handling ABBs
apparatus.
Fix the circuit-breaker to the truck before
moving it.
To carry out the 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 people.
In case higher IP is needed please follow the instructions described
in manual 1VLG100101.
5.1 General
On commencement of installation on site, the switch-room must be
completely nished, provided with lighting and the electricity sup-
ply, 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.
Where switchgear panels have top-mounted structures for earthing
switches or instrument transformers, it must be ensured that the ceiling
height is sufcient for the opening travel of the pressure relief plates.
The ceiling must be high enough to allow the assembly of the pres-
sure relief duct and/or top mouted VT box and earting switch box.
See table in capture 5.7.
Compliance with the conditions for indoor switchgear according to
IEC 60694, including the conditions for the minus 5 indoor tem-
perature class must be ensured.
5.2 Foundations
The following three basic methods of installing switchgear in
the switchroom are identified:
Method A installation on C profile base irons
As standard, it is recommended to install the switchgear
on C profile base irons set into the concrete floor of the
switchroom. In this case, the units are fastened using the
special bolt blocks (ABB delivers these on request).
Method B installation on the levelled concrete floor
Installation directly on the levelled concrete floor makes
much higher demands on the floor levelling, which must, in
this case, fulfil the same tolerances as the base irons during
method A installation.
Fastening is carried out by anchoring bolts in the concrete
floor.
Method C installation on a raised false floor
In this case, fastening of the units is carried out by welding
outside panels to the steel floor frame in the places where
the frame is larger than the base of the switchgear, i.e. on the
outside lateral walls of the unit row. This method of installation
is not recommended if seismic resistance is required.
Generally, the following procedure for switchgear anchoring
can be recommended for any of the installation methods
mentioned:
1 The switchgear panels are bolted together in the front and
rear part to make one unit;
1)
Pay attention to appropriate national standards.
2)
Applies to low voltage compartments of standard height.
3)
Approximate numbers depending on the type of panels.
Dimension chart of structural data
Rated voltage kV 12/17.5 kV 24 kV
Panel width FT mm 650 800 1000 800 1000
Aisle width
1)
G mm 1450 1600 1800 1600 1800
Switchgear room door width mm 850 1000 1200 1000 1200
Switchgear room door
height
2)
mm 2400 2400 2400 2525 2525
Opening in ceiling if
transported through roof:
Width mm 1000 1000 1200 1000 1200
Length mm 1500 1500 1500 1800 1800
Ceiling load
3)
kg/m
2
1200 1400 1400 900 850
5.2.1 Method of installation A Installation of the base
irons
The general foundation drawing is given in figures 38-72
according to the parameters of the units.
The C" shaped base irons can be supplied by ABB
together with the switchgear. Their installation is usually
carried out by personnel on site and should, if possible, be
performed under supervision of an ABB specialist. The base
irons must be installed in the slab before finishing the floor;
Rest the irons in the specified position on the concrete
floor as shown in the relevant foundation drawing and mark
out the places for drilling the holes. Then drill the holes for
anchoring bolts, i.e. for plugs 14 for fixing the base irons
in the floor. Then put the plugs in the holes and attach the
base irons to the floor loosely with bolts 13, without final
tightening so that any required levelling is possible.
Carefully level the base irons both longitudinally and
transversally over the entire length and to the correct height
by putting strips of suitable thickness under them and using
a levelling instrument.
2 Further structural data guidelines given provide a rough
calculation of the space required and the plan for designing the
room for a switchgear project.
If seismic resistance is not required, it is not necessary to attach each
switchgear panel to the oor or frame, but it sufces to x outside panels
in each row of switchgear only.
If seismic resistance is required, it is necessary to attach each switchgear
panel to the oor or frame. To achieve seismic resistance the special xing
system is used. This system preferably uses a steel oor frame with C
prole shape but moreover with an addition special xing element please
contact ABB for details.
When the final building construction documents are drawn up, the
binding data supplied by ABB for a particular case must always be
taken into account!
29
5. Assembly of the switchgear at site
Tolerances for laying the floor frame are
Evenness tolerance: 1 mm over a measuring length of 1 m
Straightness tolerance: 1 mm per 1m, but not more than
3 mm over the entire length of the frame.
After levelling the base irons, tighten bolts 13. The adjusted
position of the base irons on the concrete floor must not
be changed during this operation! Check again and, if
necessary, correct any deviations;
Weld Individual parts of the base irons together inside the
C" profile at the seams so that there is a mutual conductive
connection.
Take any necessary measures for perfect earthing of the
base irons with galvanized steel strips with minimum
dimensions of 30 x 4 mm. Two earthing connections are
recommended for a panel row longer than approx. 5 panels;
When the floor top covering is applied, carefully backfill
the floor frame, leaving no gaps. The top edge of the floor
frame should be 2 mm above the finished floor surface; the
tolerance of this value is within the limits of 0 to 5 mm. This
facilitates erection and alignment of the switchgear panels.
In some cases, this means that the material thickness of an
additional floor covering to be fitted later must be taken into
account separately;
The base irons must not be subjected to any harmful impact
or pressure, particularly during the installation phase.
If these conditions are not respected, problems during
assembly of the switchgear and possibly with movement of
the withdrawable parts, as well as opening and closing of
the doors cannot be ruled out.
Attachment of the units to the C" shape base irons
The switchgear is attached to the base irons by special bolt
blocks, which can be supplied on request.
Place the individual units of the switchgear in sequence
onto correctly levelled and installed base irons and level
them according to the relevant foundation drawings;
Level the units and then bolt them together in the front and
rear part;
To attach them to the base irons, insert specially prepared
bolt blocks in the fixing holes in the bottom of the units and
tighten them.
5.2.2 Method of installation B Fixing with anchoring
bolts to concrete floor
The general foundation drawing is given in figures 38 - 72
according to the parameters of the units.
Clean the switchgear installation area carefully;
On the slab, visibly trace the perimeter of all the units
making up the switchgear according to the relevant
drawing, taking the minimum wall and obstacle clearances
into account;
Level the floor both longitudinally and transversally,
evenness tolerance is 1mm over a measuring length of
1 m;
Drill the floor at the intended fixing points, referring to the
slab drilling drawings. To make the holes, use a hammer
drill with a bit according to the steel plugs used;
Insert the plugs in the holes and put the individual panels on
the traced perimeters of the units to create the switchgear;
rear part;
Fix the units with bolts with special washers (the coupling
material is supplied on request);
In the case of a metal floor, use the attachment according
to the figure. To make the holes, use a drill with a suitable
bit for the type of fixing to be made (through or threaded
hole).
5.2.3 Method of installation C Fixing to a raised false
floor
The general foundation drawing is given in figures 38 - 72
according to the parameters of the units. In most cases,
the floating floor is created by a steel structure in which the
welded steel frame is installed. A frame produced using
suitable steel profiles is used. ABB does not supply this
frame.
Clean the installation area.
After installation of the frame, take any necessary measures
for perfect earthing of the frame with galvanized steel strips
with min. dimensions 30 x 4mm. Two earthing connections
are recommended for a panel row longer than approx. 5
panels.
Place the units on the frame according to the relevant
foundation drawings, taking the minimum wall and obstacle
clearances into account.
rear part.
Carry out attachment by welding the outside panels to the
steel floor frame in the place where the frame juts out from
the switchgear bottom, i.e. on the outside lateral walls of
the unit row. This method of installation is not
recommended if seismic resistance is required.
In the case of a metal floor, use attachment according to
the figure. To make the holes, use a drill with a suitable bit
for the type of fixing to be made (through or threaded hole).
30
Figure 38: UniGear 12/17,5 kV up to the nominal current of T-offs 2500 A
Guideline structural data for foundation frame on concrete floor
It is not valid for the panel with switch-disconnector
C Typical panel depth C = 1340 mm however always consider annotation 2)
G Width of operating aisle
FT Panel width
TB Door width = FT + 200 mm
TH Door height = panel height + 200 mm
1) Minimum dimensions; recommended space 500 mm
2) Dimension must be verified in documentation of the relevant order
10 Door
11 Rear cover
12 Side end cover
13 Screw
14 Steel dowel
1
)
1) 2)
1
)
1)
2
)
1
)
1)
1)
600 100
FT=800
843
TB
C G
5
0
200
C
30
cca 20
75
80
G
75
FT=1000
TH
<
2
5
0
0
A
<
2
0
0
0
A
5
0
100 800 100
3
5
100
5
0
80
50
240
116
>
0

<
5
4 25 25
14
13
80 FT=550
75
nxFT
<
1
2
5
0
A
50 450 50
12
94 670
FT=650
100
75
100
FT=800
10
450
1
2
5
0
A
<
11
75
A
A
Structural data
Top view
Section A-A
31
1
)
1)
1
)
1)
2
)
1
)
1) 2)
1)
600
FT=800
TH
843
C G
200
5
0
75
FT=1000
75
G
80
100 100 800 100
C
1
0
0
166
100
290
FT=650
75
80 nxFT
450 100 100 100
3
1
5
0
/
4
0
0
0
A
5
0
TB
<
2
0
0
0
A
1
2
5
0
A
<
FT=1000
800 100
75
100
<
2
5
0
0
A
30
cca 20
11
12
10
3
5
8
5
5
0
80
>
0

<
5
4
25 25
14
13
94 670
Pohled shora
ez A-A
A
A
Stavebn daje
Figure 39: UniGear 12/17,5 kV for the nominal current of T-offs 3150/4000 A and/or 50 kA
FT Panel width
10 Door
11 Rear cover
12 Side end cover
13 Screw
14 Steel dowel
Top view
Section A-A
32
1)
1
)
1
)
1)
2
)
1
)
1) 2)
1)
170 785
TH
1300
TB
C
5
0
G
200
G
80
C
cca 20
5
0
50
255
80
150
10
12
11
75
FT=1000
75
FT=800
800 100 100
2
5
0
0
A
<
1
2
5
0
A
600
<
100 100
nxFT FT=800
1
2
5
0
A
<
75
600 100 100
30
4
0
5
0
80
>
0

<
5
4
25 25
14
13
Pohled shora
ez A-A
A
A
Stavebn daje
Figure 40: UniGear 24 kV
FT Panel width
10 Door
11 Rear cover
12 Side end cover
13 Screw
14 Steel dowel
Top view
Section A-A
33
1
)
1)
1
)
1)
1
)
2
)
2) 1)
1)
5
0
G
C
80
G
75
30
cca 20
5
0
25
80
>
0

