ZX2

ZX2
Gas-insulated medium voltage switchgear Instruction manual BA 435/02 E
ABB Power Distribution
Your safety first always!

That's why our instruction manual begins with these recommendations: Only install switchgear and/or switchboards in enclosed rooms suitable for electrical equipment. Ensure that installation, operation and maintenance are carried out by specialist electricians only. Comply in full with the legally recognized standards (DIN VDE / IEC), the connection conditions of the local electrical utility and the applicable safety at work regulations. Observe the relevant information in the instruction manual for all actions involving switchgear and switchboards. Danger! Pay special attention to the hazard notes in the instruction manual marked with this warning symbol. Make sure that under operation condition of the switchgear or switchboard the specified data are not exceeded. Keep the instruction manual accessible to all persons concerned with installation, operation and maintenance. The users personnel are to act responsibly in all matters affecting safety at work and the correct handling of the switchgear.
WARNUNG
Anerkannte Regeln der Technik und Betriebsanleitungen beachten ! Gefhrliche Spannung kann elektrischen Schock und Verbrennungen verursachen. Vor Aufnahme von Arbeiten jeder Art dieses Gert unbedingt freischalten, erden und kurzschlieen.
WARNING
Always observe the instruction manual and follow the rules of good engineering practice ! Hazardous voltage can cause electrical shock and burns. Disconnect power, then earth and short-circuit before proceeding with any work on this equipment.
If you have any further questions on this instruction manual, the members of our field organization will be pleased to provide the required information.
Contents 1 1.1 1.2 Summary General Standards and specifications
Page 6 6 6 6 6 6 6 7 8 8 9 10 11 12 17 17 17 18 18 18 18 19
Contents 4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Despatch and storage Condition on delivery Packaging Transport Delivery Intermediate storage Erection of the switchgear at site General site requirements Construction data Fundamental notes on erection work Foundation frame Laying of the foundation frame Raised false floor Erection and connection of the panels
Page 28 28 28 28 28 28 30 30 30 31 31 31 33 38 38 38 44 44 44 44 44 45 45 45 45 45 45 46 46 46 46
1.2.1 Switchgear manufacture 1.2.2 Installation and operation 1.3 Operating conditions
1.3.1 Normal operating conditions 1.3.2 Special operating conditions 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Technical data Panel type ZX2 Disconnector/earthing switch type UX2TE, and disconnector type UX2T Dimensions and weights Resistance to internal arc faults Design and function of the switchgear system and its equipment Design and equipment of the panels Gas system in the panels/switchgear Vacuum circuit-breakers, type VD4 X Disconnector/earthing switch, type UX2TE Disconnector, type UX2T Sensor systems High voltage connections Bay control and protection unit REF542 (SCU)
5.7.1 Preparatory work 5.7.2 Erection of the switchgear 5.8 Connection of cables and wiring
5.8.1 High voltage plastic-insulated cable with plug connectors 5.8.2 Control cables and wiring 5.9 5.10 6 6.1 Preparing the insulating gas system for operation Final erection work Commissioning/operation Commissioning
Protection against maloperation/interlock dependencies/earthing of tee-off 19 19 19 20 20 21 22
6.1.1 Preparatory work 6.1.2 Initial start-up 6.2 Switching operations
3.9.1 Interlock dependencies 3.9.2 Earthing a tee-off in a single busbar system 3.9.3 Earthing the busbar in a single busbar system 3.9.4 Earthing a tee-off in a double busbar system 3.9.5 Earthing the busbar in a double busbar system 3.10 Test facilities
6.2.1 Circuit-breaker 6.2.2 Three-position switch and disconnector 6.2.3 Undervoltage release 6.3 Observation of the display and monitoring facilities
6.3.1 Gas monitoring
6.3.2 Electrical/mechanical display/monitoring 46
Contents 6.4 Test procedures
Page 46 46 47 47 48 48 49 53 53 53 54 54 54 54 54 55 55 55
6.4.1 Testing for the off-circuit condition 6.4.2 Testing for the in-phase condition 6.4.3 High voltage tests 6.4.4 Current tests 6.4.5 Maintenance earthing 6.5 7 7.1 7.2 Application of the X-ray regulations Maintenance General Inspection/servicing
7.2.1 Vacuum circuit-breaker 7.2.2 Three-position switch and disconnector 7.2.3 Gas system and gas servicing 7.2.4 Outlet filter 7.3 7.4 Repair Working and auxiliary materials
7.4.1 Working materials 7.4.2 Auxiliary materials
We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual - or extracts to third parties is prohibited. The information supplied is without liability. Subject to alteration. ABB Calor Emag Mittelspannung GmbH, 2000
1 1.1
Summary
General Fundamental features of the ZX2 panels: rated voltage up to 36 kV three-phase metal-enclosed gas-insulated gas-tight metal-clad busbar compartment gas-tight metal-clad circuit-breaker compartment computerised switchbay control system sensor technology for adapted measured value acquisition indoor installation factory-assembled type-tested. Basic panel variants: incoming and outgoing feeders bus sectionalisers in single and double busbar systems bus coupler panels in single and double busbar systems bus riser panels in single and double busbar systems metering panels in double busbar systems supplementary equipment: busbar metering system in single busbar systems Panel equipment, variants: vacuum circuit-breaker single or double busbar systems: busbar system 1 with disconnector/earthing switch (three-position switch) with functions of: busbar connection, disconnection, earthing. busbar system 2 with disconnector with functions of: busbar connection, disconnection. 1.3 1.2
Details on the technical design and equipment of a switchgear, such as technical data, detailed list of equipment fitted, detailed circuit diagrams, etc. can be found in the order documents. Standards and specifications
1.2.1 Switchgear manufacture The panels comply with the following VDE standards and the corresponding IEC publications: VDE 0670 and IEC 60056, 60129, 60298 and 60694 VDE 0373 and IEC 60376 and 60480. 1.2.2 Installation and operation The relevant standards are to be observed during installation and operation, in particular: DIN VDE 0101, Power installations exceeding AC 1 kV, VDE 0105, Operation of electrical installations DIN VDE 0141, Earthing systems for special power installations with rated voltages above 1 kV, the accident prevention regulations issued by the appropriate professional bodies, the safety guidelines for production materials, the order-related details provided by the switchgear manufacturer. Operating conditions
1.3.1 Normal operating conditions Designed in accordance with VDE 0670 Part 1000, Common specifications for high-voltage and controlgear standards and IEC Publication 60694, with the following limit values: Ambient temperature: Maximum Maximum 24 hour average Minimum (corresponding to minus 5 indoor class) Site altitude: 1000 m above sea level Ambient air: The ambient air is not to be significantly contaminated by dust, smoke, corrosive or flammable gases, or salt. +40 C +35 C 5 C
1.3.2 Special operating conditions Special operating conditions are to be agreed by the manufacturer and operator. The manufacturer is to be consulted in advance about each special operating condition: Site altitude above 1000 m: Adjustment of the gas monitoring system is required for greater altitudes. Increased ambient temperature: The current carrying capacity is reduced, Additional cooling facilities for heat dissipation are to be provided. Climate: The risk of corrosion or other impairment, e.g. in the control cabinets, is to be avoided in areas: with high humidity and/or with major, rapid temperature fluctuations. Take countermeasures to prevent condensation phenomena (e.g. provide electric heaters).
2 2.1
Technical data
Panel type ZX2 Electrical data Rated voltage kV 12 28 1) 75 1.0 17.5 38 1) 95 1.0 50/60 1250/2500 ...2000/25004) ...100 ...40 ...40 ...100 ...100 ...40 ...40 ...100 ...100 ...40 ...40 ...100
5)
24 50 1) 125 1.0
36 70 1) 170 1.0
Rated power frequency withstand voltage kV Rated lightning impulse withstand voltage kV All voltages quoted apply to an insulating gas pressure, absolute, at 20 C, of bar 2) Rated frequency Rated current of busbars Rated current of tee-offs
3)
Hz A A kA kA kA kA
Rated peak withstand current 3) Rated short time current, 3 s 3) Rated short-circuit breaking current of the circuit-breaker Rated short-circuit making current of the circuit-breaker Rated operating sequence Break time: manual tripping protection tripping Closing time: manual tripping protection tripping Insulating gas system2)6) Insulating gas Design pressure, absolute Operating pressure, absolute, 20 C (equals filling pressure) Rated pressure, absolute, 20 C (minimum operating pressure) Motor and release data Charging motor Closing coil Opening coil Rated supply voltage DC voltage Gas-tight enclosure Control cabinet
1) 2) 3) 4) 5) 6)
...100 ...40 ...40 ...100
O-0.3 sCO-3 minCO ms ms ms ms 4590 4055 6595 60 4590 4055 6595 60 4590 4055 6595 60
4590 4055 6595 60
N2 7) bar bar bar W W W V IP 65 IP 4X 10)

7) 8) 9) 10)
SF6 8) 1.36 1.3 1.2 <200 250 250 60, 110, 2209) IP 65 IP 4X 10)
SF6 8) 1.36 1.3 1.2 <200 250 250
SF6 8) 1.36 1.3 1.2 <200 250 250
1.36 1.3 1.2 <200 250 250
Degree of protection (IEC 60529, DIN VDE 0470-1) IP 65 IP 4X 10) IP 65 IP 4X 10)
Higher values in accordance with international standards on request 1 bar = 100 kPa For details refer to table: "Panel width-classification" section 2.4 Cooling included Other operating sequences on request For further details see BA 427 - insulating gas system for ZX switchgear
Insulating gas: nitrogen Insulating gas: sulphur hexafluoride Other voltages on request IP 5X on request
2.2
Disconnector/earthing switch type UX2TE, and disconnector type UX2T
Test voltages Rated voltage Rated power frequency withstand voltage across the isolating distance Rated lightning impulse withstand voltage across the isolating distance Insulating gas system 1) 2) Insulating gas Operating pressure, absolute, 20C ( equals filling pressure ) Rated pressure, absolute,20C ( minimum operating pressure )
1) 2)
kV kV kV
12 32 85
17.5 45 110
24 60 145
36 80 195
N2 3) bar bar 1.3 1.2
SF6 4) 1.3 1.2
SF6 4) 1.3 1.2
SF6 4) 1.3 1.2
3) 4)
1 bar = 100 kPa For further details see BA 427 insulating gas system for ZX switchgear Insulating gas: nitrogen Insulating gas: sulphur hexafluoride
Rated voltage Test currents Rated current Rated peak withstand current Rated short time current, 3 s Motor data Motor power, max 3). Motor running times, max .: Centre position to BB Centre position to earth Rated supply voltage DC 4)
1) 2) 3) 4) 5)
kV
12/17.5/24/36
A kA kA
630 5) 63 25
12501) 80 31.5
2500 2) ...100 ...40
W
3)
180
180
180
s s
18 18
18 18
20 20
60,110,220
Panel width: 600 mm Panel width: 800 mm At rated supply voltage Other voltages on request Panel width: 400 mm
2.3
Dimensions and weights

