Catalogue UG ZS1 RevF 2012 09 En

7/29/2019 Catalogue UG ZS1 RevF 2012 09 En

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Medium voltage products

UniGear ZS1Medium voltage, arc-proo, air insulatedswitchgear up to 24 kV insulated voltage


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Index

1. UniGear ZS1

4 Description

8 IEC Classiication

10 Design eatures

12 Full tpe tested

14 Saet

18 Vacuum circuit-breaker

22 Gas circuit-breaker

24 Vacuum contactor

26 Switch-disconnector

28 Service trucks

30 UFES - Ultra ast earthing switch32 Is-limiter ault-current limitation

34 Instrument transormers

36 Measurement sensors

40 Cable terminations

42 Distribution automation

56 Automatic transer sstem

58 Tpical units

60 Technical data

2. UniGear ZS1 - Double Busbar System

64 Description

66 Characteristics68 Tpical units

70 Technical data

3. Marine Applications

74 Description

76 Characteristics

78 Tpical units

80 Technical data

UniGear ZS1 - Double Level

82 Description

84 Characteristics86 Tpical units

88 Technical data


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UniGear ZS1 is the ABB mainline global switchgear up to 24 kV, 4000 A,

50 kA and is produced close to ou in all the six continents

More than 150,000 panels produced and installed in more than 100

countries

Each UniGear ZS1 panel consists o a single unit which can be equipped

with a circuit-breaker, contactor or switch-disconnector, as well as with all

the accessories available or conventional switchgear units

1. UniGear ZS1Description


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Range

Up to 12-17.5 kV, 4000 A, 50 kA

Up to 24 kV, 3150 A, 31.5 kA

Standard IEC

Highl customized versions

Safety

Fitted with saet interlocks

Internal arc classiication IAC AFLR

Classiied LSC-2B, PM

CB racking with closed door

Flexibility

Wide applications

Vacuum and SF6 circuit-breaker

Vacuum contactor

Switch-disconnector

Traditional CT/VT and sensors

Wall and ree-standing solution

Quality

ABB qual it

Large installed base

Installed in high number o countries

Design includes

Protection and control

Earthing switch

Ultra ast earthing switch

IS Limiter

Integrated capacitor banks

Ba computer

Utilities and Power Plants

Powergenerationstations

Substations

Mainandauxiliaryswitchgear

Industry

Pulp and Paper

Cement

Textiles

Food

Automotive Quarring

Petrochemical

Oil and gas

Metallurg

Rolling mills

Mines

Marine

Drilling platorms

O-shore oil rigs

Cruise ships

Container shipsTankers

Cable ships

Ferries

Transport

Airports

Ports

Railwas

Underground transport

Infrastructure

Shopping malls Hospitals

Large inrastructure and civil works

Characteristics o

UniGear ZS1

Applications

Approved to be used or special applications such marine, seismic,

nuclear and tpe tested or IEC, GB/DL, GOST and CSA standards

Units can be coupled together directl with the other products o the

UniGear amil

The switchgear does not require rear access or installation or

maintenance, all the operations are carried out rom the ront


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1. UniGear ZS1Description

UniGear ZS1 is medium voltage switchgear with a metal

enclosure, suitable for indoor installations.

Metal partitions segregate the compartments from each

other and the live parts are air-insulated.

Since the switchgear is highly modular type, this

make simple selection of components required by any

application.

The functional units of the switchgear are guaranteed arc

proof in accordance with the IEC 62271-200 Standards,

appendix AA, class A accessibility, criteria 1 to 5.

All the installation, operation and maintenance operations

can be carried out from the front of the unit.The switchgear and the earthing switches are operated

from the front with the door closed.

The switchgear can be back to wall installed.

ApparatusThe range o apparatus avai lable or Un iGear ZS1 switchgear

is the most complete on the market, including:

withdrawable vacuum circuit-breakers with mechanical or

magnetic actuator,

withdrawable gas circuit-breakers,

withdrawable vacuum contactors with uses,

ixed version o switch-disconnectors.