<
5
50
200
843
C
116
4
25
5
0
14
13
TH
TB
75
3
5
nxFT
10
80
11
12
FT=800 FT=800 FT=800
75
2
0
0
1
0
0
4
6
0
0
5
4
5
160 300 300 160
6
0
0
5
4
5
300 160
6
0
0
5
4
5
Stavebn daje
A
ez A-A
Pohled shora
A
Figure 41: UniGear 12/17,5 kV with NAL switch-disconnector
FT Panel width
2) Dimension must be verifed in documentation of the relevant order
10 Door
11 Rear cover
12 Side end cover
13 Screw
14 steel dowel
Top view
Section A-A
34
1
)
1) 2) 1)
1
)
1)
1
)
2
)
1)
C
1300
G
5
0
80
25
4
5
0
150
50
25
>
0

<
5
13
14
75
FT=1000
C
G
80
5
0
30
cca 20
TB
TH
4
0
80 nxFT
10
11
12
300 150
8
0
0
5
8
0
8
0
0
300 5
8
0
150
FT=1000
75
2
0
0
1
2
1
0
200
ez A-A
Pohled shora
A
Stavebn daje
A
Figure 42: UniGear 24 kV with NAL switch-disconnector
FT Panel width
TH Door heigh = panel height + 200 mm
2) Dimension must be verified in documentation of the
relevant order
10 Door
11 Rear cover
12 Side end cover
13 Screw
14 Steel dowel
Top view
Section A-A
35
Figure 43: Example of 12/17,5 kV switchgear for 2500 A on foundation frame
on concrete oor. Panel with examples of gas duct including
chimneys or pressure relief to the outside.
A Typical panel depth A = 1340 mm however always consider annotation 2)
Caption to fig. 43 to 47:
2) Dimension must be verified according to documentation of the relevant order
1 Operator aisle
6 Control cabinet (optional)
8 Opening for ventilation
9 Height of cable base - as required
10 Concrete
12 Opening for power cables
14 Door
16 Wall opening for pressure relief
17 Pressure relief duct
Figure 44: Example of 12/17,5 kV switchgear for 3150/4000 A on foundation frame on concrete oor.
Panel with examples of gas duct including chimneys or pressure relief to the outside.
B Typical panel depth B = 1340 mm however always onsider annotation 2)
36
Figure 45: Example of 12/17.5 kV, 40/50 kA switchgear on foundation frame on
concrete oor. Panel with examples of gas duct including

Figure 46: Example of 24 kV, 25 kA switchgear on foundation frame on
concrete oor. Panel with examples of gas duct including
D Typical panel depth D = 1340 mm however always consider annotation 2)
37
Figure 47: Example of 24 kV, 31.5 kA switchgear on foundation frame on concrete oor.
Panel with examples of gas duct including chimneys or pressure relief to the outside.

E Typical panel depth E = 1340 mm however always consider annotation 2)
38
Figure 48: Guideline structural data for a raised false oor UniGear 12,
17,5 and 24 kV
A Larger dimension is valid for the cubicle with circuit breaker
HD4 including combination with them, in other cases smaller
dimensions are valid however always consider annotation 2)
FT Panel width
1) Min. dimensions
x) Max. dimensions
3) In case of rear access or inspection window on the rear cover
min. recommended distance from the wall is 500 mm.
Top view
Section A-A
Example of profiles for foundation
frame for a raised false floor
Section B-B
View B
Rated
voltage
kV
Panel depth A
2)
m
Bm
C
1)
m
12/17,5 up to 2500 A 1340/1300
1235
135
12/17,5 for 3150/4000 A 1390/1350 185
12/17,5 - 40, 50 kA 1390 185
24 1700/1560/1520 1590/1450 140
,
3
)
,3)
,3)
39
1
2
3
5
1
2
3
5
3
1
1
3
6
0
3
1
1
3
6
0
A
FT
2
0
0
105
75
6
6
A
FT
105
6
6
2
0
0
105
75
105
B
6
7
0
2
0
5
100 B
8
4
3
8
1
100
6
7
0
2
0
5
100
8
4
3
8
1
100
1000
800
mm
650
mm
590
440
790 800
600
450
mm
ka skn A
B
Figure 49: 12/17,5 kV up to 31,5 kA 650/800/1000 mm wide units
anchoring bolt fixing system
Figure 50: 12/17,5 kV up to 31,5 kA 650/800/1000 mm wide units
base iron fixing system
FT
(width of cubicle)
mm
A
mm
B
mm
650 440 450
800 590 600
1000 790 800
Figure 51: 12/17.5 kV, 40, 50 kA, 1250-2000 A - 800 mm wide units
Figure 52: 12/17.5 kV 40, 50 kA, 1250-2000 A 800 mm wide units
40
Figure 53: 12/17.5 kV, 40, 50 kA, 2500-3600 A -1000 mm wide units
Figure 54: 12/17.5 kV, 40, 50 kA, 2500-3600 A -1000 mm wide units
Figure 55: 12/17.5 kV, 40, 50 kA, 4000 A -1000 mm wide units
Figure 56: 12/17.5 kV, 40, 50 kA, 4000 A -1000 mm wide units
41
75
75
1000
1000
800 800
1
4
5
0
1
4
5
0
1
4
5
0
1
4
5
0
1
3
0
0
4
5
0
1
3
0
0
4
5
0
790 105
8
0
2
0
0
4
0
105 790
105
2
0
0
8
0
4
0
105
1
1
0
7
8
5
800
100
2
1
5
100
1
1
0
800
7
8
5
100
2
1
5
100
1
3
0
0
7
8
5
590 105
4
5
0
2
0
0
8
0
75
105
4
0
600
2
1
5
100 100
1
1
0
1
3
0
0
7
8
5
590 105
75
4
5
0
2
0
0
8
0
105
4
0
600 100
2
1
5
100
1
1
0
Figure 57: 24 kV, 25 kA 800 mm wide units
- base iron fixing system
42
Figure 61: 24 kV, 31.5 kA 800 mm wide units
43
105
800
6
6
75
105
2
0
0
590
5
1
0
8
4
3
1
2
3
5
3
1
1
75
105
2
0
0
6
6
8
1
8
4
3
1
2
3
5
105
3
1
1
8
1
1
4
5
0
1000
75
75
1000
1
4
5
0
300
6
0
0
160
590
800
300 160
5
1
0
6
0
0
1
1
0
4
0
105
1
3
0
0
1
3
0
0
790
2
0
0
8
0
105
4
0
105
5
4
0
1
1
0
105
8
0
2
0
0
790
300 150
8
0
0
300 150
5
4
0
8
0
0
Figure 65: 12/17,5 kV cubicle with Switch-disconnector
Figure 66: 12/17,5 kV cubicle with Switch-disconnector
Figure 67: 24 kV cubicle with Switch-disconnector
Figure 68: 24 kV cubicle with Switch-disconnector
44
8
0
16
>