View X A B
ZX2 ZX2
A B
895
n panels 2)
800
600
220
30
1232
1710
Figure 2/1:
Dimensions, double busbar system Figure shows panels with rated currents 2000 A. A B C D E
1)
Pressure relief duct with absorber Pressure relief duct, top Pressure relief duct, side End cover Pressure relief duct, rear Panels with rated currents greater than 2000 A are also fitted with a cooling fan. The panel height is then increased by 200 mm to 2500 mm or 2800 mm. n1
2)
View X A B
ZX2 ZX2
A B
n panels
Figure 2/2:
2)
800
600
220
30
1105
775
1710
Dimensions, single busbar system Figure shows panels with rated currents 2000 A. A Pressure relief duct with absorber B Pressure relief duct, top C Pressure relief duct, side Optionally also with voltage sensors for busbar metering D End cover E Pressure relief duct, rear
1)
2)
Panels with rated currents greater than 2000 A are also fitted with a cooling fan. The panel height is then increased by 200 mm to 2500 mm or 2800 mm. n1 ABB Power Distribution
10
2100
2300
26001)
X
1)
2100
2300
26001)
X
1)
Weights: Weight of a standard panel, double busbar, panel width 400 mm, rated current 630 A: Weight of a standard panel, double busbar, panel width 600 mm, rated current 1250 A: Weight of a standard panel, double busbar panel width 800 mm, rated current 2000 A: approx. 650 kg approx. 1200 kg approx. 1700 kg
See section 5.2 for dimensions of the switchroom (construction data).
2.4
Resistance to internal arc faults Panel width 400 mm Core modul/BB-compartment Cable compartment 25 kA, 1s 20 kA, 1s, three-pole 600 mm 31.5 kA, 1s 25 kA, 1s, three-pole 800 mm 40 kA, 1s 25 kA, 1s, three-pole
Resistance to internal arc faults: Criteria 1 - 6 of PEHLA directive no. 4 (in conjunction with VDE 0670 Part 6 and IEC 60298) are fulfilled. The panels have integrated pressure relief ducts with the opportunity for: channelling out of the switchroom in a manner suitable for the building dimensions, or channelling through an absorber on the last two panels (when the ceiling height is sufficient). Table: Panel width-classification Rated voltage IK, 3s IP Itee-off kV kA kA A 25 63 630 31.5 80 1250 12 31.5 80 2000/ 2500 800 40 100 1250 40 100 2000/ 2500 800 20 50 630 25 63 1250 17.5 31.5 80 2000/ 2500 800 40 100 1250/ 2000/ 2500 800
Panel width
mm
400
600
600
400
600
Rated voltage IK, 3s IP Itee-off
kV kA kA A 630 20 25 63 1250
24 25 63 2000/ 2500 800 31.5 80 1250/ 2000/ 2500 800 40 100 1250/ 2000/ 2500 800 25 63 1250
36 31.5 80 1250/ 2000/ 2500 800 40 100 1250/ 2000/ 2500 800
Panel width
mm
400
600
600
11
Design and function of the switchgear system and its equipment
20
1.1
Figure 3/1:
Panel, front view
Figure 3/2:
Panel type ZX2 with control cabinet open 1.1 3 8 20 Control cabinet door Three-position switch operating mechanism Circuit-breaker operating mechanism Disconnector operating mechanism
5.1
5.2
Figure 3/3:
Bay control and protection unit REF542 5 5.1 5.2 6 Bay control and protection unit LCD display (example) LEDs Measuring sockets for capacitive voltage indicator system ABB Power Distribution
12
B 23.5 G 2 19 20 E H
Figure 3/4: Panel, double busbar, with pressure relief ducts at top and rear The side walls of busbar compartments 1 and 2, of the circuit-breaker compartment and the cable termination compartment have been cut open to provide a better view. B E G H I 2 19 20 23.5 Pressure relief duct, top Pressure relief duct, rear Control cabinet Circuit-breaker compartment Cable compartment Disconnector/earthing switch (three-position switch) in busbar compartment 1 Disconnector -Q2 in busbar compartment 2 Operating mechanism for item 19 Bushing for plug-in busbar connection
Figure 3/5:
Pressure relief disk for a busbar compartment in the upper pressure relief duct
Figure 3/6:
Vacuum circuit-breaker type VD4 X (before installation in the works)
13
-Q5
-Q1 -Q0
-Q5
-Q1
-Q16 -Q11 -Q0
-Q15 -Q12
Feeder
Cable connection
Coupler
Riser
Busbar metering
Figure 3/7a: Examples of panels type ZX2, with single busbars
-Q5
-Q1
-Q2
-Q25 -Q1 -Q15 -Q2 -Q0
-Q16 -Q11 -Q15 -Q12 -Q26 -Q21 -Q25 -Q22 -Q0 -Q0
-Q0
Feeder
Bus coupler
Bus sectionaliser
-Q16 -Q11 -Q26 -Q21 -Q15 -Q12 -Q25 -Q22
-Q51 -Q1 -Q52 -Q2
Bus sectionaliser (without C.B.)
Trunking bar connection
Busbar metering
Figure 3/7b: Examples of panels type ZX2, with double busbars
14
Figure 3/8:
ZX2 panel, single busbar, 1250 A
Figure 3/9:
ZX2 panel, single busbar, 2000 A
Figure 3/10: ZX2 panel, double busbar, 2000 A
15
26 25 24 23 22 (21) 20 19 18 17 K 16 15 14 13
B G 1 2
SS2
SS1
3 (4) 5
7 H 8 9 10 I 11 12
-Q5
-Q1
-Q2
-Q0 -T1 -R1 -C1
Figure 3/11: ZX2 panel, double busbar, 1250 A, fundamental structure SS1 SS2 B E G H I 1 2 Busbar system 1 Busbar system 2 Pressure relief duct, top Pressure relief duct, rear Control cabinet Circuit-breaker compartment Cable termination compartment
-Q0 -Q1 -Q2 -Q5 -T1 -R1 -C1
Circuit-breaker Tee-off disconnector Tee-off disconnector Tee-off earthing switch Current sensor Voltage sensor Capacitive voltage divider
Panel enclosure Disconnector/earthing switch -Q1/-Q5 (three-position switch) 3 Three-position switch operating mechanism (4) Pressure sensor for busbar compartment 1 5 Bay control and protection unit REF542 6 Measuring sockets for capacitive voltage indicator system 7 Pressure sensor for circuit-breaker compartment 8 Circuit-breaker operating mechanism 9 Cable or test plug socket 10 Cable socket 11 Cable plug 12 Surge arrester 13 Floor plate, split 14 Connecting link panel/panel for item 15 15 Main earthing bar 16 Combined current and voltage sensor 17 Pressure relief disk 18 Circuit-breaker 19 Disconnector -Q2 20 Disconnector operating mechanism (21) Pressure sensor for busbar compartment 2 22 Tee-off conductor 23 Busbar connection, plug-in type 24 Busbar 25 Drying agent bag 26 Pressure relief disk Inert gas
16
3.1
Design and equipment of the panels (Figures 2/1, 2/2, 3/1 to 3/11) The metal-enclosed ZX2 panels are laser cut and welded panel enclosures, completely earthed and thus protected against accidental contact. The stainless steel encapsulation and the insulating gas protect all live parts in the high voltage area permanently from soiling, humidity, foreign bodies and other injurious influences. The modular structure provides the conditions necessary for all panel variants normally required in a relatively simple manner. Facilities are also provided, for instance, for: one or two busbar systems, three-position switch or disconnector, different connection methods, such as multiple cables. Relieved pressure is guided into pressure relief ducts (A), (B), (C) and (E): In the case of internal arcing fault, the following pressure relief disks open: Pressure relief disk 17 on circuit-breaker compartment (H) into pressure relief duct (E). The gases are channelled out via ducts (C) and (A). Pressure relief disk 26 on the busbar compartment into pressure relief duct (B). In the case of an arc in the cable compartment (I), a pressure relief flap in pressure relief duct (E) opens. The gases are channelled out via ducts (C) and (A). Each panel is a unit, They are linked together by plug-in busbar connections 23. Basic equipment in the panels: Circuit-breaker VD4 X Three-position switch UX2TE Disconnector UX2T Sensor system Control cabinet with the bay control and protection unit REF542 Cable and test plug sockets. The insulation test criteria of VDE and IEC list 2 are fulfilled by the ZX2 standard series up to and including 36 kV even when the gas filling is at atmospheric pressure. 3.3
The circuit-breaker compartment and the busbar compartments in each panel are separate gas compartments with their own filling connectors. The gas compartments in the individual panels set up side by side are not connected together. The operating pressure (pe) (equals filling pressure) in the individual compartments is monitored by temperature compensated pressure sensors: Pressure sensor 7 for the circuit-breaker compartment, Pressure sensors 4 and 21 for busbar compartments 1 and 2. When the pressure drops below the minimum operating pressure, a pressure loss signal is output. With a rapidly rising pressure as a consequence of an internal arc fault and a correspondingly high current, the bay control and protection unit REF542 shuts the incoming feeders or couplers down. Details on the gas system and gas servicing of the ZX2 switchgear can be found in instruction manual BA 427 Insulating gas system for ZX switchgear. The gas compartments contain drying agent bags 25. Further details on the drying agent material can be found in instruction manual BA 427. Vacuum circuit-breakers, type VD4 X (Figures 3/2, 3/6 and 3/11, and separate manual BA 436/E) Functions of the vacuum circuit-breaker 18: opening and closing on rated currents, short-circuit breaking operations, earthing function in conjunction with three-position switch 2. The earthing function of the three-position switch prepares - under no current - for the connection to earth. Earthing proper is performed by the circuitbreaker. This integration of functions is advantageous, as a circuit-breaker is of higher quality in the earthing function than any other earthing switch. The circuit-breaker poles are installed horizontally in the circuit-breaker compartment (H). The circuitbreaker operating mechanism is located outside the gas compartment and is therefore easily accessible. It is connected to the breaker poles by a gastight thrust bushing.
3.2
Gas system in the panels/switchgear (Figures 3/11 and 3/15) A permanently protected climate for the entire live primary area is ensured by the gas-tight encapsulation of the panels and their filling with dry insulating gas.
17
3.4
Disconnector/earthing switch, type UX2TE (Three-position switch) (Figures 3/2, 3/4 and 3/11) The ZX2 panels are fitted with specially designed three-position disconnectors and earthing switches -Q1/-Q5. These switches are motor-operated rodtype switches whose live switching components are located in busbar compartment 1 (insulating gas compartment), while the operating mechanism block is easily accessible from the control cabinet (G). The operating mechanism block contains the drive motor, the position indicators (sensors and mechanical indicators) and the emergency manual operating system. The three-position switch performs the functions of: connecting, disconnecting, and earthing. The three switch positions are unequivocally specified by the operating mechanism. The switch has its disconnecting position at the centre. In the limit positions, disconnector ON and earthing switch ON, the moving contact (sliding part) driven by an insulating spindle, reaches the isolating contacts, which are fitted with one or two spiral contacts respectively.
Sensors 4, 7 and 21 for insulating gas pressure monitoring Sensors to detect the switch positions of the circuit-breaker, disconnector/earthing switch and disconnector Sensor to detect the charging condition of the circuit-breaker spring energy store. Arrangement of the sensors: Current and voltage sensors are located in the rear part of the circuit-breaker compartment. The external connections allow wiring to be fed through the cable compartment (I) to the REF542. Sensors for pressure monitoring: B0G for the circuit-breaker compartment: on the circuit-breaker base plate in control cabinet (G). B1G for busbar compartment 1: beside the operating mechanism for the disconnector/earthing switch -Q1/-Q5 in the control cabinet (G). B2G for busbar compartment 2: beside the base plate for the drive motor of disconnector -Q2 at the rear of the panel. Sensors for detection of the switch positions: B0E and B0A for the circuit-breaker: on its mechanism shaft. B1E, B1A, B5E and B5A for the disconnector/earthing switch: on its operating mechanism in the control cabinet. B2E and B2A for the disconnector: beside its emergency manual operating mechanism in the control cabinet. Sensor B0S for detection of the charging condition of the spring energy storage mechanism: above the spring drum in the circuit-breaker operating mechanism. 3.7 High voltage connections (Figures 3/4, 3/8 to 3/11, 5/15 and 5/16) Cable plug connector systems: high voltage plastic-insulated cable with internal cone cable plug connector system and sockets to DIN 47 637. Plug-in cable sockets 9 and 10 mounted in a gastight manner in the floor plate of the circuit-breaker compartment maintain the partitioning between the insulating gas compartment and the cable termination compartment.
3.5
Disconnector, type UX2T (Figures 3/2, 3/4 and 3/11) Disconnector -Q2 is a motor-operated rod-type switch. Its live switching components are located in busbar compartment 2 (insulating gas compartment). The operating mechanism block is split and located outside the gas compartment. The drive motor is located at the rear of the panel behind a removable cover. The position indicators (sensors and mechanical indicators) and the emergency manual operating system are accessible from control cabinet (G). Disconnector -Q2 is structured similarly to the three-position switch, but without the earthing switch assembly.