This makes i t possible to oer a single switchgear-user

interace, with the same operational and maintenance

procedures.

The switchgear can be i tted with instrument transormers or

sensors or current and voltage measurement and protection

and an tpe o protection and control unit.

Switchgear, busbar conigurationIn the completion o the traditional unctional units in single

level-single busbar arrangement, the UniGear ZS1 switchgear

platorm is itted with:

Double-level,

Compact units equipped with contactors with uses,

Double Busbar Sstems.

The use o these un its allows extremel e icient use o

space. In addition UniGear ZS1 single busbar is possible to

combine to other members o UniGear amil like:

UniGear 550,

UniGear 500R, UniGear MCC.

Normal operation conditionsThe rated characteristics o the switchgear are guaranteed

under the ollowing ambient conditions:

minimumambienttemperature:5C

maximumambienttemperature:+40C

For dierent temperature ranges, please contact our ABB

sales representative.

Ambienthumidity:

- maximum 24 h average o relative humidit 95% RH

- maximum 24 h average o water vapour pressure 2.2 kPa

- maximum monthl average o relative humidit 90% RH

- maximum monthl average o water vapour pressure 1.8 kPa

The normal operational altitude is up to 1,000 m above sea

level. For higher altitude applications, please contact our

ABB sales representat ive.

Presence o normal, non-corrosive and uncontaminated

atmosphere.


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IEC electrical characteristics o UniGear ZS1 - Single Busbar Sstem

Rated voltage kV 7.2 12 17.5 24

Rated insulation voltage kV 7.2 12 17.5 24Rated power requenc withstand voltage kV 1min 20 28 38 50

Rated lightning impulse withstand voltage kV 60 75 95 125

Rated requenc Hz 50/60 50/60 50/60 50/60

Rated short time withstand current kA 3 s 50 50 50 31.5

Peak current kA 125 125 125 80

Internal arc withstand current kA 1 s 50 50 50 31.5

Main busbar rated current A ...4,000 ...4,000 ...4,000 ...3,150

Circuit-breaker rated current A

630 630 630 630

1,250 1,250 1,250 1,250

1,600 1,600 1,600 1,600

2,000 2,000 2,000 2,000

2,500 2,500 2,500 2,3003,150 3,150 3,150 2,500

Circuit-breaker rated current with orced ventilation A3,600 3,600 3,600 2,500

4,000 4,000 4,000 3,150

1) For other versions, please reer to the chapters no. 2 (Double Busbar Sstem) and chapter no. 3 (Marine Applications).

2) GB/DL version is available with higher request in dielectric characteristics (42 kV) and short time withstand current (4 s).

3) The values indicated are valid or both vacuum and SF6 circuit-breaker.

4) For panel with contactor the rated current value is 400 A.

5) CSA version is available or 27,6 kV.

StandardsThe switchgear and main apparatus contained in it compl

with the ollowing Standards:

IEC62271-1forgeneralpurposes.

IEC62271-200fortheswitchgear.

IEC62271-102fortheearthingswitch.

IEC62271-100forthecircuit-breakers.

IEC60071-2fortheinsulationcoordination.

IEC60470forthecontactors.

IEC60265-1fortheswitch-disconnectors.

IEC60529fordegreeofprotections.

Colour o the external suracesRAL7035 - ligh gre (ront doors and side sheets).

Other colours available on request.

Degrees o protectionThe degrees o protection o the switchgear conorm wi th IEC

60529 Standards.

UniGear ZS1 switchgear is normall supplied with the

ollowing standard degrees o protection:

IP4Xfortheenclosure.

IP2Xforthepartitionbetweencompartments.

On request, the external housing can be supplied with a

higher degree o protection; in this case please contact our

ABB sales representative.

The electrical characterist ics o the switchboard can var or

ambient conditions other than those described in the previous

section and also i a higher degree o protection is used.


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With the release of the IEC 62271-200 standard, new

definitions and classifications of Medium Voltage

switchgear have been introduced.

One of the most significant changes is that classification

of switchgear into metal-enclosed, compartmented and

cubicle types has been abandoned.