0
,
5
8
0
16
M 12
M 12
Figure 69: anchoring bolts on concrete oor Figure 70: base irons on concrete oor
Figure 71: through hole on metal structure Figure 72: threaded hole on metal structure
45
46
When the switchgear has been properly assembled, fix the panels to the floor using plugs, or weld or adequately bolt
them to the foundation frame.
Figure 73: Fixing to the oor - method of installation A with base irons
Figure 74: Fixing to the oor - method of installation B with anchoring bolts to concrete oor
Figure 75: Fixing to the oor - method of installation C to raised false oor
1)
The recommended maximum tightening torques are based on a coefcient of friction for
the thread of 0.14 (without lubrication) or 0.10 (with lubrication).
2)
Thread and head contact surface lubricated.
3)
The tightening torques are recommended for screws ISO 4014-4018 and ISO 4762 (tensile
class 8.8). If using other types of screws please contact ABB for clarication.
4)
Applicable only for xing of subsidiary covers or terminal connections.
5.3 Assembly of the switchgear panels
Use screws of tensile class 8.8. The maximum recommended
tightening torques based on each type of connection are
given in the following tables:
Any tightening torques that deviate from those in the general
tables (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 to achieve
the precise tightening torque.
Maximum recommended tightening torque
1)
Nm
Lubricant
2)
Thread
3)
Without (=0,14) Oil or grease (=0,10)
M5
4)
2,5 -
M6
4)
10 8
M8 25 20
M10 50 40
M12 85 69
M16 200 170
The preparation work for installation is as follows:
Remove withdrawable parts 13 (Fig. 144, 145) from the
switchgear panels and store them with suitable protection.
Dismantle lifting eyebolts 1.5 (Fig. 28).
Transport the switchgear panels to the prepared installation
point following the sequence shown on the switchgear plan.
Remove covers 43.2 and 43.3 (Fig. 4) from the vertical
control wiring ducts at the front left of the panel.
Tightening torques for copper bars or combined busbar
connections
1)
Nm
Lubricant
2)
Thread
3)
M8 15 -
M10 32 -
M12 45 -
M16 110 -
M20 220 -
Tightening torques for copper bar connections combined
with epoxy insulators
1)
Nm
Lubricant
2)
Thread
3)
M12 70 -
Tightening torques for copper bar connections combined
with ABB CTs
1)
Nm
Lubricant
2)
Thread
3)
M10 20 -
Tightening torques for copper bar or cable connections
combined with ABB VTs
20
43.1
1.8
43.2
Figure 76: View into the high voltage area at the front
1.8 Blocking adjustable pin
20 Horizontal partition, removable
43.1 Duct cover for external control cables
43.2 Duct cover for external control cables
47
5.4 Procedure for setting-up the
doors of UniGear switchgear with
adjustable hinges
48
Instructions from the standpoint of the safety at work:
The relevant work and adjustments must be carried out by
trained specialists familiar with the installation, taking into
account all relevant safety regulations according to IEC and
other relevant professional bodies, and other local and works
regulations and instructions.
The switchgear doors are always mounted and set up at the
factory. It is always necessary to reset these doors on site and to
do this before commissioning the switchgear. During setting-up,
the switching station must be connected to the control voltage,
otherwise it will not be possible to operate the withdrawable part
with circuit-breaker/contactor and earthing switch.
The working method:
a) The circuit-breaker compartment door:
Loosen (but do not dismantle) 2 lock screws M6 (fg. 77) on the
lateral side of the door - this releases the blocking stop and it
is possible to open the door.
Withdraw the withdrawable part with circuit-breaker/
contactor from the circuit-breaker compartment onto the
service truck and move it outside of the switchgear
Dismount the left lateral cover of the control cables (fg. 78)
Withdraw the left lateral cover of the control cables from the
circuit breaker compartment outside of the switchgear (g. 79)
Loosen (but do not dismantle) all M8 screws at all hinges
(g. 80)
The setting-up of the door position is based on rotating the
door in the opening on an axis of the middle hinge (the
second hinge from the bottom edge of door in the case of
a door with 4 hinges)
Set up the door in the position in which its upper edge
is parallel with the gap between the circuit-breaker
compartment and the low voltage control cabinet (g. 81)
Tighten the upper hinge and check the correct function of
the door including the insertion of blocking lever in the door
slot with the blocking stop
If the door closes correctly, tighten all screws at all hinges to a
torque of 20 Nm
Set up the blocking stop so that its lower edge is in the range
of 29.8-30.3 mm above the level of the lower edge of the
slot in the door draw bar when the door handle is in the
closed position (g. 82 and 83). The required position of the
stop can be set up by insertion of the jig OCA0071, drw.No.
1VL7611226P0101.
Check that the door closes correctly
Mount the left lateral cover of the control cables. The screw
tightening torque must not exceed 2,5 Nm
Insert the withdrawable part with circuit-breaker/contactor
in the circuit-breaker compartment and leave in the test/
disconnected position
Close the door and verify the door blocking function by
operation with the withdrawable part
b) The cable compartment door:
Loosen (but do not dismantle) 2 M6 lock screws (fg. 77) on the
lateral side of the door - this releases the blocking stop and it
is possible to open the door.
Withdraw the withdrawable part with measuring voltage
transformers (if the switchgear is equipped with them)
from the cable compartment outside of the switchgear (g. 84).
Dismount the left lateral cover of the control cables (fg. 85)
Withdraw the left lateral cover of the control cables from the
cable compartment outside of the switchgear (g. 86)
Loosen (but do not dismantle) all M8 screws at all hinges
(g. 80)
The setting up of the door position is based on rotating the
door in the opening on an axis of the middle hinge (the
second hinge from the bottom edge of door in the case of
a door with 4 hinges)
Set up the door in the position in which its upper edge
of door will be parallel with the upper edge of the separating
cover (g. 87)
Tighten the upper hinge and check the correct door function
including the insertion of the blocking lever in the door
slot with the blocking stop
If the door closes correctly, tighten all screws at all hinges to a
torque of 20 Nm
Set up the blocking stop so that its lower edge is in the range
of 29.8-30.3 mm above the level of the lower edge of the slot
in the door draw bar when the door handle is closed (g. 82
and 83). The required stop position can be set up by insertion
of the jig OCA0071, drw.No. 1VL7611226P0101.
Check that the door closes correctly
Mount the left lateral cover of the control cables. The screw
tightening torque must not exceed 2,5 Nm
Insert the withdrawable part with measuring voltage
transformers (if the switchgear is equipped with them) in
the cable compartment
Close the door and verify the door blocking function by
operation with the earthing switch
49
Figure 77: Screws on lateral side of door
Figure 78: Lateral cover of control cables
Figure 79: Circuit-breaker compartment without lateral cover
Figure 80: M8 screws
50
Figure 81: Correct position of circuit-breaker compartment door
Figure 82: Setting up right position
Figure 83: Setting up right position
Figure 84: Withdrawable part with measuring voltage transformers
Figure 85: Lateral cover of control cables in cable compartment
51
Figure 86: Cable compartment without lateral cover
Figure 87: Correct position of cable compartment door
52
5.5 Installation of the bushing
Before fixing the panels side by side (according to the general
drawings) bushings 29.x (1224 kV) must be fixed (for
switchgear with busbar partitioning only).
5.5.1 Bushing of 12/17.5 kV panels
30
29.5
31
32
Lower bus-tie system:
Insert bushing 29.6 for the lower rear bus-tie into bushing
plate 28.2 from the right side in contrast to the procedure
for the other two bushings.
31 nr. 8 M8 washer
32 nr. 3 Rubber partition (busbar support)
5.5.2 Bushing of 24 kV panels
Assembly procedure for bushings main (upper) busbar
system:
Insert bushing 29.6 for the lower busbar into bushing plate
28 from the right side, and for the middle and upper busbar
from the left side.
37
28
36
35
29.6
37
28.2
36
35
29.6
37
28.2
36
35
29.6
Lower bus-tie system:
Insert bushing 29.6 for the lower rear bus-tie into bushing
plate 28.2 from the right side in contrast to the procedure
for the other two bushings.
Figure 88: 12/17.5 kV panels - xing bushings
29.5 nr. 1 bushing
30 nr. 8 8x25 screws
Figure 89: 12/17.5 kV panels - xing bushings
Figure 90: 24 kV panels - xing bushings
28 nr. 1 bushing plate
29.6 nr. 3 bushing
36 nr. 12 M8 washer
37 nr. 12 M8 die
Figure 91: 24 kV panels - xing bushings
53
5.6 Fixing of the panels
Fit and screw down the side covers.
Align the switchgear panels on the floor frame for correct
positioning and vertical alignment (deviations of the panel
edges from the vertical must not exceed 2 mm, especially
at the front) and bolt the panels together (Fig. 92). It
is advisable to start from the centre when assembling
switchgear with more than 10 panels.
Figure 92: View of the xing points
The junction points where the panels should be fix are as
follows:
- Nr.6 in the front side (A-B-C-D-E-F).
- Nr.4 in the middle part (L-M-N-O).
- Nr.5 in the rear side (G-H-I-J-K).
The nuts are already fixed on the right side of the panel
(except in the middle part); on the left side there is the an
empty space where the screws are to be fixed.
The screws needed are:
- 10 x 30 screws (complete with M10 washer) for front and
rear side.
- 10 x 35 screws (complete with washer and M10 nuts) for
middle part.
K
J
I
H
G
L
A
B
C
D
E
F
M
N
O
Before fixing the panels side by side be sure
that the bushings are fixed according to
chapter 5.5.
54
5.7 Installation of the busbars
5.7.1 Preparation of the material
Clean the insulation on the busbar sections with a soft, dry
cloth, and check for any insulation damage. Remove greasy
or adhesive dirt.
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 Isoflex Topas NB 52 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 Isoflex Topas
NB 52;
Figure 93: 12/17.5kV panels, installation of the busbars. The lower picture
shows the installation at the busbar ends.
29 busbar bushing
58 insulating cover
58.1 support for cover (at end panels only)
58.5 lid
58.6 washer, ISO 7089
58.7 washer, 25mm diameter
Prepare insulating covers 58 and lids 58.5 (figure 93, 94) to
suit the relevant busbar connections and pull them on the
busbar. (For insulated busbars only).
55
Figure 94: 24 kV panels - Arrangement of the busbar and branch conductors
at the busbar ends. In continuous busbars, the connections are
similar, but without the lid holder 58.1 and without the spacer
plate 3.5.
2 Branch conductor
3 Busbar section
3.5 Spacer plate
58 Insulating cover
58.1 Lid holder
58.5 Lid for insulating cover
(58.6) Washer ISO 7089
58.7 Washer 25 mm diameter
163 M10 hexagon socket head screw
164 M10 nut
165 10mm spring washer
58.5 58.1 165 165 58 2 58.5 3
(58.6) 163 164 58.7
58.5 3.5 165 58 2 58.5 3
58.1 163 164(58.6) 58.7
2 165
165 3
(
1
0
)
(
1
0
)
During assembly, cut out the insulating cover and lid to fit the cross-section
of the feeder bar or busbar.
a) Arrangement for 1250 A branch current and 1600 or 2500 A busbar
current.
b) Arrangement for 2500 A branch and busbar current.
56
5.7.2 Busbar compartment access
Access to the busbar compartment is possible either from the
top of the panel after dismounting the pressure relief plate 1.1
(Fig. 2) before the mounting of the gas duct, or from the front
of the circuit-breaker compartment.
After circuit-breaker 13 (Fig. 2) has been withdrawn from the
panel, it is possible to dismount the horizontal partition 20 by
unscrewing 4 screws holding the partition from the inside.
After that, the partition 20 can be dismantled and taken out of
the panel, which makes access to busbars from the circuit-
-breaker compartment possible.
20
5.7.3 Busbars installation
Install the busbars panel by panel according to the rating
of the switchgear (Fig. 98108). Screw on the individual
busbar elements one above the other (depending on the
system layout) and in line with the flat branch conductor.
For the tightening torque please refer to the table at page
51.
Use tightening material supplied by ABB
Bolt one holder 58.1 (figure 93, 94) 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 (Fig. 93, 94) over
the relevant bolted joint, and slide the lid onto the cover
until it clicks into place. (For insulated busbars only).
Note:
Busbar connection is carried out with stabilized
connections.
This means that the quality of the copper busbar connections
does not deteriorate according to 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.
We recommend only checking tightness of busbar
connections during inspections (see chapter 8).
Figure 95: Accessing busbar compartment