3.6
Sensor systems (Figures 3/3, 3/11, 3/12 to 3/15, 6/3 and 6/7) In comparison with conventional inductive instrument transformers, sensors require much less space. They facilitate measured value acquisition suitable for the control and automation system REF542. The following sensors are used in ZX2 panels: Sensors for current measurement 16 Sensors for voltage measurement 16 Capacitive pick off for voltage display
18
3.8
Bay control and protection unit REF542 (Figures 3/3 and 3/15) The following functions are integrated in the bay control and protection unit REF542: Busbar protection Tee-off protection Control Measurement Position indication Hazard and fault signalling Connection to control systems. Panel interlocks and the sequence of switching operations (e.g. isolation, testing of the off-circuit condition and earthing) are controlled by the REF542 panel unit. The single-line diagram providing information on switching device positions is made visible on LC display 5.1. Measured values such as conductor currents, phase voltages, energy metering and active and reactive power, number of operating cycles and number of operating hours appear numerically and/or as a bar diagram on the display. Further information, such as alarm and fault signals, is displayed with text by LEDs 5.2. The bay control and protection unit REF542 can be connected to a control system via optical fibre cables. Electromagnetic interference is avoided by the use of optical fibre cables. Please consult the REF542 instruction manual no. BA 453 for details on handling of the bay control and protection unit and the detailed technical description.
3. Dependence of the disconnectors -Q1 or -Q2 on the circuit-breaker -Q0. 4. Dependence of the circuit-breaker -Q0 on the earthing switch -Q5. 5. Interdependence of the disconnectors -Q1 and -Q2. 6. Dependence of the disconnectors -Q1 and -Q2 on bus coupler circuit-breakers and vice versa. 7. Dependence of the bus section disconnector on the busbar tee-off disconnectors and vice versa (for bus sectionalising without circuit-breaker only). Details of interlocks/dependencies over and above those listed in points 1 to 7 (e.g. with neighbouring systems) can be found in the individual order documents. The interlock polling between panels is effected by loop lines from panel to panel. Operation on failure of the auxiliary power supply: On failure of the auxiliary power supply, the devices can be operated manually. No provision is however made for interlocked emergency manual operation of the three-position switches and disconnectors. Emergency manual operation: Intervention in the interlock concept is possible by opening the control cabinet door. Emergency manual operation without maloperation prevention is possible by means of a hand crank and mechanical push-button. 3.9.2 Earthing a tee-off in a single busbar system (Figure 3/7) 1. Manual earthing Operating sequence for tee-off earthing: Circuit-breaker -Q0 OFF. Disconnector -Q1 OFF. Earthing switch -Q5 ON. Test for off-circuit condition (display on REF542 or capacitive voltage indicator system (see section 6.4.1)). Circuit-breaker -Q0 ON (only possible when the REF542 has detected the off-circuit condition and enabled the switching operation). Secure panel to prevent reconnection (m.c.b. F101 and F106 OFF). Label the panel to indicate that earthing has been effected.
3.9
Protection against maloperation/interlock dependencies/earthing of tee-off In order to prevent dangerous situations and maloperation, a series of interlocks are provided to protect the operators and the switchgear itself. In ZX2 panels with digital control systems, protection against maloperation is fundamentally effected by the software in the panel unit. The circuit-breaker, three-position switch and disconnector can be controlled directly at the panel or from the control room using the local/remote lock-switch. Operation at the panel is by selection on the REF542.
3.9.1 Interlock dependencies 1. Limit position blocking of the switching devices. 2. Dependence of the disconnectors -Q1 or -Q2 on the earthing switch -Q5 and vice versa.
19
2. Automatic earthing by selecting the earthing sequence on the REF542 display (this facility depends on the order placed) Condition: circuit-breaker -Q0 OFF. Select and start the automatic earthing sequence: Disconnector -Q1 OFF. Earthing switch -Q5 ON. Check on off-circuit condition by REF542. Circuit-breaker -Q0 ON. M.c.b. F101 and F106 OFF. Feedback message Earthed and secured. Label the panel to indicate that earthing has been effected. 3. Cancelling the earthing of a tee-off Open the control cabinet door and switch on the m.c.b. F101 and F106 manually. Circuit-breaker -Q0 OFF. 3.9.3 Earthing the busbar in a single busbar system (Figures 3/7 and 6/7) Earthing of the busbar or a busbar section is dependent on the switchgear configuration. Systems with bus ties / risers permit the earthing of a single busbar section. 1. Manual earthing of a busbar section using the bus tie / riser Operating sequence: Circuit-breaker -Q0 in the bus tie (tie breaker) OFF. All disconnectors -Q1 in the busbar section to be earthed OFF. Disconnectors (-Q11 or -Q12) between the busbar section to be earthed and the tie breaker ON. Earthing switch (-Q15 or -Q16) on the opposite side of the tie breaker ON. Tie breaker -Q0 ON. M.c.b. F101 and F106 OFF. Label the busbar section to indicate that earthing has been effected. The busbar section is then earthed. All disconnectors in the earthed busbar section are blocked. 2. Automatic earthing of a busbar section by selecting the earthing sequence on the REF542 display (this facility depends on the order placed) Condition: Circuit-breaker -Q0 in the bus tie (tie breaker) OFF.
All disconnectors -Q1 in the busbar section to be earthed OFF. Select and start the automatic earthing sequence: Disconnectors (-Q11 or -Q12) between the busbar section to be earthed and the tie breaker -Q0 ON. Earthing switch (-Q15 or -Q16) on the opposite side of the tie breaker -Q0 ON. Tie breaker -Q0 ON. M.c.b. F101, F102 and F106 OFF. Feedback message Earthed and secured. Label the busbar section to indicate that earthing has been effected. The selected busbar section is then earthed. All disconnectors in the earthed busbar section are blocked. 3. Cancelling the earthing of a busbar section Open the control cabinet door and switch on the m.c.b. F101, F102 and F106 manually. Circuit-breaker -Q0 in the bus tie OFF. 4. Maintenance earthing of a busbar via free sockets in a tee-off Condition: The tee-off is earthed. All disconnectors in the busbar to be earthed OFF. Operating sequence: Fit a short-circuiting bridge to the free sockets and connect to main earthing bar 14. Circuit-breaker OFF. Earthing switch OFF. Disconnector ON. Circuit-breaker ON. M.c.b. F101 and F106 OFF. Label the busbar to indicate that earthing has been effected. All relevant panels are to be secured to prevent switching operations, e.g. tripping m.c.b. 3.9.4 Earthing a tee-off in a double busbar system (Figures 3/7 and 3/11) 1. Manual earthing Operating sequence for tee-off earthing: Circuit-breaker -Q0 OFF. Disconnectors -Q1 and -Q2 OFF. Earthing switch -Q5 ON.
20
Test for off-circuit condition (display on REF542 or capacitive voltage indicator system (see section 6.4.1)). Circuit-breaker -Q0 ON (only possible when the REF542 has detected the off-circuit condition and enabled the switching operation). Secure panel to prevent reconnection (m.c.b. F101, F102 and F106 OFF). Label the panel to indicate that earthing has been effected. 2. Automatic earthing by selecting the earthing sequence on the REF542 display (this facility depends on the order placed) Condition: circuit-breaker -Q0 OFF. Select and start the automatic earthing sequence: Disconnectors -Q1 and -Q2 OFF. Earthing switch -Q5 ON. Check on off-circuit condition (by REF542). Circuit-breaker -Q0 ON. M.c.b. F101, F102 and F106 OFF. Feedback message Earthed and secured. Label the panel to indicate that earthing has been effected. 3. Cancelling the earthing of a tee-off Open the control cabinet door and switch on the m.c.b. F101, F102 and F106 manually. Circuit-breaker -Q0 OFF. 3.9.5 Earthing the busbar in a double busbar system (Figures 3/7 and 3/11) Earthing of the busbar or a busbar section is dependent on the switchgear configuration. Systems with bus couplers permit the earthing of a single busbar section. 1. Manual earthing of a busbar section Operating sequence: a) Busbar 1: Circuit-breaker in the bus coupler OFF. Disconnector -Q2 in the bus coupler OFF. All disconnectors -Q1 in the busbar section to be earthed OFF. Disconnector -Q1 in the bus coupler ON. Earthing switch -Q15 in the bus coupler ON. Circuit-breaker in the bus coupler ON. M.c.b. F101, F102 and F106 OFF. Label the busbar section to indicate that earthing has been effected.
The busbar section of busbar 1 is then earthed. All disconnectors in the earthed busbar section are blocked. b) Busbar 2: Circuit-breaker in the bus coupler OFF. Disconnector -Q1 in the bus coupler OFF. All disconnectors -Q2 in the busbar section to be earthed OFF. Disconnector -Q2 in the bus coupler ON. Earthing switch -Q25 in the bus coupler ON. Circuit-breaker in the bus coupler ON. M.c.b. F101, F102 and F106 OFF. Label the busbar section to indicate that earthing has been effected. The busbar section of busbar 2 is then earthed. All disconnectors in the earthed busbar section are blocked. 2. Automatic earthing by selecting the earthing sequence on the REF542 display (this facility depends on the order placed) Condition: Circuit-breaker -Q0 in the bus coupler OFF. All disconnectors in the relevant busbar section OFF. Select the operating sequence: a) Busbar 1: Disconnector -Q2 in the bus coupler OFF. Disconnector -Q1 in the bus coupler ON. Earthing switch -Q15 in the bus coupler ON. Circuit-breaker in the bus coupler ON. M.c.b. F101, F102 and F106 OFF. Feedback message BB1 earthed and secured. Label the busbar section to indicate that earthing has been effected. The busbar section of busbar 1 is then earthed. All disconnectors in the earthed busbar section are blocked. b) Busbar 2: Disconnector -Q1 in the bus coupler OFF. Disconnector -Q2 in the bus coupler ON. Earthing switch -Q25 in the bus coupler ON. Circuit-breaker in the bus coupler ON. M.c.b. F101, F102 and F106 OFF. Feedback message BB2 earthed and secured.
21
Label the busbar section to indicate that earthing has been effected. The busbar section of busbar 2 is then earthed. All disconnectors in the earthed busbar section are blocked. 3. Cancelling the earthing of a busbar section Open the control cabinet door and switch on the m.c.b. F101, F102 and F106 manually. Circuit-breaker -Q0 in the bus coupler OFF. 3.10 Test facilities The panels are properly filled with insulating gas at the works and tested to the VDE or IEC standards. Testing on completion of switchgear installation is therefore unnecessary. Should there be any need to perform tests, the tests are to be performed as follows: For voltage and current tests, direct access to the conductors in the connection area is possible without removing the cable connection or extracting the insulating gas. Access is effected via free cable connecting sockets or via the cable sockets for the surge arresters. The surge arresters must be removed during voltage tests. Voltage tests: cable tests with DC voltage, cable fault location measurements with impulse voltage and system tests (without cables) with a AC voltage can be performed with a test plug as shown in Figure 6/8. A test plug for current tests as shown in figure 6/9 can be used to test the protection devices by primary current injection (see also the note in section 6.4.4). This configuration is short-circuit proof and can also be used as an additional maintenance earth. The possible testing processes are described in the following sections: testing for the off-circuit condition: testing for the in-phase condition: high voltage tests: current tests: Section 6.4.1 Section 6.4.2 Section 6.4.3 Section 6.4.4.
22
23
-XI.. ,-XU..
Terminal designation 1 -1 2 2 Front view 80A /240A /640A /150mV Class 1 without correction factor 3
P1
-XI..
S1 Primary conductor In = 1250 A Ip = 100 kA Ith 3sec = 40 kA
640A/150mV
S2
240A/150mV
S3
Capacitance C1 35pF max 55pF
80A/ 150mV
S4
20kV/ V3 Class 1 2V/ V3 1 2 Working area S1 - S2: 320...1280A S1 - S3: 120... 480A S1 - S4: 40... 160A
Figure 3/12:
-XU..
Pick-off: 10 000 :1 a n
CK
Leakage capacitance 25pF
P2
Combined current and voltage sensor with capacitive pick-off KEVCI 24 AE1, for rated voltages up to 24 kV and panel width 600 mm
The following changes apply to rated voltage 36kV:

-XI.. ,-XU..
Terminal designation 1 -1 2 2 Front view
Sensor: Pick-off: Capacitance:
KEVCI 36 AE1 20 000:1 bzw.

30 kV / 3 1,5 V / 3
C1 18 pF, max. 22 pF
P1
-XI..
S1 Primary conductor In = 2500 A Ip = 100 kA S2 Ith 3sec = 40 kA
1600A/150mV
1600A/150mV Class 1 without correction factor 3
Capacitance C1 35pF max 55pF
20kV/ V3 Klasse 1 2V/ V3
-XU..
1 2
Pick-off: 10 000 :1 a n
CK
Leakage capacitance 25pF
Working area S1 - S2: 800...3200A

Figure 3/13:
P2
Combined current and voltage sensor with capacitive pick-off KEVCA 24 BE1, for rated voltages up to 24 kV and panel width 800 mm
The following changes apply to rated voltage 36kV: Sensor: Pick-off: Capacitance:
24
KEVCI 36 BE1 20 000:1 bzw.

30 kV / 3 1,5 V / 3
C1 18 pF, max. 22 pF
L1 L2 L3
P1 P1 P1
I II IL1
-X3
d28 z28 1 2 2 1 d24 1 2 2 1 1 2 2 1 d16 z16 1 2 2 1 d12 z12 1 2 2 1
T1L1
S1
-XIL1 -XItL1 -XIL2 -XItL2 -XIL3 -XItL3 -XUL1
S.
-A200
-Q1/Q5 -Q2
-XI.. ,-XU.. Terminal designation
T1L2
S1 S.
IL2
z24
T1L3
S1 S.
d20
Current and voltage sensors
IL3
z20
R1L1
P2
a n
-Q0 -T1L1..L3
150mV P1 3 Front view P2
1
Tee-off protection; measurement, metering
UL1
-XUtL1 -XUL2
R1L2
P2
a n
UL2
-XUtL2 -XUL3
R1L3
P2
a n
-R1L1..L3
20kV/ V 3 2V/ V 3 3
-C1L1..L3
UL3
d8 z8
1 2 2 1
-XUtL3
3 single core cables
GND
d4
1 2 2 1
-XIL0 -XItL0
IL0
z4
Figure 3/14: Current and voltage sensors in an outgoing cable feeder panel, up to 24 kV, double busbar The circuit diagram is identical for the single busbar system, but without tee-off disconnector -Q2. -Q0 -Q1 -Q2 -Q5 -T1... -R1... -C1... Circuit-breaker Busbar tee-off disconnector Busbar tee-off disconnector Tee-off earthing switch Current sensors Voltage sensors Capacitive voltage divider
Inputs and interfaces of the bay control and protection unit REF542: IL... UL... -XI... -XU... -XIt... -XUt... -A200 Measurement inputs for current Measurement inputs for voltage Interfaces of the current sensors Interfaces of the voltage sensors Test interfaces of the current sensors and the inputs Test interfaces of the voltage sensors and the inputs Bay control and protection unit REF542
25
+ -
26
(2)
+
X4: d6
E3
3
X4: z6 X4: d24
Figure 3/15a:
110 kPa
X4: d10
BK BN BU
-A200
- F116
(1)+
140 kPa
E5
X4: z20
-B0G
E12
110 kPa
X4: z10
140 kPa
12
X4: z24 X4: d8
BK BN BU
X1: 1
2 1
11
E10
X4: d20
12 11
-A200
E4
3
X4: z28
X4: z8 X4: d14
110 kPa
X4: d18
BK BN BU
X1: 3
12
11
E14
- F100 - F101 - F102 - F106
4
X4: d28
140 kPa
E9
-B1G
11
110 kPa
X4: z18
MMK
140 kPa
E7
12
X4: z14 X4: d4
Figure 3/15b:Continued from figure 3/15a

BK BN BU
E2
BK BN BU
X4: z4 X4: d2
E1
BK BN BU
X4: z2 X4: d12
3
E6
X4: z12
SPA - BUS
110 kPa
X5: d6
-B5E -B5A -B1E -B1A -B0E -B0A -B0S
4
-B5E1 -B5E2 -B5E3
X4: d16
140 kPa
BK BN BU
E17
-B2G
3 1 2 4
-F106:24
110 kPa
X5: z6
6
X4: z16 X6: d22 X6: d20
140 kPa
(2)
X5: d4
E16
BK BN BU
- F101
X5: z4
E8
X5: d2
A5
X6: d18
E15
-B2A -B2E
BK BN BU
X5: z2
A3
-M1
X6: z20
X6: z18
A4
-F102
X6: z22
A6
A14
X7: d18
23
24
X7: d22
1 2
X7: d20
-F100
X6: d12
X6: d10
2 1
M
X7: z18
-M2
24
A13
X7: z20
A7
-M0
X6: z12
X6: z10
A12 A15
X7: z22
-V3
23
X6: d8
X6: d6
23 24
A2
-F106
-Y3 -Y2
X6: z8
X6: z6
C1 C2 C1 C2
X6: d4
X6: d2
A1
X6: z4
4 3
X6: z2
-V2
24
-F102: 24 23 (1)
Figure 3/15: Circuit diagram of the panel controller for a double busbar system The circuit diagram is identical for the single busbar system, but without M2, B2G, B2E, B2A and F102. Inputs E15, E16 and E17 and outputs A12 to A15 on the REF542 are not then used. -B0A -B0E -B0S -B5E -B5A -B5E13 -B1E -B1A -B2E -B2A -B0G -B1G -B2G -M0 -M1 -M2 -MMK -Y2 and -V2 -Y3 and -V3 -A200 -F100 -F101 -F102 -F106 -F116 Sensor, Circuit-breaker -Q0 OFF signal Sensor, Circuit-breaker -Q0 ON signal Sensor, spring energy store charged signal Sensor, Earthing switch -Q5 ON signal Sensor, Earthing switch -Q5 OFF signal Reed contacts, Earthing switch -Q5 ON signal Sensor, Disconnector -Q1 ON signal Sensor, Disconnector -Q1 OFF signal Sensor, Disconnector -Q2 ON signal Sensor, Disconnector -Q2 OFF signal Pressure sensor for circuit-breaker compartment Pressure sensor for busbar compartment 1 Pressure sensor for busbar compartment 2 Charging motor for spring energy store, circuit-breaker Drive motor for disconnector/earthing switch -Q1/Q5 Drive motor for disconnector -Q2 Man/machine communications Shunt release off with series rectifier for -Q0 Shunt release on with series rectifier for -Q0 Bay control and protection unit REF542 M.c.b. for charging motor, circuit-breaker M.c.b. for drive motor, disconnector/earthing switch -Q1/-Q5 M.c.b. for drive motor, disconnector -Q2 M.c.b. for controller, circuit-breaker ON/OFF M.c.b. for auxiliary power supply to the REF542
27
4 4.1
Despatch and storage

Condition on delivery The factory-assembled panels are checked for proper assembly and function. Condition on delivery: Compliance of the equipment with the order checked. Routine testing to VDE 0670 Part 6 or ICE 60298 performed. Installation material and accessories packaged separately. Bushings for the busbars closed off with transport covers. Condition of the gas compartments: Filled with insulating gas at rated operating pressure, Fitted with drying agent bags. Note: Air freight is to be discussed and agreed in individual cases. Packaging Panels with basic packaging or without packaging. Panels with seaworthy or similar packaging (also containerised for overseas transport): sealed in polythene sheeting, transport drying agent bags inserted, moisture indicators inserted, sight window fitted for checking of the indicator when AL composite sheeting is used. Observe the directions for the drying agent bags to DIN 55 473. The following applies: Coloured indicator blue: contents dry. Coloured indicator pink: contents moist (e.g. relative humidity over 40%). Transport (Figures 4/1 to 4/3) Note: Do not walk on the tops of the panels (rupture point for the pressure relief system!). The transport units are normally individual panels. Take account of the weights of the transport units. Take account of the high centre of gravity. Handle the panels in the upright position. Only perform loading operations taking account of all safety precautions to protect personnel and the material transported with: a crane, and/or fork-lift truck. Handling by crane: Attach suspension ropes of a sufficient loadbearing capacity with shackles (opening angle 30 mm).
Fit these to the four lifting lugs. Attach rope guide harness to the top of the panel. Handling in the switchgear room can be effected by a trolley with steerable wheels. Take account of the high centre of gravity of the panels. Danger of tipping! 4.4 Delivery The responsibilities of the consignee include but are not limited to: Checking the delivery for completeness and freedom from damage (e.g. also for moisture and its injurious effects). Any deficiencies/transport damage noted are to be documented on the waybill, reported to the shipper/carrier in accordance with the ADSP or KVO liability conditions for German insurance. Note: Always document major damage with photographs. 4.5 Intermediate storage Conditions for optimum intermediate storage: 1. Panels with basic packaging or without packaging. Dry and well ventilated storage room. Climate in accordance with VDE 0670 Part 1000/ IEC 60694. Room temperature not falling below -5C. No other injurious environmental influences. Store the panels upright. Do not stack panels. Panels with basic packaging: open the packaging at least partially. Panels without packaging: loosely cover with protective sheeting. sufficient air circulation must be preserved. Check regularly for any condensation. 2. Panels with seaworthy or similar packaging with internal protective sheeting: Store the transport units: protected from the weather, in a dry place, protected from damage. Check the packaging for damage. Check the drying agent (see section 4.2): on delivery, later at appropriate intervals. When the service life from the date of packaging has been exceeded: the protective effect of the packaging is no longer ensured, take action for further intermediate storage.
4.2
4.3
28
4 n.
ZX2
725 895
1232
530
Figure 4/1:
Preparation for handling by crane, double busbar system
1152 (for panel width 800) 952 (for panel width 600) 752 (for panel width 400)
ZX2
(170) 1)
565 775
530
Figure 4/2:
1105
Preparation for handling by crane, single busbar system
Figure 4/3:
Preparation for handling by fork-lift truck