The revision of switchgear classification rules has been

based on the users point of view, in particular on aspects

like service and maintenance of the switchgear, according

to the requirements and expectations for proper

management, from installation to dismantling.

In this context, Loss of Service Continuity (LSC) has beenselected as a fundamental parameter for the user.

According to the IEC 62271-200, UniGear ZS1 switchgear

can be defined as follows.

Loss o service continuit - LSC-2BThe various LSC categor ies describe the possibili t o

keeping other compartments and/or panels energized while

a compartment in the main circuit is opened. The deined

categories are:

LSC-1: The whole switchgear shall be put out o service or

opening a main circuit compartment or normal operation

and/ornormal maintenance or or gaining access to an

switchgear components.

LSC-2A: The same as LSC-1 with the exception that the

main busbars and the unctional units adjacent to the one

under maintenance can remain energized.

LSC-2B:The same as LSC-2A with the exception that the

cable compartment can remain energized.

UniGear ZS1 is classiied as LSC-2B because the busbar,

circuit-breaker and cable compartments are phsicall and

electricall segregated.This is the categor that deines the

possibilit o accessing the circuit-breaker compartment

with the busbars and cables energized. In case o using the

ixed version o the switch-disconnector, the panel is deined

LSC-2A because the cable and apparatus compartments are

not phisicall segregated.

Partition Metallic - PMWith regard to the tpe o partitions or shutters between

live parts and an open compartment, a distinction is made

between two partition classes:

Class PM (Partition made o Metal);

Class PI (Partition made o Insulating material).

UniGear ZS1 is deined with PM partition class having the

segregation between compartments made o metallic sheets/

shutters.

Interlock-controlled accessiblecompartmentThe ront s ide o UniGear ZS1 is classiied inter lock-controlled

because the access o the compartments containing high-

voltage parts, intended to be opened or normal operation

and/or normal maintenance, is controlled b the integral

design o the switchgear.

Tool-based accessible compartmentThe rear part o the UniGear ZS1 is classi ied tool-based

because it is possible to open the compartment containing

high-voltage parts, that ma be opened, but not or normaloperation and maintenance, onl using a tool. Special

procedures are required.

InternalarcclassificationIACAFLRUniGear ZS1 switchgear is classiied IAC AFLR.

When the switchgear is speciied and installed, some

undamental points must be taken into consideration:

Levelofthefaultcurrent(16...50kA).

Durationofthefault(0.1...1s).

Escaperoutesforthehotandtoxicgasesproducedby

combustion o materials.

Dimensionsoftheroom,withspecialattentiontotheheight.

Please consult our ABB representatives or detailed

inormation.

1. UniGear ZS1IEC Classiication


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CompartmentsEach switchgear unit consists o three power compartments:

circuit-breaker [A], busbars [B] and cables [C]; please reer to

igure 1.

Each unit is itted with a low voltage compartment [D], where

all the auxiliar instruments are housed.

Arc-proo switchgear is normall provided with a duct [E] or

evacuation o the gases produced b an arc; dierent tpes o

gas ducts are available.

All the compartments are accessible rom the ront and

maintenance operations can correctl carried out with the

switchgear installed up against a wall.

The compartments are segregated rom each other b

metallic partitions.

Main busbarsThe busbar compartment contains the main busbar sstem

connected to the upper isolating contacts o the circuit-

breaker b means o branch connections.

The main busbars are made o electroltic copper.

For ratings up to 2500 A, the busbars are lat bars; while or

currents between 3150 A and 4000 A, a special D-shape

busbar is used.The busbars are covered with insu lating material .

There is a sing le busbar compartment along the whole length

o the switchgear up to 31,5 kA, which optionall can be

divided into compartments. For 40/50 kA these bushings are

a standard eature.

Cable connectionsThe cable compartment contains the branch sstem or

connection o the power cables to the lower contacts o the

circuit-breaker.

The eeder connections are made o e lectrolt ic copper and

the are lat busbars or the whole range o currents.