Figure 96: Washer before tightening

Figure 97: Washer after tightening

Example of using washers:
43.1
43.2
57
5.7.3.1 Busbars for 12/17.5 kV units
Busbars are made of copper and have a flat cross-section
for rated current up to 2500 A. For 3150, 3600 and 4000 A,
the busbars have a double D-shaped cross-section. 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. For bus-
tie units the bushings are single and are arranged in the lower
part of the unit. Bushings are held in bushing plates.
For 12 kV, the busbars are bare (without insulation) and
without insulating covers up to 2500 A.
3150, 3600 and 4000 A open D-shaped busbars are insulated
by shrink fitting sheaths and are fitted with insulating covers.
For 17.5 kV, the busbars are insulated and fitted with covers
over the whole current range.
Figure 98: 12 kV panels T-off 630-1250A, busbars 1250A
42 nr. 8 M10 washers
43 nr. 4 M10 nuts
Figure 99: 12/17,5 kV panels T-off 630-1250A, busbars 1600A-2000A-2500A
43 nr. 4 M10 nuts
44 nr. 1 spacer (15mm)
40
42
43
41
42
43
44
58
Figure 100: 12/17.5 kV panels T-off 1600-2000A-2500A, busbars
1600A-2000A-2500A
43 nr. 4 M10 nuts
Figure 101: 12-17.5 kV panels T-off 630-1250A, busbars 3150A-3600A-
4000A
43 nr. 4 M10 nuts
41
42
43
45
41
42
43
44
59
Figure 102: 12-17.5 kV panels T-off 630-1250A, busbars 3150A-3600A-
4000A, open D
43 nr. 4 M10 nuts
41
42
43
44
Figure 103: 12-17.5 kV panels T-off 16004000A, busbars 3150A-3600A-
4000A
43 nr. 4 M10 nuts
41
42
43
45
60
Figure 104: 12-17.5 kV panels T-off 16004000A, busbars 3150A-3600A-
4000A, open D
43 nr. 4 M10 nuts
41
42
43
Figure 105: 24 kV panels T-off 1250A, busbars 1250A
43 nr. 4 M10 nuts
41
42
43
45
5.7.3.2 Busbars for 24 kV units
Busbars and branches are made of copper and both have a
flat cross-section. The bushings are different from the 12/17.5
kV versions. They are single for each phase and have an
electrode inside, which must be connected to the busbar.
Busbars for 24 kV units are insulated by means of shrink
fitting sheaths and the connection points are covered by
insulating covers.
61
41 nr.4 10x60 screws
42 nr.8 M10 washers
43 nr.4 M10 nuts
42 nr.8 M10 washers
43 nr.4 M10 nuts
41
42
43
41
42
43
62
41
42
43
42 nr.8 M10 washers
43 nr.4 M10 nuts
Figure 109: 24 kV panels - detail of the busbar bushing, sectional view
3 Busbar
29 Busbar bushing
29.2 Busbar support for double conductor
29.3 Contact spring
29.4 Metal tube
Important note:
Always check that there is good contact
between the metal tube 29.4 in the bushing
and the busbars via contact spring 29.3.
Ensure that the contact spring is in the
correct position! (figure 109).
Important note:
The contact springs 29.3 must be inserted
during the installation of busbars. These
contact springs make the connection
between the busbar 3 and the metal tube
29.4 and prevent damage caused by partial
discharges inside the bushing on live
busbars.
For ease of transportation top mounted boxes are delivered
separate from the panel in pre-assembled sections.
5.8.1 Voltage transformer for busbar metering
Top-mounted box 79 (114-116, 118, 119) with screw fixing
material in the set of bags Top-mounted box for metering
must be mounted on the busbar compartment.
Notes:
- In panels without busbar bushing plate 28 (Fig. 90), the
partition between the busbar compartment and the top-
mounted box is necessary. They are installed at the factory
in the top-mounted box.
- As far as equipment with busbar partitioning is concerned
(i.e. with bushing plate 28), the space between the busbar
compartment and the top-mounted box must remain open
for pressure relief.
Connecting bars 2.2 with branch conductors 2 at the
junction point must be screwed together according to
figures 110 and 112. However, if necessary, the additional
spacer plate 3.2 or 3.3 and threaded plate 3.4 or 3.8, as
well as the screw fixing material from the top-mounted box
for metering set of bags must be used.
Insulating cover 58 must be placed into position as is
described in section 5.5.
Intermediate box 79.1 (Fig. 114, 115, 119), with the screw
fixing material from the top-mounted box for metering
set of bags must be mounted on the control cabinet.
Conduction tube 79.2 must be positioned and inserted in
reducer rings 79.3.
Secondary circuits from the voltage transformers must be
led to the terminal strips and connected according to the
cable core markings and circuit diagram.
5.8 Installation of the top-mounted boxes
63
3.2
2.2
3.2
3.8
64
Figure 110: Panels - 12/17.5 kV - Bar connection to the top-mounted box. The
gure shows the arrangement in panels the busbar ends
2 Branch conductor
2.2 Connection bar
3.2 Spacer plate, 5 mm thick
3.8 Tapped plate
58.5 3.5 (58.6) 3.4 58 2.2 58.5 3 162
58.1 58.7
(35)
165 2 3 163
3.3 3,4 162 2.2
(
1
0
)
58.1 58.7 (58.6) 165 2 3 163
65
Figure 111: Panels - 12/17.5 kV - Bar connection to the top-mounted box.
3.3
35
2
4
3
2
8
0
70
M10
35
5
0
3
2
15
3.4
25
2
4
3
2
8
0
3.5
Figure 112: Panels 24 kV - Bolted busbar joint for top mounted box, shown for
left-hand busbar end. In continuous busbars the connection is simi-
lar, but without the lid holder 58.1 and without the spacer plate 3.5.
2 Branch conductor
2.2 Branch conductor to the top-mounted box
3 Busbar section
3.4 Threaded plate
3.5 Spacer plate
58 Insulating cover
58.1 Lid holder
58.5 Lid for insulating cover
(58.6) Washer 2 mm
58.7 Washer 3 mm
162 Cylinder screw
163 M10 hexagon socket head screw
165 10 mm spring washer
Figure 113: Panels 24 kV - Bar connection to the top-mounted box.
66
79.4
79
2.3
28
79.2 79.3 79.1
Figure 115: Panels - 24 kV - Top-mounted box with high voltage transformers
for busbar metering. The gure shows the arrangement in panels
with busbar bushing plate 28 and bushings 29
2.3 Flat branch conductor for voltage transformers
28 Bushing plate
79 Top-mounted box for busbar voltage transformers
79.1 Intermediate box
79.2 Conductor tube
79.3 Reducer ring
67
79
79.2
28.3
79.3 79.1
Figure 114: Panels - 12/17.5 kV - Top-mounted box with voltage transformers
for busbar metering. The gure shows the arrangement in panels
without the busbar bushing plate 28 (see the notes in section 5.8.1)
28.3 Partitioning
79 Top mounted box with voltage transformer
79.2 Conductor tube
79.3 Reducer ring
5.8.2 Earthing switch for busbar earthing
Top-mounted box 79 with screw fixing material from
the top-mounted box for earthing set of bags must be
mounted on the busbar compartment.
Operating mechanism box 78 with screw fixing material
from the top-mounted box for earthing set of bags must
be mounted on the control cabinet.
Pre-mounted single parts of hexagonal shaft 78.1 must be
removed.
Please pay attention to the sequence and angling of the
parts!
The hexagonal shaft from the operating mechanism box
must be pushed through into the bevel gear of the earthing
switch.
The sequence and angles of the part must be restored!
Connecting bars 2.2 with the branch conductors 2 at the
junction point must be screwed together according to figure
110 and 112. However, if necessary, additional spacer
plate 3.3 or 3.2 and threaded plate 3.4 or 3.8, as well as
the screw fixing material from the top-mounted box for
earthing set of bags must be used.
Insulating cover 58 must be brought into position as
described in section 5.7.
Note:
The auxiliary switches for the earthing switch are adjusted
at the factory. Correct operation is only guaranteed if the
working elements on the hexagonal shaft are correctly
mounted.
During final installation of the earthing switch and operating
mechanism on site, it may be necessary to make precise
adjustment of the auxiliary switches. In this case, the following
is important:
The auxiliary switch OFF 78.5 must be operated:
- before slide 78.2 has uncovered half of the opening in
front of the hexagonal shaft and
- before the lower edge of the slide has touched the anchor
of locking magnet 78.6.
The auxiliary switch ON 78.4 must be operated
- before the toggle spring of the earthing switch has
reached its dead centre point.
The push-rod of the auxiliary switch must still have about
0.5 mm to go to the end position in the operated position.
79
78.1
78
Figure 116: Busbar earthing switch up to 31.5 kA
79 Top-mounted box for top mounted earthing switch
78 Operating mechanism box
78.1 Operating shaft
68
2.2
79
78.1 78
Figure 117: Panels - 12/17.5 kV - Top-mounted box with earthing switch for
busbar earthing

78.2 Slide
78.4 Auxiliary switch ON
78.5 Auxiliary switch OFF
78.6 Locking magnet
Figure 118: Panels - 24 kV - Top-mounted box with earthing switch
for busbar earthing. The arrangement is the same as the gure
above
2.2 Flat branch conductor for earthing switch
79 Top-mounted box for earthing switch
78 Operating mechanism box
78.1 Hexagonal shaft
69
When using a ferroresonance resistor for VTs open delta
connection is necesary to adjust the position of this resistor
during site installation.
The ferroresonance resistor is placed on the top of switchgear
on the CB relief flap for the transportation (Fig. 120).
When moving the resistor from relief flap to LV compartment
(LVC) please follow pictogram (Fig. 121) on the top of LVC.
The resistor has to be fixed by means of screws on the top of
the LVC (Fig 122).
Assemble resistor prior to instalation of preassure relief gas
duct. Pay attention to the resistors wires whilst installing gas
duct.
5.8.4 Anti-ferroresonant resistor for voltage transformers
open delta connection
Figure 120: Transport position of antiferro-
resonant resistor
Figure 121: Pictogram on the top of LVC
Figure 122: Correct position of antiferro-
resonant resistor
Figure 119: Top-mounted box with UFES
79 Top-mounted box with UFES
79.2 Conductor tube
79.3 Reducer ring
79.4 UFES
79.5 Earthing bar
5.8.3 Ultra fast earthing switch UFES
79.4 79
79.2 79.3
79.1
79.5
70
For more information see document 1VLG100128 Manual for
installation of UFES into UniGear ZS1.
5.9 Pressure relief ducts
The pressure relief duct is supplied dismantled in single
components. The rear and front wall correspond, as far as
length is concerned, with the appropriate panel width.
The screw fixing material is contained in the pressure relief
duct set of bags. Rivet nuts are already provided in the
metal sheets.
Detailed instructions for gas exhaust duct assembly are
described in document Assembly manual 1VLM000034.
Note:
The rear pressure relief flap must be mounted according to
figure 123.
Details regarding connection to the wall and a discharge
grating for pressure relief outside the switchroom will be
agreed on with the customer.
1)
Figure 123: Schematic diagram of the pressure relief duct.
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
5.9.1 Gas duct with outlet
Once the panels are bolted up, and busbars are installed,
it is possible to start fixing the gas duct on the top of the
switchgear. Every panel has three fixing points in the front part
(Fig. 124) and three fixing points on the rear part (Fig. 125).
Figure 124: Fixing points on the front.
Figure 125: Fixing points on the rear.
Figure 126: Assembly of pressure relieve aps without gas duct