1)
Note: The forks must support the full section length.
1464
(64)
29
Erection of the switchgear at site

In the interests of the best possible erection sequence, and in order to ensure a high quality standard of the panels, local installation of the switchgear should only be carried out, or at least responsibly managed and supervised, by specially trained skilled personnel.
5.1
General site requirements At the start of erection, the switchgear room at site must be complete, fitted with lighting and power for the erection work, lockable, dry, and with good ventilation facilities. All necessary provisions for laying of the power and control cables such as openings, ducts, etc. must already be in place. Compliance with the conditions for indoor switchgear to VDE 0670 Part 1000 etc., including those for the minus 5 indoor temperature class, must be ensured.
5.2
Construction data (Figures 5/4 to 5/7) Panel width Rated current mm A 400 630 mm mm mm mm 2500 2800 600 1250 2500 2800 800 2000 2500 2800 800 > 2000
Ceiling height1)2): without additional absorber with additional absorber with additional cooling fan and without absorber with additional cooling fan and with absorber Assembly opening1): in ceilings: in doors: width length width height
2800 3100
mm mm mm mm
500 1810 900 2300
700 1810 1100 2300
900 1810 1300 2300
900 1810 1300 2300
Aisle width3): Inspection aisle Operator aisle Panel weight (outgoing feeder, double busbar) Floor load
1) 2) 3)
mm mm kg kg/m2
800 1100 ca. 650 ca. 1200
800 1300 ca. 1200 ca. 1400
800 1500 ca. 1700 ca. 1500
800 1500 ca. 1800 ca. 1600
Minimum dimensions Panel including top pressure relief duct Governed by DIN VDE 0101 and the data on maximum panel width.
The ZX2 switchgear installations are mounted on a foundation frame set into the screed, or on a raised false floor. The openings shown in figure 5/4 are intended as an aid to planning. Instead of the large openings shown, drill holes can also be used, depending on the number of high voltage cables. Openings (drill holes) for power cables in the station floor are to be constructed so as to be eddy-current free.
Note: The following is to be taken into account in determining the foundation data: Single busbar systems: Any additional frame available for the voltage sensors in the busbar metering system. The distance from the additional frame including end coffer to the side wall of the room should be 500 mm to ensure sufficient room for movement (see also section 2.3). Double busbar systems: From 5 panels onwards, a pressure relief duct is required at both ends of the switchgear installation.
30
5.3
Fundamental notes on erection work DIN-bolts of tensile class 8.8 are to be used.
Tolerance conditions for laying of the frame to DIN 43 661, version A: Evenness tolerance: +/- 1 mm per metre.
Recommended
tightening torque1)
Nm Lubricant2)
Straightness tolerance: max. 1 mm per metre, but max. 2 mm for the entire length of the frame. 5.5 Laying of the foundation frame (Figures 5/1 to 5/3) Bolt the individual parts of foundation frame elements 27 together. Bolt the individual sections composed of foundation frame elements 27 (where the switchgear has several panels) together using connecting links 27.1 and bolts 27.5. Set up the complete foundation frame on the concrete floor precisely at the specified position. Fasten the foundation frame to the concrete floor sufficiently firmly with the bolts and dished washers 27.2, checking the correct dimensional position continuously. Enter jacking screws 27.3 into the relevant threaded bores (different lengths to correspond to the height of the screed), inserting a steel shim 27.8 below each screw. Loosen the compensation bolts 27.4 and carefully align the entire surface of foundation frame 27 in the horizontal plane and at the correct height, using a levelling instrument and screwing in jacking screws 27.3 to the appropriate depth. The top edge of the foundation frame must be 1 to 3 mm above the screed (take account additionally of the material thickness of any additional floor covering). Tighten the compensation bolts 27.4, performing a final check on the dimensions and horizontal position of the frame. Weld jacking screws 27.3 firm to prevent inadvertent changes to their settings. Perform the necessary work for proper earthing of the foundation frame with 30 x 4 mm galvanised steel strip. Two connections are necessary in switchgear with more than 6 panels. Carefully backfill the foundation frame when applying the screed. Note: Before applying the screed, insert auxiliary bolts 27.9. These prevent the screed from penetrating into the rivet nuts. Remove auxiliary bolts 27.9 when the screed has hardened. The foundation frame must not be subjected to any undue impacts or pressures, particularly, during the installation phase.
Thread M M M M M M
1)
Without 10 ,5 26 12 50 86 200
Oil or grease 4 ,5 10 4 ,5 20 40 80
6 8 83) 10 12 16
2) 3)
The rated tightening torques for fasteners without lubrication are based on a coefficient of friction for the thread of 0.14 (the actual values are subject to an unavoidable, partly not inconsiderable, spread). Rated tightening torques for fasteners with lubrication in accordance with DIN 43 673. Thread and head contact surface lubricated. These values apply to welded on studbolts only. Any tightening torques which deviate from those in the general table (e.g. for contact systems or device terminals) are to be taken into account as stated in the detailed technical documentation. It is recommended that the threads and head contact surfaces of bolts should be lightly oiled or greased, so as to achieve a precise rated tightening torque.
Remove any dirt from the surfaces in general and from insulating material surfaces. Observe the cleaning instructions in Section 7.2. When handling SF6, avoid any escape of gas into the switchroom: as incorrect readings may be caused during leakage testing. ventilate well if leakage occurs. 5.4 Foundation frame (Figures 5/1 to 5/3) Switchgear on a foundation frame: The relevant data for the order in hand can be found in the ABB documentation. The single or multiple panel foundation frame can be supplied with the switchgear. It is as a rule laid by site personnel and should be aligned and inspected under the supervision of a responsible specialist. The specifications of DIN 43 661 are also to be maintained when laying the foundation frame, in particular the evenness and straightness tolerances as a condition for perfect switchgear assembly.
31
27.1 27.4
Figure 5/1: Individual parts of a foundation frame element, 2-panel example version 27.1 Connecting link 27.4 Compensation bolt
n x FT = a Panel width FT
27
(1423)
1333
27.3
27.1
27.9 Panel width FT 400 600 800