For 17.5 and 24 kV the are covered with insulating material.

Earthing switchCable compartment can be itted with an earthing switch or

cable earthing.

The same device can a lso be used to earth the busbar sstem

(measurements and bus-tie units).

It can also be installed directl on the main busbar sstem in a

dedicated compartment (busbar applications).

The earthing switch has short-circuit making capacit.

Control o the earthing switch is rom the ront o the

switchgear with manual operation, and optionall, can also be

motor operated.

The position o the earth ing switch can be seen rom the

ront o the switchgear b means o a mechanical coupled

indicator.

Earthing busbarThe earthing busbar is made o electroltic copper and it runs

longitudinall throughout the switchgear, thereb guaranteeing

maximum personnel and installation saet.

Insulating bushings and shuttersThe insu lating bush ings in the c ircui t-breaker compartment

contain the contacts or connection o the circuit-breaker with

the busbar compartment and cable compartment respectivel.

The insu lating bush ings are o s ingle-pole tpe and are made

o epox resin. The shutters are metallic and are activated

automaticall during movement o the circuit-breaker rom the

racked-out position to the operation position and vice versa.

CablesSingle and three-core cables up to a maximum o twelve per

phase can be used depending on the rated voltage, the unit

dimensions and the cable cross section (please reer to page

40).The switchgear can be back to wall installed as the cables are

easil accessible rom the ront.

1. UniGear ZS1Design eatures


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Gas exhaust ductThe gas exhaust duct is positioned above the switchgear and

runs along its whole length.

Each power compartment is itted with a lap on its top

surace. The pressure generated b the ault makes it open,

allowing the gas to pass into the duct.

Evacuation rom the room o the hot gases and incandescent

particles produced b the internal arc must normall be

carried out. The UniGear ZS1 switchgear can be itted with a

complete range o solutions to satis all requirements, either

in the case where evacuation is possible directl at the end

o the switchgear, or when solutions rom the ront or rear are

requested.

Some installations, such as marine applications, do not

allow evacuation o the gases to the outside o the room and

thereore a dedicated solution has been developed to

guarantee personnel saet and conormit with the

Standards, such as longitudinal evacuation chimnes.

Please contact our ABB sales representative or more

inormation.

Busbar applications

Each switchgear unit can optionall be itted with anaccessor busbar application:

currentorvoltagetransformersforbusbarmeasurements.

busbarsystemearthingswitch.

topentryductorcablestomakeinterconnectionsbetween

dierent sections o switchgear.

Unit compartmentsA Circuit-breaker compartment

B Busbar compartment

C Cable compartment

D Low voltage compartment

E Compact gas duct channel

Figure 1: UniGear ZS1 single level section view


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The UniGear ZS1 switchgear has undergone all the tests

required by the international (IEC) Standards and local

Standards organizations (for example, the Chinese GB/DL

and Russian GOST standards).

In addition, the tests required by the main shipping

registers (LR, DNV, RINA, BV and GL) have been carried

out for use of the switchgear in marine installations.

As indicated in these standards, the tests were carried

out on the switchgear units considered most sensitive

to the effects of the tests and therefore the results were

extended across the whole range.

Each switchgear unit is subjected to routine tests in thefactory before delivery.

These tests are intended to provide a functional check of

the switchgear based on the specific characteristics of

each installation.

IEC tpe tests Short-time and peak withstand current

Temperature r ise

Internal arc capabilit

Dielectric test

Making and breaking capacit o circuit-breaker and

contactors

Earthing switch making capacit

Mechanical operations o circuit-breaker and earthing

switch

IP protectiondegree

IEC routine actor testsVisual inspect ion and check

Mechanical sequence operations

Cabling check

Electrical sequence operations Power requenc withstand voltage

Measurement o the resistance o the main circuits

Secondar insulation test

Special tpe tests required b shipping

registers or marine application Highambienttemperatures(+45C)

Inclination

Vibration

Figure 2: UniGear ZS1 during internal arc test

Description o IEC tpe tests

Short-time and peak withstand current

The test shows that the main power and the earthing circu its

resist the stresses caused b the passage o the short-circuit

current without an damage.