Note:
This side of the preassure relief flaps has to be fixed by
plastic screws. The marked screws must be plastic.
Figure 127: Assembyly of pressure relieve aps with gas duct
Note:
If a gas duct is used turn off the cable compartment flap
according to figure. The marked screws must be plastic.
71
5.9.2 Gas duct with top chimneys
In order to mount the gas duct with top chimneys please
follow the appropriate instructions.
The difference between the two solutions is that in this case
there are no side exits, but the gas generated from an internal
the arc exits from the duct through the top chimneys located
on the top part of the gas duct on each panel.
On the top of the gas duct there are two openings (figure
129); for each opening the perforated metal plate must be
fixed with 6 spacers (figure 130).
At this point it is possible to fix the top cover with 12 x M8
screws.
Figure 128: Openings on top of the gas duct.
Figure 129: Net and spacers of top chimneys.
Figure 130: Top cover of top chimneys.
Note:
For UniGear ZS1 24 kV; 31,5 kA with gas duct with top
chimneys for a duct height of 500 mm it is necessary to use a
deflector.
Insert the deflector onto gus duct - open side in direction of
LVC. For fixation use connecting parts included in gas duct
assembly.
Deflector is designed to divert hot gas away of rear part of
panel to shield a staff behind the panel.
It is not necessary to aply the deflector in case of placing
panels directly to wall. No access from rear side.
Figure 131: Deector
72
Cable termination kits are mounted on the cable cores
according to the manufacturers instructions. It is possible to
use cable termination kits from different manufacturers (e.g.
Prysmian, Raychem etc.), but it is necessary to keep the
same length of the cable ends, including cable termination
kits, 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.
5.10 Cable connection
5.10.1 Power cables
The standard method for entry of power cables in the
switchgear is shown in Fig. 132 and 133. The cables are
conveyed from below 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.
6.1
23
17.2
17
39
19.1 21 17 17.2 19 19.2
Figure 132: View into the cable connection compartment, max. six parallel
cables possible
6.1 Earthing switch position indicator
17 Floor cover, split
17.2 Reducer ring
23 Cable connection bar
Figure 133: Partial view of the cable compartment, prepared here for
connection of triple cables
17 Floor cover, split
17.2 Reducer ring
19.1 Connecting link
19.2 Earthing connection pin
21 Cable clamp
39 Mounting rail, conncted to earth potential
The bars are equipped with holes for M16 screws. If M12
screws are used for cable connections, special washers
with the correct 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.
It is also possible to place the removable arrangement of
voltage transformers in the cable compartment. These can be
fitted with HV fuses similar to those in the measuring panel.
Three fixed mounted surge arresters can also be installed
here. In both cases the number of parallel cables that can be
installed is reduced - see the table below.
73
Important note:
The cable connection bars are equipped with
holes for M16 screws, but they are supplied
without screws, washer and nuts.
The supply of this material, according to the
cable termination, is an additional customer
charge.
1)
In cases 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.
2)
In cases 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.
Cable connection in the panel with switch-disconnector:
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 termination kits must be prepared and mounted on
cable cores according to manufacturers instructions.
Cable eyes must be connected to the prepared connection
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 into the prepared cable clamps
21 (the maximum tightening torque applicable to the clamp
screws is 9 +2 Nm).
Connection of cables in typical panels:
Rated
voltage
(kV)
Panel
width
(mm

)
Max. number
of parallel
cables
in phase
Max. cross
section of
cables
(mm
2
)
Range of
cable clamp
(mm)
Range of
reducer ring
(mm)
12/17.5
650 3
1)t
630

35 - 54 27 - 62
800 6
2)
1000
24
800 3
1)
500
1000 6
2)
Rated
voltage
(kV)
Panel
width
(mm

)
Max. number
of parallel
cables
in phase
Max. cross
section of
cables
(mm
2
)
Range of
cable clamp
(mm)
Range of
reducer ring
(mm)
12/17,5 800
1 240 35 - 54 27 - 62
24 1000
Important notice:
Connection with single-core plastic insulated
cables is presumed in 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 ABB.
74
17.2 21
C C C C C B
A
23
D
1)
75
Figure 134: Dimension of power cable connection of UniGear 12/17,5 kV panels
D Typical panel depth 1340 (1390) mm- however always consider
annotation 1)