Figure 5/2: Foundation frame 27 27.1 27.2 27.3 27.6 27.9 Foundation frame element, individual parts bolted together Connecting link Bolt and dished washer for foundation frame fastening to concrete floor Jacking screw for foundation frame Plug Auxiliary bolt for frame mounting and panel fastening bolt 1.4 ABB Power Distribution
Foundation frame width a Number of panels n 1 400 600 800 2 800 1200 1600 3 1200 1800 2400 4 1600 2400 _
27.2 27.6
32
Section A-A
(without item 1) (1423) 1.5 1
13 mm
1333 27.3 27.5 27.9 27.4
1.4
A
h
A
27
Figure 5/3: Foundation frame on concrete floor (showing the panel) 1 1.4 27 27.2 Panel Panel fastening bolt Foundation frame element Bolt and dished washer for fastening of the foundation frame to the concrete floor Jacking screw for foundation frame Compensation bolt Bolt for the connecting link Plug Steel shim Auxiliary bolt for frame installation Screed height 40 to 50 mm
27.8
27.2,27.6
27.3 27.4 27.5 27.6 27.8 27.9 h
5.6
Raised false floor (Figures 5/6 and 5/7) When a raised false floor is used, the manufacturers installation instructions are to be observed. The false floor must satisfy all requirements specific to the switchgear installation.
33
3
8x150
190
210 210
190
150
150
580 1)
110
430
1)
85
230 150 160 160 230
150
870 1)
660 1) 265 180
(1423)
815
665
8
660 500 85
3x160
150
1710
800 1)
4
1)
400
a 1)
1)
250
600
600
800
800
800
600
600
250
1)
800
c 1)
2000 60
(155)
50
Figure 5/4:
Guideline construction data for a foundation frame on a concrete floor See figure 5/5 for sections
1)
Panel width in switchgear
a mm
( 27 )
b mm 1455
c mm 1300
d
d mm 1100 1500 1300 Room height mm 2800 2500 3100 2800 ABB Power Distribution
Minimum Inspection aisle Operator aisle Basement entrance Platform, approx. 25 kN Pressure relief duct at side, including end cover Instead of individual openings, continuous openings or drilled holes are possible Earthing bar Panel without cable connection, e.g. bus coupler panel Door Waste air opening Intake air opening Intake air opening, if required Waste air opening Or as shown in figure 5/7 Height of cable basement as required To earthing bar Opening for control cable Opening for power cable, plug size 2 Opening for power cable, plug size 3 Instrument transformer for billing purposes Screed, see also figure 5/3
600 mm 800 mm or 600 mixed with 800 mm
1327
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 34
1527
1655
Room height Rated current A 2000 2000 > 2000 > 2000
22
: Absorber
with without with without
1)
Section A - A
800 1) 1710 c 1) 800 1)
Section B - B
1710 c 1)
200
1
ZX2
11
200
1
ZX2 230 150
1)
11
2800
2100 2600
10
16
2300
(27)
10
16
(27)
21
20
21
15
12
18
265 180
17
a 1)
14
12
18
265 180
17
a 1)
14
(1423)
(1423)
a) Panel width 600 mm, without instrument transformer
b) Panel width 600 mm, with instrument transformer
Section C - C
800
1)
Section D - D
c
200
1)
1710
800
1)
1710
200
1)
200
1)
ZX2
2600 2100 2300 1)
ZX2
2600 2100
200
11
11
10
16
230 160 160 660 (155)
d 1)
9
d
1)
(27)
10
16
160 160 160 500 (155) (27)
20
21
21
15
12
19
85 180
17
a 1)
14
12
19
85 180
17
a 1)
14
(1423)
(1423)
c) Panel width 800 mm, with instrument transformer
d) Panel width 800 mm, without instrument transformer
Figure 5/5:
Sections for figure 5/4 See figure 5/4 for legends and dimensional table
1)
Minimum
15
35
870
b 1)
13
2300 1)
22
870
b 1)
13
22
1)
15
660
b 1)
13
2300
150 150 665 (155)
1)
1)
2100 2600
9
d
1)
1)
815 (155)
660
b 1)
13
2800
1)
150
8x150 150
190
210 210
190
230 150 160 160 230
150
1333
815
665
8
660 500
3x160
150
1710
800
1)
4
600 250 800 1)
b 1)
400
a 1)
1)
250
600
600
800
800
800
600
2000 M 10 M 10 M 10 100
B
100 600 100 100 400
Figure 5/6:
Guideline construction data for a raised false floor See figure 5/7 for sections
1)
Panel width in switchgear
a mm
b mm 1300
c mm 1100
Minimum Inspection aisle Operator aisle Basement entrance Platform, approx. 25 kN Pressure relief duct at side, including end cover False floor structure, only shown in the area of the switchgear Earthing bar Panel without cable connection, e.g. bus coupler panel Door Waste air opening Intake air opening Intake air opening, if required Waste air opening Or as shown in figure 5/5 Height of cable basement as required To earthing bar False floor structure, supplied by others Power cable, plug size 2 Power cable, plug size 3 Instrument transformer for billing purposes 2000 2000 > 2000 > 2000 Rated current A Room height 21 : 600 mm 800 mm or 600 mixed with 800 mm
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1327
1572
1500
1300
Absorber
Room height mm
with without with without
2800 2500 3100 2800
36
1)
Section A - A
800 1) 1710 b 1)
800
1)
Section B - B
1710
200
b 1)
200
13
14
2800 1)
ZX2
200
11
13
11
1)
2100 2600
2300
10
16
665 (72)
c 1)
10
16
230 160 160 660
c1)
20
a 1)
15
12
17
18
1333
X
1333 a
a) Panel width 600 mm, without instrument transformer
b) Panel width 800 mm, with instrument transformer
Detail X
(72)
Figure 5/7:
Sections for figure 5/6 See figure 5/6 for legends and dimensional table
1)
Minimum
15
37
12
17
19
(72)
1)
2300 1)
150 150
2100 2600
1)
14
21
ZX2
5.7
Erection and connection of the panels (Figures 5/3 and 5/8 to 5/14) Note: Do not walk on the top of the panels (rupture point for pressure relief system!).
Slide the adjacent panel carefully and evenly (without tipping) against the erected panel in such a way that the contact tubes, insulating parts and guide pins slide into the corresponding bores without the use of force. If necessary, align the panel appropriately with the panel height adjustment bolts 1.5. As soon as the distance between the two panels is so small that bolts 36 and 37 can be entered in the bores in the erected panel, insert these, each with nuts and dished washers respectively. Spacer 38 is also to be fitted on socket head bolt 37 (see figure 5/9, section B-B). Then join the two panels together by tightening bolts 36 and 37 step by step. Completely bolt the panels together with bolts 40, each with dished washers (see figure 5/8). When the panels have been completely joined, check the second panel again for correct alignment and fasten it to the foundation frame with the panel fastening bolts 1.4. Dismantle connecting link 14 for the main earthing bar 15 in the cable compartment and lead it through to the adjacent panel. Bolt the connecting link to the main earthing bar with bolts 39 and one dished washer at each of the bolt head and nut ends. Check the bolted connection between main earthing bar 15 and the connecting link 14 in the previously erected panel and tighten bolt 39 if necessary. Erect the further panels by following the same procedure. Assembly of the top pressure relief duct, the absorber and the cooler if fitted can be effected during installation of the individual panels or when all panels have been joined together.
5.7.1 Preparatory work Grease the upper surfaces of the foundation frame (this facilitates erection and alignment of the individual panels). Enter the two or four guide pins 35 at the sides of the panels into the relevant bores (see figure 5/10, section A-A). 5.7.2 Erection of the switchgear Erect the end panel of the switchgear at the precise position specified on the foundation frame. Lightly enter panel fastening bolts 1.4 into the relevant threaded bores in the foundation frame. Align the panel if necessary. Perform a final check on the aligned position of the panel and fasten it to the foundation frame by tightening the panel fastening bolts 1.4. Remove the protective caps from the busbar sockets 23.1. Carefully check insulating parts 23.2 and contact tubes 23.3 for any dirt, and clean if necessary (see also section 7.2). Note: Only prepare insulating parts and contact tubes for the panel currently being erected. Protect them from further contamination! Evenly apply a thin coating of assembly paste AP to the conical surfaces A of insulating parts 23.2. Note: Leave no ungreased areas on conical surface A. Carefully insert contact tubes 23.3 and insulating parts 23.2 into the busbar sockets 23.1.
38
View X 40 37.2 40 37.1 37.2 A B B 40 37.2 X 40 37.2 C 40 37.2 A 40 37.2 23 23.3 35 23.1 23.2
40 37.1 37.2
40 37.2
a) Double busbar
40 37.2 40 37.1 37.2 B B
40 37.2
A 40 37.2
40 37.1 37.2
40 37.2
C 40 37.2
40 37.2
b) Single busbar Figure 5/8: Switchgear erection (See figure 5/9 for sections and details) 23 23.1 23.2 23.3 35 37.1 37.2 40 ABB Power Distribution Busbar connection, plug-in type Busbar socket Insulating part Contact tube Guide pin M8 hexagon nut Dished washer 8 Socket head bolt M8 x 25 39
Section A-A 23.4 23.1 23 23.2
ca. 50 10 Panel division