It should also be noted that both the earthing sstem o the

withdrawable circuit-breaker and the earthing busbar o the

switchgear are subjected to the test.

The mechanical and electrical properties o the main busbar

sstem and o the top and bottom branch connections remain

unchanged even in the case o a short-circuit.

Temperature rise

The temperature rise test is carried out at the rated current

value o the switchgear unit and shows that the temperature

does not become excessive in an part o the switchgear unit.

During the test, both the switchgear and the circuit-breaker or

contactor it ma be itted with are checked.

Internal arc capability

Please reer to page 14.

Dielectric test

These tests veri that the switchgear has suicient capabilit

to withstand the lightning impulse and the power requenc

voltage.

The power requenc withstand voltage test is carr ied out as a

tpe test, but it is also a routine test on ever switchgear unit

manuactured.

1. UniGear ZS1Full tpe-tested


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Figure 3: inclination test Figure 4: vibration/seismic test

Tpe tests required b the shipping

registers

High ambient temperature

The serv ice cond itions or the electrical apparatus in marine

installations are generall more severe than those in normal

land applications.

Temperature is a main actor and or this reason the shipping

register regulations require the switchgear to be able to

operateathigherambienttemperatures(45Corhigher)than

thosestatedintheIECStandards(40C).

Inclination

The test is carried out b inclining the switchgear or a deined

timeupto25alternatelyonallfoursidesandoperatingthe

apparatus.

The test proves that the switchgear is able to res ist these

extreme service conditions and that all the apparatus it

contains can be operated without an problems and without

being damaged.

Vibration

The reliabili t and sturdiness o the UniGear ZS1 switchgearhas been deinitivel proved b the result o the withstand test

to mechanical stresses due to vibration. The service

conditions on shipping installations and marine platorms

require the switchgear to work in environments strongl

aected b vibrations, such as those caused b the motors

on large cruise ships or the drilling plants o oil rigs.

1mmamplitudeinthefrequencyrangebetween2and

13.2 Hz.

0.7gaccelerationamplitudeinthefrequencyrange

between 13.2 and 100 Hz (see picture on the previous

page).

Circuit-breaker making and breaking capacity

The circu it-breaker or contactor is subjected to the rated

current and short-circuit current breaking tests.

Furthermore, it is also subjected to the opening and closing o

capacitive and inductive loads, capacitor banks and/or cable

lines.

Earthing switch making capacity

The earthing switch o the UniGear ZS1 switchgear can be

closed under short-circuit. Although, the earthing switch is

normall interlocked to avoid being operated on circuits which

are still live.However, should this happen or an one o several reasons,

personnel saet would be ull saeguarded.

Mechanical operations

The mechanical endurance tests on all the operating parts

ensures the reliabilit o the apparatus. General experience in

the electro-technical sector shows that mechanical aults are

one o the most common causes o a ault in an installation.

The circu it-breaker is tested b carring out a high number o

operations - higher than those which are normall carried out

b installations in the iled.

Furthermore, the switchgear components are part o a qualitcontrol program and samples are regularl taken rom the

production lines and subjected to mechanical lie tests to veri

that the qualit is identical to that o the components subjected

to the tpe tests.

IP protectiondegree

The IP protection degree is the resistance oered b the

UniGear ZS1 against penetration o solid objects and liquids.

This degree o res istance is indicated b the preix IP ollowed

bytwocharachters(i.e.IP4X).

The irs t number identiies the degree o protection against the

entrance o solid objects, the second one is related to liquids.


14/9214

When developing modern medium voltage switchgear,

personnel safety must necessarily take priority. This is

why the UniGear ZS1 switchgear has been designed and

tested to withstand an internal arc due to a short-circuit

current of the same current level as the maximum short-

time withstand level.

The tests show that the metal housing of UniGear

ZS1 switchgear is able to protect personnel near the

switchgear in the case of a fault which evolves as far as

striking an internal arc.