1) Dimension must be verified according to the
relevant order documentation
17.2 Reducer ring
21 Cable clamp
I
n
Width I
th
Max. number of cables per
phase
A B C
A mm kA single core triple core mm mm mm
630
650 31,5
3 3
535
840 -
1000
3 3 480 180 1250
1250
800
40/50 465
1600
31,5/40/50
6 6
440
460 100
2000
1600
1000
2000
2500
3150
40/50 455
4000
17.2
21
C C C C C B
A
23
D
1)
76
I
n
Width I
th
phase
A B C
1000
800
25
3 3 497 608 180
1250
1000
1000
1250
1600
6 6 432 645 100 2000
2500
Figure 135: Dimension of power cable connection of UniGear 24 kV, 25 kA
panels
D Typical panel depth 1700 mm - however always consider annotation 1)
17.2 Reducer ring
21 Cable clamp
77
I
n
Width I
th
phase
A B C
Up to IF 800
31,5
6 6 465 700 100
1250 IFM 800 2 2 460 740 118
Up to IF 1000 5 5 425 770 120
3150 IFM 1000 6 6 415 690 100
Figure 136: Dimension of power cable connection of UniGear 24 kV, 31.5 kA
panels
D Typical panel depth 1700 mm - however always consider annotation 1)
17.2 Reducer ring
21 Cable clamp
78
23
21 17.2
1)
230
800
4
5
0
235 170 170
D
1)
17.2 21
23
275 275 236
D
4
5
0
276.5
1000
Figure 137: Dimensions of cable connection in panels of UniGear switchgear
with 12/17,5 kV switch-disconnector
D Typical panel depth is 1340 (1390) mm - however always consider
annotation 1)
1) The dimension must be verified according to the
17.2 Reducer ring
21 Cable clamp
Figure 138: Dimensions of cable connection in panels of switchgear UniGear
with 24 kV switch-disconnector
D Typical panel depth is 1700 mm - however always consider
annotation 1)
1) The dimension must be verified according to the
17.2 Reducer ring
21 Cable clamp
5.11 Earthing the switchgear
Connect main earthing bar 19 with connections 19.1
provided in every panel (Fig. 133).
Ensure protection for the wiring connection of the floor
frame or the erected raised false floor.
Connect the earthing conductor from the earth electrode,
preferably via a removable bolted connection for testing
purposes, to the main earthing bar 19 of the switchgear.
5.12 Installation of interconnecting
bundles
The interconnecting bundles are supplied rolled up in the
control cabinet or in the accessories. They are marked and
fitted with ferrules or connectors 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.
5.13 Final erection work
Figure 139: Lift-up terminal frame swung up for connection works
Figure 140: Fixed terminal frame
Check painted areas of the switchgear for possible
damage, touching up where required.
Check bolt connections and tighten where required, in
particular all those carried out during on-site erection of the
busbars and earthing system.
After the lifting eyebolts have been removed, the Ith
limiter auxiliary switch (if delivered) must be mounted and
adjusted:
- The auxiliary switch holder is fixed by screws in the panel.
- The auxiliary switch holder must be positioned
horizontally.
- The control pin of the auxiliary switch must be moved to
the centre of the hole in the pressure relief flap.
- Adjust the auxiliary switch according to figure 34.
- If the auxiliary switch is mounted and adjusted according
to the above instructions, checking during regular
inspections is not necessary.
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 Isoflex Topas NB
52 where necessary.
Withdrawable circuit-breaker parts must be inserted and
the control wirings connected.
Panels doors must be properly closed.
5.10.2 Control cables
The control cables are conveyed into the panel through the
control wiring duct 1.2 (Fig. 2) on the left hand panel side.
Mounting procedure:
Insert the cables into the control wiring duct on the left-
hand side. The duct is covered by covers 43.1, 43.2 (Fig.
4).
Fasten the control cables at the top end of the duct, strip
the insulation and convey cable control cores into the low
voltage compartment, after the terminal strip frame has
been swung up (Fig. 139).
Connect control cables to the terminal strip according to
the circuit diagram.
Make the control wiring connections to adjacent panels
using bushing 24.
79
80
Note on safety at work
The work and operating procedures must be
carried out carefully by trained specialists
familiar with the operation of UniGear ZS1
switchgear, taking into account all the
required safety regulations according to the
IEC and other relevant professional bodies,
as well as any local and work regulations and
instructions.
Warning
Do not walk on the top surfaces of the
switchgear panels (rupture points for
pressure relief).
The pressure relief devices could be
demaged!
6. Operation of the switchgear
6.1 Switching operations
6.1.1 Withdrawable apparatus
Manual insertion from the test/disconnected position to the
service position:
Connect control wiring plug 10.2
Close the front door.
Ensure that the apparatus is in the OFF position.
Fit hand crank 121 on square spigot 18.1 of the spindle
mechanism 18, after opening the aperture 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 noted 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 (Fig. 174) of spindle
mechanism 18 (Fig. 2). 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!
Carry out switching operations with the front
doors closed!
Figure 141: Control wiring plug connector blocked to prevent disconnection
with the withdrawable part in the service position
32 Interlock
32
10.2
10.1
145 121.1
Figure 142: Before inserting the hand crank, it is necessary to open the aper-
ture for it - turn the slide by using the key
121.1 Slide
145 Double bit key
81
121
Figure 143: Movement of the withdrawable part between the test/disconnected
position and the service position, clockwise up to the stop to the
service position and anti-clockwise for the test/disconnected position
121 Hand crank
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 (Fig. 2), in a similar way to
operation of a withdrawable circuit-breaker with manual
systems.
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 damaged!
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 (Fig. 145) with guide pins 124.2
(Fig. 146) 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 (Fig. 145) 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 (Fig. 145) (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.
147).
Insertion from the service truck into the test/disconnected
position:
Carry out the procedure described above for withdrawal in
reverse order.
Manual withdrawal from the service position into the test/
disconnected position:
Ensure that the apparatus 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
applied to the insertion/withdrawing lever
is 260 N. In any case, the maximum applied
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 apparatus open!
Do not use force to move withdrawable parts
with locking magnet Y0 or RL2 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.
Caution.
In emergency manual operation of a
motorized withdrawable circuit-breaker part,
the interlock with the earthing switch is not
effective!
IN
OUT
124.2
124.3
124.1
13
13.11
124.4
13.12 124.1 124
124
82
Figure 144: Service truck engaged with the switchgear panel. Withdrawable
part released for withdrawal with the handles slid inwards
13.11 Sliding handle
124 Service truck
Figure 145: Withdrawable part standing on service truck and secured
in the catches
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)
Figure 146: 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
38
130
Figure 147: Shutters secured with padlock to prevent unauthorized operation
38 Locking of lower shutter
130 Locking of upper shutter
83
6.1.2 Circuit-breaker - type VD4
Charging the stored energy spring system:
Charging of the circuit-breaker is carried out automatically
by the charging motor. If the charging motor should fail,
the charging procedure can be carried out or completed
manually.
If mechanical charging is necessary open the door with the
withdrawable part in the test position, insert charging lever
128 into the recess and pump for approx. 25 strokes until
the charged condition is indicated.
On breakers where the charging lever is integrated, take the
lever and pump 10 times.
When the charged condition is reached, the charging
mechanism is automatically disengaged, and any further
strokes of the lever have no effect (Fig. 148). Pumping is
effective if the lever is moved oevr an angle of 90.
Opening and closing the circuit-breaker:
Opening and closing operations with the withdrawable part
in the service position should only be performed with the
door closed.
Operate the local or remote electrical control.
Observe the switch position indicator.
The switching operation counter 13.5 for the circuit-breaker
automatically increases by one unit with each operating cycle.
An additional control mechanism fitted in the door of the
circuit-breaker compartment enables
mechanical operation of the circuit-breaker with the door
closed and with the withdrawable part in either position.
Figure 148: 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
13.12 Locking OFF position
128 Charging lever
13.1
13.8
13.4
13.5
128
13.11
13.2 13.12
90
Press the relevant mechanical pushbutton, having
previously turned knob 45.2 (Fig. 7) anti-clockwise to the
stop if the withdrawable part is in the service position.
For further details regarding operations and maintenance of
VD4 circuit-breakers, see instruction manuals BA 460-06,
BA 414-06.
6.1.3 Circuit-breaker - type VM1
The maintenance-free VM1 circuit-breaker applies a
combination of moulded-in vacuum interrupters, a magnetic
actuator and an electronic controller without auxiliary switches
and with sensors.
Before connecting the primary voltage:
Connect the auxiliary voltage. OFF command (closed
circuit release) and the closing lock-out must be energized
before the circuit-breaker can be closed.
The auxiliary voltage has been established when the (Ready)
LED 31.2 lights up.
Carry out the closing and opening test of the circuit-breaker
by pressing pushbuttons 31.3 and 31.4.
Closing:
- by remote control via closing contacts or locally by
pressing ON pushbutton 31.3.
84
Opening:
- by remote control via closing contacts or locally by
pressing OFF pushbutton 31.4.
Opening on failure of the auxiliary power supply:
- Electrical opening is still possible within the first 200 s.
- After a period of 200 s, emergency manual opening is
necessary:
- Insert emergency manual operating lever 31.28 (Fig. 187)
onto the spigot of the emergency shaft 31.9 in the front
plate and turn it anticlockwise to open the circuit-breaker.
Just before the final stop is reached, a slight resistance on
the emergency shaft has to be overcome.
Closing on failure of the auxiliary power supply:
- Closing is not appropriate and not possible.
31.5 31.6
31.9
31.16
31.2
31.3
31.4
Figure 149: Withdrawable part with VM1 type circuit-breaker - 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
8
28
Figure 150: Emergency manual switch-off
8 Recess for emergency manual opening lever
28 Emergency manual opening lever
After each operating cycle (ON-OFF), the operating cycle
counter 31.5 increases by one full digit.
On termination of a switching operation, the position indicator
31.6 in the window of the front plate displays the related
switch position.
Anti-pumping system:
- The circuit-breaker controller ensures that circuit-breaker
closing is locked when an opening command is active.
- When closing on a subsequent opening command, further
closing with the closing command still active is locked.
The closing command must be given again for the next
closing operation.
For details, refer to manual BA 433/E.
10.2
13.15
90.2
90.3
90.4
90.5
90.7
90.6
Figure 151: HD4 type circuit-breaker - side view
13.15 Withdrawable assembly
Figure 152: Operating and signalling parts of HD4 circuit-breaker
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
85
6.1.4 Circuit-breaker - type HD4
Manual operation for spring charging:
To manually charge the closing springs, fully insert charging
lever 90.8 (Fig. 187) into seat 90.6 and turn it until the yellow
indicator 90.7 appears.
Electrical operation for spring charging:
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 90.7 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. In any case, it is always
possible to complete the charging operation manually.
Circuit-breaker closing:
This operation can only be carried out with the closing springs
completely charged. For manual closing press pushbutton
90.3. When there is a shunt closing release, the operation can
also be carried out by means of a control circuit. The indicator
90.4 shows that closing has been accomplished.
Circuit-breaker opening:
For manual opening, press pushbutton 90.2. 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 90.4 shows that opening has been accomplished.
An additional control mechanism fitted in the door of the
circuit-breaker compartment enables mechanical operation
of the circuit-breaker with the door closed and with the
withdrawable part in either position.
Press the relevant mechanical pushbutton, having
previously turned knob 45.2 (Fig. 7) anti-clockwise to the
stop, if the withdrawable part is in the service position.
Detailed information about installation and maintenance can
be found in instruction manual 647016.
91.15
91.14
91.13
Figure 153: VSC type vacuum contactor - front view
91.13 Signalling device ON/OFF
91.14 Operating cycle counter
Figure 154: VSC type vacuum contactor - pole side
91.15 MV fuses
86
6.1.5 Vacuum contactor - VSC
The VSC vacuum contactor is ideal for controlling AC
installations requiring a high number of operations. The
contactors basically consist of a moulded resin monoblock,
housing the vacuum interrupters, moving apparatus, control
electromagnet, multivoltage control feeder and auxiliary
accessories. The monoblock is also the support for assembly
95.2
95.1
95.3
Figure 155: Withdrawable part with metering unit
95.1 Voltage transformer
95.2 Cast resin tube (with fuse cartridge)
Figure 156: 95.3 Mini circuit breakers of transformer secondary circuits
(mounted in the cabinet of auxiliary circuits as standard)
of the fuse-holder frame. Closing of the main contacts is
carried out by the control electromagnet. Opening is carried
out by 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 6497011.
87
6.1.6 Withdrawable metering parts
Handling of the withdrawable metering part in the metering
panel is as described in section 6.1.1, without, however, the
switching operations and interlocking functions.
Withdrawable metering parts in incoming and outgoing feeder
panels are moved into the cable compartment using a ramp.
They reach their service position immediately and engage
in the panel earthing by 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.
6.1.7 Earthing switch - type EK6 and ST-E
The earthing switch has a snap closing mechanism which
is independent of the rotation of the drive shaft. An earthing
switch 6 (Fig. 2) allocated to a circuit-breaker is only enabled
for switching when withdrawable part 13 (Fig. 144, 145)
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 downwards onto the operating lever recess
socket. (When the switch is closed, it is already in this
position!)
Note:
Position operating lever 122 to point up or down 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 anti-clockwise
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.
Opening and closing with motor operator: (EK6 only)
The earthing switch can also be fitted with a motor operator.
Briefly operate the electrical control for opening or closing.
The earthing switch is then switched automatically into the
opposite position.
Emergency manual operation:
If a fault should occur in the motor operator, the earthing
switch can be switched to emergency manual operation with
lever 122, in a similar way to manually operated earthing
switches.
Note:
The lever may only be fitted temporarily to carry out an
emergency manual switching operation.
The power to the motor operator must be switched off for the
duration of any breakdown.
Caution!
If the operation is prevented, do not force
the interlock and check that the operation
sequence is correct.
Fit operating lever 122 (Fig. 158) onto
hexagonal shaft 14.1,which is now released
for operation.
Caution!
During emergency manual operation of a
motor-operated earthing switch, the interlock
is not functional!
On emergency manual operation, coupling
with the motor operator is automatically
released. To disengage the coupling to
the motor operator, first turn the lever 122
further in the pre-selected direction up to
the relative stop (turning through a small
angle). On the next operation with the motor
operator after its function has been restored,
the coupling automatically re-engages.
14.1
14.2
Figure 157: Preparation for operation of branch earthing switch - press the
slide downwards.
14.1 Hexagonal shaft of earthing switch operating mechanism
14.2 Slide
88
6.1.8 Busbar earthing switch
To earth the busbars, EK6 earthing switches are also
used. Their operating mechanism is identical to that of the
branch earthing switches. The conditions for panel to panel
interlocking of the busbar earthing switches are described in
section 3.4.2.
6.1.9 Shutter lifting truck
Shutter lifting truck (optional accessories) can be used for
access to spouts after removing the circuit-breaker from the
circuit-breaker compartment:
Place the shutter lifitng truck (62) into the rails for the
circuit-breaker truck in circuit-breaker compartment
Push the shutter lifting truck in using the isolated operation
rod (63) and open the shutters for access to spouts
Rotate the operation rod to lock the truck and pull the truck
out when finished
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.
122
Figure 158: Preparation for operation of branch earthing switch - operating
lever prepared for switching on/off
122 Operating lever
Figure 159: Shutter lifting truck in
circuit-breaker compartment
Figure 160: Opening shutters
Figure 161: Isolated operation rod
ON
OFF
Caution!
Never operate shutter lifting truck only by
hand.
62
63
89
6.1.10 NALF switch-disconnectors
The NALF switch-disconnectors, combining a switch-
-disconnector with fuses and E type earthing switches are
intended for indoor use in switchboards. The switch-
-disconnectors can open and close loaded and
unloaded inductive and capacitive circuits. In the open
position the device has a visible isolating distance.
The switch-disconnectors are used in combination with power
fuses as short-circuit protection. This combination excludes
two-phase power supply, because the interruption of any fuse
link causes the opening of the switch-disconnector by
its tripping system.
The E type earthing switches are constructed with a snap
closing mechanism. They can close and carry short-circuit
currents.
Operating mechanism of the switch-disconnector for use in
UniGear switchgear:
Operating mechanism A with two springs.
The opening spring is always charged before the closing of
The switch-disconnector. This means, that the closed switch-
-disconnector always has stored energy in the opening spring
and the opening follows immediately with the manual lever,
opening shunt release or fuse tripping mechanism. This
mechanism facilitates remote opening and in combination with
the motor operating mechanism makes completely remote
control possible.
The E type earthing switch is always operated locally by
the operating lever 215.
To secure the protection of connected MV equipment the
UniGear switchgear with switch-disconnector uses CEF
medium voltage fuses. The UniGear switchgear with NALF
switch-disconnector can be equipped with a range of fuses
according to the following table::
In cases that the switch-disconnector without MV fuses
will be required, the current-carrying bars will be inserted in
holders instead of the MV fuses to maintain the same location
of the earthing switch.
Notice:
The switch-disconnector and earthing switch can only be
operated with the switchgear panel door closed.
The switch-disconnector and earthing switch are mutually
mechanically interlocked.
switch-disconnector operating lever prepared for the ON
operation
207.1 Position indicator of earthing switch
208.1 Operating shaft for the earthing switch
209 Lockable operating handle Chubb lock
210 Lockable operating handle padlock
switch-disconnector operating lever prepared for the OFF
operation
215 Operating lever
215
207.1
209
210
208.1
U
rated
[kV] I
rated
min. [A] I
rated
max. [A]
3,6 / 7,2 6 200
12 6 125
17,5 6 160
24 6 125
90
Closing and opening of NALF switch-disconnector
The switch-disconnector can only be switched on if the
earthing switch is open
Put operating lever 215 in position pointing up or down
on the grooved shaft of the switch-disconnector so that
there is sufficient room for movement of the operating lever
even if space is limited at sides
Turn the lever clockwise through approx. 180 to charge the
opening spring
Turn the lever anti-clockwise to charge the closing spring
and to close the switch-disconnector
Turn the lever clockwise through approx. 20 to open the
switch-disconnector
Observe switch positioning indicator 200.1 (Fig. 3)
Caution: Until the latch of the opening or closing spring
actuates, the lever will be returned back into the starting
position through the spring action. Proceed with caution
during this operation to prevent the slipping of lever from
hand - RISK OF INJURY
Closing and opening of integrated E type earthing switch
The earthing switch can only be switched on if the switch-
disconnector is open
Put operating lever 215 in position pointing left or up
on the grooved shaft of the earthing switch 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. 90 until the stop
is reached to close the earthing switch
Turn the lever anti-clockwise through approx. 90 until the
stop is reached to open the earthing switch
Observe switch positioning indicator 207.1
Closing and opening of NALF switch-disconnector with the
motor operating mechanism.
The switch-disconnector can also be equipped with the
UEMC 40 K3 motor operating mechanism.
Briefly operate the control buttons for closing or opening.
The switch-disconnector is then switched automatically or
the springs of the switch-disconnector are charged
Emergency manual operation
If a fault should occur in the motor operating mechanism,
the switch-disconnector can be switched manually with the
operating lever 215 directly on the shaft of the switch-
-disconnector 201.1
Notice:
After the manual operation the motor operating mechanism
will not be synchronous with the switch-disconnector,
which means that it must be manipulated twice to reach
synchronization, e.g. opening closing.
Caution: The operating lever may only be
fitted temporarily to carry out an emergency
manual switching operation RISK OF
INJURY.
Notice:
We recommend using a protective circuit-
-breaker in the supply circuit of the motor
operating mechanism. The opening time of
mechanism A operated with motor operating
mechanism is approx. 1s. If faster opening
is required, it is necessary to equip the
mechanism A with an opening coil.
91
6.2 Test procedure
6.2.1 Testing the off-circuit condition
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 a module - see Fig. 159-161.
If the panels are equipped with capacitive voltage indication,
this can be used to check the off-circuit condition. In this
case, proceed according to the manufacturers instructions or
the indicators. (Optionally, switchgear can be equipped with
various types of indicators from differents 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!
6.2.2 Current and voltage tests
5
4.1
12.2
12.1
4.3
4.2
5
12.2
Figure 164: 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 165: View inside the circuit-breaker compartment, withdrawable part
removed, shutters open
4.1 Isolating contact
5 Isolating tulip
12.2 Lower shutter
The testing and earthing module 142 (Fig. 167) 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.
92
6.3 Service trucks
Instead of earthing, short-circuiting and testing with module
142 (see Fig. 166, 167) 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 a further safety measure for personnel. The
use of these trucks anticipates 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 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 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.
Figure 166: Earthing trolley without short circuit switching capability
130 Earthing module without short circuit switching capability
130.1 Actuating bars
130.2 Contact arms
130.3 Contact system
130.4 Earthing contact
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 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 effective
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 anticipates 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 the 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 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 these trucks anticipates 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 the connectors it is fitted with, allows
connection of the test apparatus cables.
This truck can only be used in the incoming/outgoing units.
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, it connects to the two sides of
the busbar system.
This truck is used in the UniGear switchgear to make
incoming/outgoing units without circuit-breakers in radial
networks, to make cable connections between two
switchgear units 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).
93
Earthing and short-circuiting with earthing module
Isolate the area to be earthed and secure it against
reconnection.
Carefully follow all safety regulations.
Remove the withdrawable circuit-breaker part from the
relevant 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 (Fig. 187) (for procedure - see sect. 6.1.1).
133.1
Figure 167: 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 180
o
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
133.1 Earthing cable
142 Testing and earthing module with manual mechanism
142.1 Actuating bars (1 pair)
142.2 Contact arms (3 pcs.)
142.3 Contact systems
142.4 Ball handles (3 pcs.)
142.5 Insulating plate with 3 removable bushinghs
142.6 Bushings
142.7 Contact pin
142.8 Short-circuiting connection, complete
Using a high voltage tester, check that the contact pins
142.7 of the earthing module are definitely off-circuit.
Withdraw the earthing module back into the test/
disconnected position (see sect. 6.1.1).
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. 87).
Display earthing warning label on the switchgear panel
door.
Secure neighboring areas to prevent inadvertent contact
with live parts (e.g. feeder cables).
The procedure for removing earthing is the same, only in
reverse order.
94
7. Commissioning
7.1 Preparatory work
In preparation for commissioning, the following work must be
carried out:
Check the general condition of the switchgear for any
damage or defects.
13.9
13.13
Figure 168: Withdrawable part with VD4 type high current circuit- breaker -
pole side
13.9 Transport caps (to be removed on commisioning)
13.13 Lifting eyebolt (to be removed on commissioning)
13.10
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 8.5.
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 8.4.
Correctly remount all covers etc. removed during assembly
and testing procedures.
Transport caps 13.9 on heavy duty vacuum circuit-breakers
- if applicable - must be removed.
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.
In switchgear panels with an additional ventilation system
for high current circuit-breakers (required for ambient
temperature higher than > 40 C and/or higher frequency
- 60Hz -according to section 1.3 and figure 168 and 169),
flap 20.3 hanging in partition 20 must rest loosely against
leaf spring 20.4 (with the centrifugal fan at a standstill, if
fitted ). This is not standard.
To check:
Insert a suitable screwdriver through opening 20.5 in
horizontal partition 20 and into bracket 20.6 on flap 20.3.
Swing flap 20.3 upwards and allow it to rest loosely again
on leaf spring 20.4.
If the flap is in the locked position, use the screwdriver
to press leaf spring 20.4 downwards by approx. 5 mm to
release the lock before swinging the flap.
If any centrifugal fans controlled in relation to primary
current are fitted, also check that these function correctly.
Figure 169: Fitting of horizontal partition 20 with additional ventilation for high
current circuit-breakers, required due to increased ambient
temperature (>40C) and/or increased frequency (60 Hz) according
to section 1.3. The internal ap is shown in the service position
(open). Side view, but without the wind vane with micro-switch
required with a fan. Not standard.