1)
1)
Evenly greased with assembly paste AP
Busbar connection
Insulating part
Section B-B
10 Panel division
Section C-C
Panel division
15 39 35.2 14 35.2 35.1
38
37.2
37 Earthing bar connection
Panel/panel connection
Figure 5/9:
Switchgear erection (section for figure 5/8) 14 15 23 23.1 23.2 23.4 35.1 35.2 37 37.2 38 39 Panel/panel connecting link Main earthing bar Busbar connection, plug-in type Busbar socket Insulating part O-ring M10 hexagon nut Dished washer 10 Socket head bolt M8 x 40 Dished washer 8 Spacer Socket head bolt M10 x 35
40
Section A-A
A B
35
36
35.2
35
A
35.1
Section B-B 35.2 35.2
35.1
36
a) Panel joined up from the right
36
35
b) Panel joined up from the left
Figure 5/10: Switchgear erection panel/panel connection, view from top (without pressure relief duct) 35 35.1 35.2 36 Guide pin M10 hexagon nut Dished washer 10 Socket head bolt M10 x 50
41
Detail X 35.2 43 35.2 35.1
42 37.2 41 40
Detail Y
Evenly greased, assembly paste AP
42
Y
Figure 5/11: Busbar end in an end panel 35.1 35.2 37.2 40 41 42 43 M10 hexagon nut Dished washer 10 Dished washer 8 Socket head bolt M8 x 25 Plate for blanking plug Blanking plug Socket head bolt M10 x 30
1330 665
250 220
44 45
A B
F
2600
Figure 5/12: Pressure relief duct, side, double busbar, right-hand side mounting shown A B C D F Pressure relief duct with absorber Pressure relief duct, top Pressure relief duct, side End cover Panel 44 45 Fastening material, packed in bag group Screw fasteners for side pressure relief duct Plug
42
23.1
23.2
23.3
L3
L2
L1
Figure 5/13: Busbar connection 23.1 Busbar socket 23.2 Insulating part 23.3 Contact tube
Figure 5/14: Assembly of the busbar connection, shown for 1250 A L1: Protective cap removed L2: Contact tube 23.3 fitted L3: Insulating part 23.2 and contact tube 23.3 fitted
12
10
27
11
13
Figure 5/15: Plug connector for single-core plastic-insulated cable 10 11 K Socket Cable plug Cable earthing conductor to be connected to switchgear earth, do not establish cable earthing via the plug
13.1
13.2
13.3
13.4
Figure 5/16: Cable compartment (panel side wall cut out) 12 13 13.1 13.2 13.3 13.4 27 Surge arrester Floor plate, split Reducer ring Cable mounting Supporting section, at earth potential Insulated earthing point for cable jacket (nonstandard) High voltage cable
43
5.8
Connection of cables and wiring The cable compartments (I) in the panels are fitted with cable connection fittings in accordance with the cable types and sizes specified in the project planning for the switchgear as a whole.
5.10
Final erection work Clean the external surfaces of the enclosure and control cabinets in the switchgear where necessary and check for any damage to the paintwork, touching up with a suitable paint if necessary (see Section 7.3). Properly refit any cladding and covers of operating mechanisms, cable ducts, etc. removed during the erection work. Remove all tools and other foreign bodies from the switchgear. Check the general condition of the switchgear. Check that the areas adjacent to the switchgear are in the proper condition.
5.8.1 High voltage plastic-insulated cable with plug connectors (Figures 3/4, 3/11, 5/15 and 5/16) Lay the single-core plastic-insulated cables as specified in the project planning to the individual panels. Remove the transport covers fitted to protect the sockets. Expose the cable cores, check the correct phase assignment, and secure. Fit cable plug 11 in accordance with the manufacturers instructions. Fit the plugs to the sockets 10 mounted in the circuit-breaker compartment floor (without opening the insulating gas compartment) and secure them with bolts. Align the cables and fasten them at mountings 13.2 Close off any unused sockets, e.g. in spare panels, with suitable cable blanking plugs to ensure the necessary insulation. 5.8.2 Control cables and wiring (Figures 3/2 and 5/11) Establish the necessary connections for incoming and outgoing cables and wiring, and cross connections. The control cables and wiring are to be laid in cable ducts at the right of the cable compartment (for external wiring). The connections from panel to panel are to be made by plug connectors in the control cabinets. 5.9 Preparing the insulating gas system for operation Observe the relevant data in instruction manual BA 427/E Insulating gas system for ZX switchgear.
44
Commissioning/operation
Note on safety at work Operation by trained specialists familiar with the particular switchgear only.
Cancel any existing short-circuiting and earthing connections in the critical switching area. Energise the switchgear step by step, observing the displays on the REF542. Check that corresponding conductor sections are in phase where relevant with several incoming feeders and switchgear sections. Check measurements and functions dependant on high voltage. Look out for irregularities of any kind. 6.2 Switching operations
6.1
Commissioning
6.1.1 Preparatory work In preparation for commissioning, the following work is to be performed prior to connection with the high voltage power supply: Connect the auxiliary and control voltage and check the correct polarity. Check mechanical and electrical interlocks for compliance with the specified conditions. Perform a functional test on the protective devices (observe DIN VDE 0141). Check the general condition of the switchgear and external conditions for detrimental factors of any kind. Display the instructions for handling SF6 in the switchroom. The handling specifications for SF6 also apply accordingly to nitrogen. Display the ABB instruction manual on the handling of insulating gas and behaviour during faults in the switchroom. Instruct the local operators on the fundamental details of operating the switchgear in normal service. Check the readiness for operation and the switching condition of the upstream and downstream electrical equipment. Perform further checks where necessary on the following equipment from the areas adjacent to the switchgear: power cables control wiring auxiliary voltage and its polarity remote controls external earth with connection to main earthing bar 15 switchroom equipment switchroom condition. 6.1.2 Initial start-up Comply with all relevant safety regulations Ensure that the switchgear circuit-breakers are in the OFF position. Close the disconnector for the relevant busbar system.
6.2.1 Circuit-breaker (Figures 3/2, 6/1, 6/2 and 6/4) The circuit-breaker is fitted with a charging motor. Charging of the spring energy storage mechanism takes place automatically. Opening and closing the circuit-breaker: Opening and closing are effected by selection on the bay control and protection unit REF542. ON-OFF switching operations may only be performed with the control cabinet door closed. Opening the control cabinet door constitutes intervention in the interlock system. Observe the position indicator. Emergency manual operation: 1. On failure of the charging motor, the charging process can be performed or completed by hand: Open control cabinet door 1.1. Insert charging lever 8.9 into recess 8.8 and pump for approx. 25 strokes until the charged condition is displayed. When the charged condition is reached, the charging mechanism automatically disengages and further strokes of the charging lever have no effect. Key to the charging condition displays:
Discharged
Charged
2. If the control voltage fails with the circuit-breaker closed, it is possible to open it using the mechanical OFF push-button 8.3. Note: On failure of the control voltage, there is no maloperation protection for the circuit-breaker, three-position switch and disconnector during emergency manual operation.
45
6.2.2 Three-position switch and disconnector (Figures 3/2, 3/11, 6/3, 6/5 and 6/6) The three-position switch 2 and the disconnector 19 are fitted with motor-operated mechanisms. Opening and closing are effected by selection on the bay control and protection unit. ON-OFF switching operations may only be performed with the control cabinet door closed. Opening the control cabinet door constitutes intervention in the interlock system. Observe the position indicator on LCD display 5.1 or on the control unit. Sensors 29 to 32 on the three-position switch operating mechanism 3 detect the following switch positions: Disconnector -Q1 ON and OFF, and earthing switch -Q5 ON and OFF. Sensors 33 and 34 on disconnector operating mechanism 20 detect the following switch positions: Disconnector -Q2 ON and OFF. Emergency manual operation: In place of motorised operation, the switching process can also be initiated and completed manually. Caution! The interlock is ineffective on emergency manual operation. Open control cabinet door 1.1 Prior to emergency manual operation, switch the relevant m.c.b. (F101 or F102) off. Insert the crank in the hollow shaft. Three-position switch -Q1/-Q5: If the three-position switch is in the central position (i.e. disconnector and earthing switch OFF), the disconnector can be closed with approx. 24 clockwise turns, and the earthing switch with approx. 24 anti-clockwise turns. If the earthing switch ON position is to be reached from the disconnector ON position, or vice versa, the crank is to be removed in the self-inhibiting central position (disconnector and earthing switch OFF) and refitted. When the crank is refitted, the further switching operation is automatically enabled. Disconnector -Q2: Close the disconnector with approx. 24 clockwise turns and open it with approx. 24 anticlockwise turns. 6.3
Note: Always perform every switching operation right up to the stop in the relevant limit position. Observe the mechanical and electrical position indicators. 6.2.3 Undervoltage release Undervoltage releases may be fitted as an option. In order to prevent the circuit-breaker being opened by the undervoltage release on power failure with teeoff earthing, an interlock rod or wire is provided. Observation of the display and monitoring facilities
6.3.1 Gas monitoring (Figures 3/11 and 6/1) All high voltage compartments in the switchgear must have a sufficient insulating gas pressure during operation. The minimum operating gauge pressure (pe) is listed in section 2.1. This is monitored by sensors 4, 7 and 21. If the gas pressure falls below the minimum operating gauge pressure, an LED on the bay control and protection unit signals that the gas should be topped up. Note: If a panel is isolated for a relatively long period (several weeks), m.c.b. F116 for the auxiliary voltage supply to the REF542 must remain on. Only in this way is monitoring of the insulating gas ensured. Details on the gas system of the ZX2 switchgear can be found in instruction manual BA 427. 6.3.2 Electrical/mechanical display/monitoring During operation of the switchgear, observe all visible operating data and condition displays in the secondary system and watch out for irregularities of any kind, including the external conditions of the switchgear. 6.4 Test procedures
6.4.1 Testing for the off-circuit condition (Figure 6/1) The panels are fitted with the low impedance, capacitive voltage indicator system LRM, including corresponding (hand-held) display units with connecting plugs for testing of the off-circuit condition. For details, see draft DIN VDE 0682 Part 415, or IEC 61243 Part 5.
46
Note: Only display units which comply with the IEC or VDE standards and the technical design of the indicator system in the relevant switchgear may be used! Note: The measuring sockets must on no account be short-circuited, except during voltage testing of the system (e.g. with power frequency withstand voltage or impulse withstand voltage)! Testing for the off-circuit condition is performed with a plug in display unit at corresponding pairs of measuring sockets 6 in the vicinity of the panel controls. Use of the display unit: Perform a functional test on the display unit immediately before and after use, e.g. with interface tester KSP. The display must be clearly visible. The presence of operating voltage is indicated by a signal. Observe the individual operating instructions for the display unit for the relevant switchgear! Interface testing: Perform interface testing as a functional test on all coupling components, e.g. with interface tester KSP. The interface test is a repeat test to IEC 61243 Part 5 or draft DIN VDE 0682 Part 415. 6.4.2 Testing for the in-phase condition Testing for the in-phase condition, e.g. when there is more than one incoming feeder, can be performed with a suitable phase comparator at measuring sockets 6 on the capacitive voltage indication system. Test procedure: Only use phase comparators which comply with the IEC or VDE specifications and the technical design of the display system in the relevant switchgear! Perform a functional test on the equipment at the start of testing. Do not exceed the maximum permissible length of measuring leads per phase. Connect the measuring leads precisely assigned to the corresponding main conductor sections. Always follow the details in the operating instructions for the phase comparator!
6.4.3 High voltage tests (Figures 6/1 and 6/8) The test plugs available for high voltage tests, shown in figure 6/8, are suitable for the following applications up to and including 24 kV rated voltage. For high voltage tests on the 36 kV rated voltage level, separate test facilities are required. Information on these can be obtained from the switchgear manufacturer. Taking account of the sensor systems used and the bay control and protection unit, the test voltages must not exceed the following values: Cable tests with DC voltage: 12 kV switchgear: 48 kV1)
24/36 kV switchgear: 70 kV1) up to 1 hour. Higher values on request. Insulation testing of the switchgear at the relevant power frequency withstand voltage: 12 kV switchgear: 28 kV 24 kV switchgear: 50 kV 36 kV switchgear: 70 kV. Performance of voltage tests: Isolate the switchgear area in accordance with the safety rules of VDE 0105 and secure it to prevent reconnection. Verify the off-circuit condition with a suitable hand-held display unit at measuring sockets 6 on the capacitive voltage indicator system. Unscrew surge arresters where fitted, or unscrew the cable blanking plugs from the free cable sockets. Check the test plug to ensure that the surface is clean and dry, and clean it if necessary. Grease the silicone part of the test plugs in accordance with the directions. Insert the test plug into the prepared cable socket and screw it tight. Notes: Only fit the test plugs for voltage tests for the duration of those tests. Short-circuit the measuring sockets 6 in the panels concerned for the duration of the testing process at test voltages up to rated power frequency withstand voltage.
1)
Applies to integrated voltage sensors. With plug-in voltage sensors/instrument transformers, the cable test voltages permissible to DIN standards may be used if the sensors are withdrawn.
47
For performance of cable tests, in the switching condition tee-off disconnected and earthed, earthing of the cable has to be cancelled by opening the circuit-breaker. This is accomplished by using the mechanical OFF button to open the circuit-breaker (see also Section 3.9). 6.4.4 Current tests (Figures 6/1 and 6/9) The test plugs available for current test are suitable for the following applications: Testing of the protection functions in the bay control and protection unit REF542 by means of primary current injection. Test instruction: The following is to be observed when testing the protection system of the REF542: In order to prevent damage to the OFF-release coil during testing, either the OFF-release coil has to be disconnected or the protection test equipment must be deactivated by the trip command. This ensures that the opening release is not energised in the meantime by the trip command, which could lead to the coil burning out. Establishment of maintenance earthing in conjunction with an earthing and short-circuiting set. The short-circuit resistance of the current test plugs for the switchgear must correspond to the condition of the individual switchgear. Handling of the plugs for current tests: Isolate the switchgear area in accordance with the safety rules of VDE 0105 and secure it to prevent reconnection. Verify the off-circuit condition with a suitable (hand-held) display unit at measuring sockets 6 on the capacitive voltage indicator system. Unscrew surge arresters where fitted, or unscrew the cable blanking plugs on the free cable sockets. Check the test plug to verify that the surface is clean and dry, and clean it if necessary. Insert the test plug into the prepared cable socket and screw it tight. Only fit the test plugs for the duration of the tests.
6.4.5 Maintenance earthing a) Double busbar systems: In the double busbar system, there is an opportunity to earth the busbar via the bus coupler. b) Single busbar systems: Earthing of the busbar with the bus tie / riser, as described in section 3.9.3. Earthing with an earthing and short-circuiting set. Handling during earthing with an earthing and short-circuiting set: (Figures 6/1 and 6/9) The plugs for current tests described under 6.4.4 are used in conjunction with corresponding cable sets for short-circuiting and earthing to establish maintenance earths. The short-circuit resistance of the cable set must correspond to the conditions of the switchgear. Caution! Observe the notes in Section 3.9 on the interlock dependencies for all work with earthing and shortcircuiting sets! Isolate the switchgear area in accordance with the safety rules of VDE 0105 and secure it to prevent reconnection. Verify the off-circuit condition with a suitable (hand-held) display unit at measuring sockets 6 on the capacitive voltage indicator system. Unscrew surge arresters if fitted, or unscrew the cable blanking plugs on the free cable sockets. Check the test plugs to ensure that the surface is clean and dry, and clean them if necessary. Carefully screw the short-circuiting and earthing cable set to the test plug. Connect the common earthing connector of the cable set to the earthing terminal of the panel. Insert the test plugs into the prepared cable sockets and screw them tight.
48
6.5
Application of the X-ray regulations One of the physical properties of vacuum insulation is the possibility of x-ray emissions when the contact gap is open. The specified type test performed by the Physikalisch-Technische Bundesanstalt (PTB) in Brunswick demonstrates that the local dosage output of 1 Sv/h at a distance of 10 cm from the touchable surface is not exceeded. The results are as follows: The use of the vacuum interrupters at rated voltage is completely safe. Application of the rated power frequency withstand voltage specified for the switching device by VDE 0670 and IEC 60056 or a DC voltage of 48 kV or 70 kV during cable tests is also safe. Higher voltages than the rated power frequency withstand voltage specified in DIN VDE or IEC standards or the DC voltage must not be applied! Fulfilment of the above requirement with the vacuum interrupter in the open position is dependent on maintenance of the specified distance between the contacts (which is automatically ensured with correct mechanism function and force transmission).
49
1.1 1.1 5 28.4 28.1 (28.2) 28
5.1
5.2 28.3
Figure 6/1:
Display area on the panel 1.1 5 5.1 5.2 6 Control cabinet door Bay control and protection unit REF542 LCD display (example) Light-emitting diode (LED) Measuring sockets for capacitive voltage indicator system
Figure 6/2:
Handling of the door-lock Opening the control cabinet door: - Open the safety lock (if fitted) - Release the catch with the double bit key - Draw the closing lever out to an angle of 45 and then swing it upwards to the left through approx. 135 until the stop is reached Closing the control cabinet door: - reverse the procedure for opening 1.1 28 28.1 (28.2) 28.3 28.4 Control cabinet door Door-lock Catch Safety lock (if ordered) Double bit key Closing lever
31 30 29 32 3 3.1 3.2 3.3 3.4 20 20.1 20.2