An internal arc is a highl unlikel ault, although it cantheoreticall be caused b various actors, such as:

Insulation deects due to qualit deterioration o the

components. The reasons can be adverse environmental

conditions and a highl polluted atmosphere.

Overvoltages o atmospheric origin or generated b the

operation o a component.

Inadequate training o the personnel in charge o the

installation.

Breakage or tampering o the saet interlocks.

Overheating o the contact area, due to the presence

o corrosive agents or when the connections are not

suicientl tightened. Entr o small animals into the switchgear (i.e. through

cable entrance).

Material let behind inside the switchgear during

maintenance activities.

The characterist ics o the UniGear ZS1 switchgear notabl

reduce the incidence o these causes or aults, but some o

them ma not be eliminated completel.

The energ produced b the internal arc causes the ollowing

phenomena:

Increase in the internal pressure.

Increase in temperature.Visual and acoustic eects.

Mechanical stresses on the switchgear structure.

Melting, decomposition and evaporation o materials.

Unless suitabl protected, these phenomena have ver

serious consequences or the personnel, such as wounds

(due to the shock wave, ling parts and the doors opening)

and burns (due to emission o hot gases).

The interna l arc test veri ies that the compartment doors

remain closed and that no components are ejected rom the

switchgear even when subjected to ver high pressures, and

that no lames or incandescent gases penetrate, therebensuring saet o the personnel near the switchgear.

The test also ensure that no holes are produced in external

accessible parts o the housing, and inall, that all the

connections to the earthing circuit remain intact, hence

guaranteeing the saet o personnel who ma access the

switchgear ater the ault.

The IEC 62271-200 Standard describes the methods to

be used or carring out the test and the criteria which the

switchgear must conorm to.

The UniGear ZS1 switchgear ull conorms to al l the ive

criteria indicated b the IEC standards.

The IAC classiication is proved b the test according to theollowing designations:

General: classiication IAC (Internal Arc Classiied)

Accessib ilit : A, B or C (switchgear accessible to authorized

personnel onl (A), to all (B), not accessible due to

installation (C)

F,L,R:accessfromthefront(FFront),fromthesides(L

Lateral)andfromtherear(Rrear).

Test values: test current in k iloamperes (kA), and duration in

seconds (s).

The parameters o each speci ic plant mean that evacuation

o the hot gases and incandescent particles must be checkedver careull in order to ensure and maintain personnel saet.

Fault limiting sstemsThe structure o the UniGear ZS1 switchgear oers complete

passive tpe protection against the eects o a ault due to an

internal arc or a time o 1 second up to 50 kA.

ABB has also deve loped excel lent active protection sstems

which allow ver important objectives to be achieved:

Detection and extinction o the ault, normall in less than

100 ms, which improves network stabilit.

Limitation o damage on the apparatus.

Limitation o outage time or the switchgear unit.

For active protection against an internal arc, devices

consisting o various tpes o sensors can be installed in the

various compartments, which detect the immediate outburst

o the ault and carr out selective tripping o the circuit-

breakers.

The aul t l imit ing sstems are based on sensors which use the

pressure or light generated b the arc ault as trigger or ault

disconnection.

1. UniGear ZS1Saet


15/9215

Melting

of Steel

Melting of

Copper

Melting

of Cables

0 100 200 500 ms

kA2 s

ITHThe ITH sensors consist o micro-switches positioned on the

top o the switchgear near the gas exhaust laps o the three

power compartments (busbars, circuit-breaker and cables).

The shock wave makes the laps open and operate the

micro-switches connected to the shunt opening release o the

circuit-breaker.

Totaltripp ing timeis 75 ms(15 ms ITH+60mscircu it-

breaker).

FRD (Fast Recover Device)This sstem cons ists o pressure sensors located in the lowvoltage compartment and connected to the three power

compartments b means o small tubes.

The sensors detect the rising ront o the pressure wave which

develops on the outburst o the arc and react b making the

circuit-breakers open.

The sensors are protected against the external environment

and the can be checked even with the switchgear in

operation.