20 Horizontal partition, here fitted with the additional ventilation
facilities for the circuit-breaker
20.3 Flap
20.4 Leaf spring
20.5 Inspection aperture
20.6 Bracket
20.7 Centrifugal fan
95
Figure 170: Horizontal partition with additional ventilation facilities. Checking
unimpeded movement of the internal ap 20.3
20.5 Inspection opening
On motorized withdrawable parts, check the direction of
rotation of the travel motor.
For any other matters regarding operation of the
withdrawable circuit-breaker part and testing facilities for
the withdrawable part.
7.2 Measurements and tests
Tests at site are mandatory prior to energization of the
switchgear.
The main purpose of site tests in general is to make sure the
switchgear is ready for energization, not to repeat the factory
testing and confirm the factory results.
For manufacturers recommendation of test scope and
method please contact ABBs Service Department.
After performing the tests, make sure that all normal service
conditions are restored.
WARNING
The check is only successful if all
the above tests have been passed
successfully.
If the inspection gives negative results,
do not put the apparatus into service but,
if necessary, contact ABBs Customer
Service Department.
Only energise the switchgear with all the
withdrawable parts in the test position and
with the circuit-breaker open.
96
8. Maintenance
8.1 Maintenance strategies
Preventive maintenance
is maintenance carried out at predetermined intervals or
according to prescribed criteria, aimed at reducing the
failure risk or performance degradation of the equipment.
This method is based on scheduled activities performed
on the out-of-service equipment including: visual checks,
apparatus cleaning, mechanical components lubrication, worn
parts replacement and routine tests.
Risk-based maintenance
is maintenance carried out by integrating analysis,
measurement and periodic test activities with standard
preventive maintenance.
The gathered information is viewed in the context of the
environmental, operation and process condition of the
equipment in the system. The aim is to perform the asset
condition and risk assessment and define the appropriate
maintenance tasks.
Please refer to next chapters for details of preventive and risk-
-based maintenance programs.
8.2 Preventive maintenance
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: Determination of the actual condition
Servicing: Measures to preserve the specified condition
Repair: Measures to restore the specified condition
Note:
When carrying out all maintenance work, the regulations in the
country of installation must be strictly complied with.
) In more demanding service conditions, we recommend reducing this interval suitably also
see sections 1 and 2.
) According to the results of the inspection.
) See the instruction manuals of the circuit-breakers.
*) Earthing switch.
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 over-riding 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: type VM1;
Gas circuit-breaker: type HD4;
Vacuum contactor: type VSC;
Switch-disconnector NAL - catalogue;
Switch-disconnector - installation, service and maintenance
instruction manual;
Operating mechanisms of the circuit-breakers with high
voltage - catalogue;
Motor operator UEMC 40 K3 - installation, service and
maintenance instruction manual (for units with NALFE
earthing switch).
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 8.3 4
1)
Servicing 8.4 4
2)
10 000
3)
Repair 8.5 As required As required
Safery warning
Always follow 7 safety steps:
Clearly identify the work location
Disconnect and secure against reconnection
Protect against any other live parts
Take special precautions when close to bare
conductors
Check the installation is dead
Carry out earthing and short circuiting
Issue a permit to work
97
Testing interlock conditions
Carry out a visual inspection of the mechanical parts of the
interlocks (key locks 22, door interlocks 23, fail safe 24) and
check for any presence of humidity and signs of corrosion
on the moving parts.
22
24
23
Cleaning and checking the auxiliary connections
Open the miniature circuit-breakers 25 (figure 171)
positioned inside the low voltage compartment to remove
the auxiliary power supply to the panel;
Carry out a visual inspection on all the cabling, terminal
boxes 26 and check for any presence of dirt;
Manually check correct insertion of the cabling in the
terminal box.
25
26
25
8.3 Inspection
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 include correct mechanical/
electrical operation of the following parts: switching
devices, actuating, interlocking, protection and signalling
devices.
Special conditions
On panels with additional ventilation devices due to
increased ambient temperature (also see section 1.3):
1. Check flap 20.3 (Fig. 2) for correct operation. (Also see
figures 169, 170);
2. The centrifugal fan (if fitted) does not require any special
maintenance. Its working life depending on the service
conditions, and one significant parameter being the room
temperature - is approx. between 20,000 and 30,000
operating hours.
Checking readiness for operation can be carried out as
follows:
a) Load-dependent functional test with controllable primary
current supply of the relative instrument transformer. on
current rise:
1. to approx. 70% of the rated instrument transformer
current, the fan must start;
2. to 80 % of the rated instrument transformer current,
the fan must have reached the required minimum air flow.
Corresponding monitoring/signalling by the wind vane with
microswitch.
b) Basic checking with temporary operation of the centrifugal
fan with an external power supply of 220 V AC;
c) In both cases, check for unimpeded normal running of the
fan and listen for any unusual bearing noise. Remove any
dirt on the fan rotor.
d) Check unimpeded operation of the wind vane and
microswitch by starting the fan several times.
e) The wiring to removable horizontal partition 20 (Fig. 2) can
be disconnected behind the right-hand side duct cover.
Follow the circuit diagram and carefully reconnect the
wiring again on completion.
Visual inspection of busbar compartment
By gaining access from the circuit-breaker compartment,
remove bulkhead 9 (Fig. 175), unscrewing 7 x M8 screws;
After removal of the bulkhead from the circuit-breaker
compartment, the main busbars are visible;
Visually check that the top monoblocs 5, where the tulip
isolating contact is housed, are fully intact and do not show
any sign of damage;
Visually check that the insulating covering of the main
busbars and the insulating joining cover of the busbars are
fully intact and do not show any sign of damage;
Figure 171:
Figure 172:
Figure 173:
Caution
With regard to the switching devices, their
separate Instruction manuals should be
followed
98
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 6.1.1!
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 (Fig. 174) 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 (Fig. 10) 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 (Fig. 10) in the
withdrawable assembly.
10.2
13.1
18.1
14
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;
Disengage locking magnet Y0 by pulling the magnet
armature;
Figure 174: Circuit-breaker compartment, open. Withdrawable part in isolated
position, control circuit plug connector open
10.2 Control circuit plug connector
13.1 Withdrawable part
18.1 Square rod
While doing so, turn crank 121 (Fig. 187) 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. Check this condition.
7. Operation of the earthing switch must only be possible
when withdrawable part 13 (Fig. 144, 145) 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 (Fig.
157), 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.
99
Figure 175: View of the busbar compartment, shown without insulating covers
2 Branch conductor
3 Busbars
5 Tulip isolating contact
9 Bulkhead, removable
3
2
9
5
8.4 Servicing
When, during an inspection as per paragraph 8.3, the need to
carry out cleaning operations is noted, proceed as follows:
Clean the surfaces:
- Remove any dry dust deposits which are not strongly
adherent using a soft dry cloth;
- Remove any more adhering dirt with ETHANOL F 25 M;
Clean the insulating surfaces and the conductive
components with ETHANOL F 25 M;
After cleaning, rinse with clean water and dry carefully;
Should any partial discharges occur as a consequence of
the condensation phenomenon, a temporary remedy which
is often effective is application of a thin layer of silicone over
the surface involved. For a permanent remedy to this type
of unusual problem, contact the ABB service department.
8.4.1 Maintenance in busbar compartment
Checking of the tightening main busbars
By accessing through the circuit-breaker compartment,
remove the bulkhead 9 (Fig. 175) unscrewing 7 x M8
screws.
After the removal of the bulkhead from the circuit-breaker
compartment, the main busbars are visible.
Using a dynamometric spanner, check tightness of all the
screws. Refer to the table on page 51 for the tightening
values;
8.4.2 Maintenance in cable compartment
Checking tightening of the cable busbar connections
Open the cable compartment door; the cable busbar
connections are visible;
Using a dynamometric spanner, check tightness of all the
values;
6.1
23
17.2
17
Figure 176: Internal view of the cable connection compartment, with a
maximum number of six cables in parallel
6.1 Earthing switch position indicator
17 Slotted bottom plate
17.2 Fairlead
23 Cable busbar connection
Note
The cable compartment door cannot be opened if the
earthing switch is open.
Earthing switches type EK6; ST-E
- Cleaning the kinematics to prevent faults on the
signalling contacts
Carry out a visual inspection of the kinematics and check
for any presence of dirt, humidity and signs of corrosion on
the moving parts;
Manually check correct changeover of the earthing switch
signalling contacts 18 (Fig. 179);
Remove any deposits of dust using a dry cloth that does
not leave any deposits on the treated surfaces (do not use
woollen cloths);
If necessary, grease the mechanical moving parts by
applying a thin layer of mechanical grease for moving parts.
Carry out a visual inspection on the toothed wheel and
pinion 20 (Fig. 177) and check any presence of dirt,
humidity and signs of corrosion on the moving parts;
100
20
19
18
Instrument transformers
- Cleaning and checking of the current transformers
Open the cable compartment door;
Remove the circuit-breaker plate to get larger access;
Visually check the connections of the current transformers;
Using a dynamometric spanner, check the tightness of all
the screws. Refer to the table on page 51 for the tightening
values.
- Cleaning and checking of the voltage transformers and
anti-ferroresonance circuit
Fixed version voltage transformers
Remove the circuit-breaker plate to get larger access;
Visually check the voltage transformer connections.;
Using a dynamometric spanner check tightness of all the
values;
Carry out a visual inspection of the transformers and check
for any presence of dirt;
woollen cloths).
Voltage transformers in removable version
Manually withdraw the VT truck.
for any presence of dirt.
woollen cloths).
Voltage transformers in withdrawable version
Manually withdraw the VT truck;
for any presence of dirt;
woollen cloths).
Figure 177:
Figure 178:
Figure 179:
Figure 180:
101
95.2
95.1
95.3
Figure 181: Withdrawable part with measurement unit
95.1 Voltage transformer
95.2 Resin tube (with fuse)
95.3 Fuse
Cleaning and checking the anti-ferroresonance circuit
Open the miniature circuit-breakers 25 (Fig. 173) positioned
inside the low voltage compartment to remove the auxiliary
power supply to the panel;
Carry out a visual inspection on the anti-ferroresonance
resistors and check for any presence of dirt;
Manually check correct insertion of the cabling.
Figure 182: Anti-ferroresonance resistor
- Cleaning and checking of the fuses
With the VT truck withdrawn, manually hook up the fuses
contained in the resin tube of the voltage transformers;
Carry out a visual inspection on the fuses and check for any
presence of dirt;
woollen cloths).
Figure 183:
21
8.4.3 Maintenance in circuit-breaker compartment
- Lubrication of the isolating contacts
woollen cloths);
If necessary, grease the mechanical moving parts by
applying a thin layer of mechanical grease for moving parts.
8.5 Repairs
8.5.1 Repair on switchgear assemblies
8.5.1.1 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 (with mechanical
grease for moving parts).
Replacement of the contact pins when the surface is
damaged
After any required replacement of contact pins 4.1 (Fig. 184),
the latter should be retightened using the socket head bolts.
See table of tightening torques on page 51.
102
5
4.1
12.2
Figure 184: View of inside circuit-breaker compartment, withdrawable
part removed, shutters open.
4.1 Isolating contact
5 Isolating tulip
12.2 Lower shutter
8.5.1.2 Repair on earthing switch signaling contact
The auxiliary switches of the interchangeable groups are
adjusted at the factory.
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.
In cases where there has been an internal arc is necessary
to repair and clean the whole substation
14.6
14.7
11.4 11.3
14.1
Figure 185: Manual earthing switch operating mechanism with auxiliary
contacts, side protection removed
11.3 Q8S1 auxiliary contact earthing switch OFF
11.4 Q8S2 auxiliary contact earthing switch ON
14.1 Drive shaft (earthing switch)
14.2 Sliding closure
14.3 Cam plate, adjustable
Figure 186: Earthing switch motor operator with auxiliary contacts installed,
protections removed
11.3 Q8S1 auxiliary contact earthing switch OFF
11.4 Q8S2 auxiliary contact earthing switch ON
14.1 Drive shaft for earthing switch
14.6 Locking disk
14.7 Cam