Figure 6/3: Operating mechanisms for the three-position switch and disconnector 3 3.1 3.2 3.3 3.4 20 20.1 20.2 29 30 31 32 33 34 Three-position switch mechanism Hollow shaft (emergency manual operation shaft) Mechanical position indicator Cam for OFF position of the three-position switch Drive motor for three-position switch Disconnector mechanism Hollow shaft (emergency manual operation shaft) Mechanical position indicator Sensor, disconnector -Q1 ON Sensor, disconnector -Q1 OFF Sensor, earthing switch ON Sensor, earthing switch OFF Sensor, disconnector -Q2 ON Sensor, disconnector -Q2 OFF
34
33
50
8 8.1 8.2 8.3 8.4 8.5 8.7 8.6 8.9 8.8
Figure 6/4:
Emergency manual operation, circuit-breaker type VD4 X 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 Circuit-breaker operating mechanism Front plate ON push-button OFF push-button Operating cycle counter Mechanical position indicator Rating plate Charging condition indicator Recess for charging lever 8.9 Charging lever for emergency manual operation
Figure 6/5:
Emergency manual operation, three-position switch UX2TE
Figure 6/6:
Emergency manual operation, disconnector UX2T
Figure 6/7:
View of the stored-energy spring mechanism for the circuit-breaker, front plate removed 51
Figure 6/8:
Test plug for high voltage tests up to 24 kV rated voltage
Figure 6/9:
Test plug for current tests Also usable as a maintenance earth in conjunction with an earthing and short-circuiting set
52
Maintenance
Maintenance serves to preserve trouble-free operation and achieve the longest possible working life of the switchgear. In accordance with DIN 31 051 and IEC 61208, it comprises the following closely related activities: Inspection: Determination of the actual condition Servicing: Measures to maintain the specified condition Repairs: Measures to re-establish the specified condition
7.2
Inspection/servicing Under normal operating conditions (see section 1.3), checking of the operating mechanisms is to be carried out by a suitably qualified electrician after 10 years at the latest or after 10,000 operating cycles of the circuit-breaker and 2,000 operating cycles of the three-position switch or disconnector. In exceptional operating conditions (including adverse climatic conditions) and/or particularly adverse environments (including heavy contamination and aggressive atmosphere) inspection at shorter intervals may be required. Inspection is first and foremost to be visual examination for contamination, corrosion and moisture. The inspection should however also include checking of the mechanical and electrical functions of the following devices: Switching devices Bay control and protection unit REF542. If an incorrect condition is found, the corresponding repair work is to be initiated immediately. Cleaning If the necessity of cleaning is established during inspections, the following procedure is to be adopted: Prior to cleaning, isolate and secure the working area if necessary in accordance with the safety rules of DIN VDE and IEC. Cleaning of surfaces in general: Remove weakly adhering dry dust deposits with a soft dry cloth. Remove more strongly adhering contamination with slightly alkaline household cleanser, or with Rivolta BWR 210. Cleaning of insulating material surfaces and conductive parts (outside the gas compartments): Minor contamination with Rivolta BWR 210. Strongly adhering contamination with Cold cleanser 716 Cleaning of busbar insulating parts, cable sockets and busbar sockets with cable cleanser MAB. Observe the manufacturers instructions and the special ABB instruction manuals BA 1002/E and BA 1006/E on safety at work. Wipe down after cleaning, using clean water, and dry properly.
7.1
General It is essential to observe the following during all maintenance work: The relevant regulations in section 1.2.2 The notes on safety at work in section 6 Standards and specifications in the country where the switchgear is erected. It is recommended that ABB after sales service personnel be called in to perform servicing and repair work. Follow/observe the instructions on SF6 systems and the ABB instruction manual on the handling of insulating gases and procedures for fault conditions. The handling regulations for SF6 also apply accordingly to nitrogen. Keep these instructions and manual permanently on display and available in the switchroom. The inspection and servicing intervals for the switching devices are determined by fixed criteria such as switching frequency and number of shortcircuit breaking operations. The length of the intervals for inspection and servicing of the control cabinet and its equipment is influenced by ambient conditions (for instance pollution and aggressive atmosphere). In addition to this instruction manual, the following instruction manuals must be observed: Insulating gas system Bay control and protection unit REF542 Circuit-breaker VD4 X BA 427/E BA 453/E BA 436/E
Further details can be found in the technical documentation for the switchgear installation (including, for example, any agreed special operating conditions).
53
7.2.1 Vacuum circuit-breaker (Figure 6/7) The vacuum circuit-breaker has a long service life. It has a low maintenance operating mechanism and the breaker poles are maintenancefree. Consult the relevant sections of instruction manual BA 436/E for further information. 7.2.2 Three-position switch and disconnector The three-position switch and disconnector are maintenance-free for 2000 operating cycles. 7.2.3 Gas system and gas servicing Consult the relevant sections of instruction manual BA 427/E for further information. 7.2.4 Outlet filter The filter mats in the outlet filter are to be changed as required. Note the information on inspection and servicing in section 7.2. Replacement procedure: Draw off the grille. This is done by prising off with the fingertips in the recesses at the bottom end of the filter. Change the filter mat. Replace the grille. Spare filter mats: Filter mat for fan system: Filter mat for control cabinet: Part no. (order ref.) GCE0995403P0100 GCE0995404P0100
7.3
Repair Remove all rust from damaged paintwork areas on sheet steel and other steel parts mechanically, 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 period, apply the top coat. Only use suitable and compatible paint products. Use top coat paint in the standard colour RAL 7032, or the relevant special colour. Carefully remove any white rust from galvanised and chromium plated functional parts and rust on phosphated parts with a wire brush or a cleaning pad, e.g. Scotch-Brite, and clean with a dry cloth. Then grease evenly with Isoflex Topas NB 52. Notes: It is essential to observe the section on safety at work in instruction manual BA 427/E for all work on gas compartments. Caution when working in gas compartments! High gas concentrations may result in a danger of asphyxiation!
54
7.4
Working and auxiliary materials Part no. (Order ref.)
7.4.1 Working materials Insulating gas system: Nitrogen (N2) Degree of purity 4.6 Delivery form: liquid gas in steel cylinders Observe the relevant ABB instruction manual BA 1007/E on safety at work! Sulphur hexafluoride (SF6 ) Delivery form: liquid gas in steel cylinders Observe the quality requirements to IEC 60376/ VDE 0373! Observe the relevant ABB instruction manual BA 1004/E, pp. 1 to 3, on safety at work! Note: If extreme temperatures 50C cannot be ruled out where gas cylinders are stored, transported or temporarily stored in the open air in direct sunlight, a reduced filling factor of 0.75 kg/l cylinder contents is to be required when ordering for safety reasons!
GCE0990267P0100
GCEA901007P0102 GCE0990253P0103
GCEA901004P0102
Drying agent material: Drying agent bag to DIN 55 473, capacity per bag 210 g 7.4.2 Auxiliary materials Lubricants: Isoflex Topas NB 52, Assembly paste AP, for insulating part/cast resin plug connections Cleaning agents for general cleaning: Rivolta BWR 210, Observe the relevant ABB instruction manual BA 1002/E Cleaning agent for conductive parts, parts in insulating material, and all parts with heavy contamination: Cold cleaner 716, Observe the relevant ABB instruction manual BA 1006/E Cleaning agent for busbar insulating parts, busbar sockets and cable sockets: Cable cleaner MAB Paintwork: Paint in standard colour RAL 7035 1 kg-box Spray tin GCE9014060R0103 GCE0007895P0100 GCE0009100P0100 GCE0007706P0100 GCEA901006P0102 GCE0007707P0100 GCEA901002P0102 GCE0007249P0100 GCE0009098P0100 GCE0990443P0100
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ABB Calor Emag Mittelspannung GmbH Oberhausener Strasse 33 D-40472 Ratingen Petzower Strasse 8 D-14542 Glindow
ABB Sace T.M.S. S.p.A Via Friuli, 4 I-24044 Dalmine Phone: +39 035/395111, Fax: +39 035/395874 E-mail: sacetms.tipm@it.abb.com Internet: http://www.abb.com
Phone: +49(0)21 02/12-12 30, Fax: +49(0)21 02/12-19 16 E-mail: calor.info@de.abb.com Internet: http://www.abb.de/calor
Instruction manual no. GCEA 68 0435 P0102 Printed in Germany (12.00-500-PPI)
We reserve the right to make changes in the course of technical development.

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Gas-insulated medium voltage switchgear Instruction manual BA 435/02 E

ABB Power Distribution

Your safety first always!

Contents 1 1.1 1.2 Summary General Standards and specifications

Protection against maloperation/interlock dependencies/earthing of tee-off 19 19 19 20 20 21 22

6.1.1 Preparatory work 6.1.2 Initial start-up 6.2 Switching operations

6.3.1 Gas monitoring

6.3.2 Electrical/mechanical display/monitoring 46

ABB Power Distribution

Contents 6.4 Test procedures

7.4.1 Working materials 7.4.2 Auxiliary materials

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...100 ...40 ...40 ...100

4590 4055 6595 60

N2 7) bar bar bar W W W V IP 65 IP 4X 10)

SF6 8) 1.36 1.3 1.2 <200 250 250

SF6 8) 1.36 1.3 1.2 <200 250 250

1.36 1.3 1.2 <200 250 250

Degree of protection (IEC 60529, DIN VDE 0470-1) IP 65 IP 4X 10) IP 65 IP 4X 10)

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Disconnector/earthing switch type UX2TE, and disconnector type UX2T

N2 3) bar bar 1.3 1.2

SF6 4) 1.3 1.2

SF6 4) 1.3 1.2

SF6 4) 1.3 1.2

2500 2) ...100 ...40

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Dimensions and weights

See section 5.2 for dimensions of the switchroom (construction data).

Rated voltage IK, 3s IP Itee-off

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Design and function of the switchgear system and its equipment

Panel, front view

Vacuum circuit-breaker type VD4 X (before installation in the works)

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-Q16 -Q11 -Q0

Figure 3/7a: Examples of panels type ZX2, with single busbars

-Q25 -Q1 -Q15 -Q2 -Q0

-Q16 -Q11 -Q26 -Q21 -Q15 -Q12 -Q25 -Q22

-Q51 -Q1 -Q52 -Q2

Bus sectionaliser (without C.B.)

Trunking bar connection

Figure 3/7b: Examples of panels type ZX2, with double busbars

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ZX2 panel, single busbar, 1250 A

ZX2 panel, single busbar, 2000 A

Figure 3/10: ZX2 panel, double busbar, 2000 A

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-Q0 -T1 -R1 -C1

-Q0 -Q1 -Q2 -Q5 -T1 -R1 -C1

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The following changes apply to rated voltage 36kV:

Sensor: Pick-off: Capacitance:

KEVCI 36 AE1 20 000:1 bzw.

1600A/150mV Class 1 without correction factor 3