11.3
11.4
14.2
14.3
14.1
103
8.5.2 Repairs on withdrawable parts
When functional tests are carried out on withdrawable parts,
compliance with the conditions listed below should also be
checked.
8.7 Spare parts, auxiliary materials and
lubricants
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 relevant switchgear or switching device should always be
quoted.
Auxiliary materials, lubricants
Lubricant
Isoflex Topas NB 52
Halogen-free cleansers
ETHANOL F 25 M (for general cleaning);
Touch-up paint
Standard colour RAL 7035.
8.6 Risk-Based maintenance
ABB supports UniGear users with optimized and cost effective
strategies to ensure that the correct actions are implemented
at the right time. Asset managers are fully supported
in moving from conventional approaches (Corrective
maintenance and Preventive maintenance) to advanced
strategies (Risk-based maintenance and Condition-based
maintenance).
In this way, the service activity is no longer driven by
predefined timeframes, observations and past experiences,
but takes into account the actual condition of the equipment,
the required reliability level and the expetation for life time
extension.
This assessment is performed by trained technicians as
part of risk-based maintenance programs or is carried out
automatically by on-line monitoring systems for condition-
-based maintenance solutions.
Please refer to brochure 1VCP000427 - Maintenance by ABB
for more details on Risk-Based maintenance.
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: type VM1;
Gas circuit-breaker: type HD4;
Vacuum contactor: type VSC;
Operating mechanisms of the circuit-breakers with high
voltage - catalogue;
104
128
145
147
31.28
31.29
122
121
90.8
Figure 187: Operation accessories
31.28 Manual emergency operating lever (to remove voltage to VM1 type circuit-breaker
31.29 Auxiliary spring to lock the opening capacity (for VM1 type circuit-breaker)
90.8 Charging lever (for HD4 type circuit-breaker)
121 Crank handle (to move the withdrawable part inside the panel)
122 Operating lever (for earthing switch)
128 Charging lever (for HD4 type circuit-breaker)
145 Double bit key (to use the central locking device and the screw type door lock)
147 Crank handle (to use the central locking device or the screw type door lock)
8.8 Operating accessories
105

The UniGear panels are produced in compliance with
the requirements of international standards for the quality
management system and environmental management system.
In these fields, the level of excellence achieved is documented
by quality certificates according to ISO 9001 and by the EMS
according to ISO 14 001.

End of life of product
ABB is committed to complying with the relevant legal and
other requirements for environmental 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.
The following methods of disposal are possible:
Disposal can either be carried out thermally in an incineration
plant or by storing on a waste site.
RAW MATERIAL RECOMMENDED METHOD OF DISPOSAL
Metal material (Fe, Cu, Al, Ag, Zn, W, others) Separation and recycling
Thermoplasts Recycling or disposal
Epoxy resin Separation of metal material and the disposal of rest
Rubber Disposal
Oil as dielectric (transformer oil) Draining from equipment and further recycling or disposal
SF
6
gas Discharging from equipment and further recycling or disposal
Packing material wood Recycling or disposal
Packing material foil Recycling or disposal
9. Product quality and environmental
protection
106
Notes
1
V
L
M
0
0
0
3
6
3

-

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v
.

H
,

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n

-

I
n
s
t
r
u
c
t
i
o
n

M
a
n
u
a
l

-

2
0
1
2
.
0
6

(
U
n
i
G
e
a
r

Z
S
1
)

(
g
s
)
Your sales contact: www.abb.com/contacts
More product information: www.abb.com/productguide
The data and illustrations are not binding. We reserve the right to make
changes without notice in the course of technical development of the product.
Copyright 2012 ABB.
All rights reserved.

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