Totaltripp ing timeis 75 ms(15 ms FRD +60msci rcuit -

breaker).

TVOCThis sstem consists o an e lectronic monitoring device located

in the low voltage compartment which is connected to optic

sensors. These are distributed in the power compartments and

are connected to the device b means o optic bres.

When a certain pre-set light level is exceeded, the device

opens the circuit-breakers.

To prevent the sstem rom intervening due to light occasionall

generated b external phenomena (fash o a camera,

refections o external lights, etc.), current transormers can also

be connected to the monitoring device.

The protection module onl sends the opening command to the

circuit-breaker i it receives the light and short-circuit current

signal simultaneousl.

Totaltripp ing timeis 62 ms(2 msT VOC +60msci rcuit -

breaker).

Figure 5: Arc duration and damage caused

REAThis sstem oers the same unctionalit as TVOC. The REA

sstem consists o the main unit (REA 101) and optional

extension units (REA 103, 105, 107) which make it possible to

create customized solutions with selective tripping. For more

inormation, please see the dedicated chapter at page 50.

Totaltripping timei s62,5ms (2, 5msRE A+60mscirc uit-

breaker).

Arc protection in IED

The REF615, RET615, REM615 and REF610 IEDs (IntelligentElectronic Device) can optionall be itted with a ast and

selective arc lash protection. It oers a two-to three-channel

arc-ault protection sstem or arc lash supervision o the

circuit breaker, cable and busbar compartment o switchgear

panels.

Totaltripping timei s72ms(12msI ED+ 60ms circu it-

breaker).

UFES (ultra ast earthing switch)The UFES is an innovative design o an extremel ast-acting

earthing switch, grounding all 3 phases within < 4 ms ater

detection o an internal arc ault.

For more inormation please see the dedicated chapter at

page 30.


16/9216

Figure 6: Double key lock on earthing switch

The UniGear ZS1 switchgear is fitted with all the

interlocks and accessories needed to guarantee the

highest level of safety and reliability for both installation

and personnel.

InterlocksThe saet mechanical inter locks are standard ones [15],

please see the dedicated table at page 17.

The are set out b the IEC standards and are thereore

necessar to guarantee the correct operation sequence.

ABB saet interlocks guarantees the highest level o rel iabi lit,

even in the case o an accidental error, and enables highest

operator saet sstem o interlocks.

KesThe use o ke interlocks is ver important in realis ing the

interlocking logics between panels o the same switchgear, or

o other medium, low and high voltage switchgear. The logics

are realised b means o distributors or b ringing the kes.

The apparatus truck [6] can be locked in the racked-

outposition and the relevant lock ke can onl be removed

with the apparatus in this position.The earthing switch closing [7] and opening [8] operations can

be locked b means o kes, ke logic is explained in the table

at page 15.

These locks can also be appl ied to the earthing switch o

busbar applications.

The circu it-breaker racking-in/out operations [9] and earthing

switch opening/closing [10] can be prevented b means o

ke locks, which prevent insertion o the relevant operating

levers.

The ke lock can also be appl ied to the earthing switch o

busbar applications. The kes can alwas be removed.

PadlocksThe circu it-breaker [11] and cables [12] compartment doors

can be locked in the closed position b means o padlocks.

Thes eca nbeap pliedt ob oth doo rclosi ngv ersi onswith

central handle (standard) or screws (optional).

The operations or apparatus racking-in/out [13] and earthing

switch opening/closing [14] can be prevented b appling the

padlocks to the insertion slots o the relevant operating levers.

The padlock can also be appl ied to the earthing switch o

busbar applications.The metallic segregation shutters [15] between circui t-breaker,

busbars and cables compartments can be locked b means

o two independent padlocks in both the open and closed

positions.

Padlocks rom 4 to 8 mm diameter can be accommodated.

Locking magnetsThe locking magnets enable automatic interlocking logics

without human intervention.

The circu it-breaker racking-in/out [16] and the earthing switch

closing/opening [17] operations can be interlocked.

This magnet can also be applied to the earthing switch o

busbar applications.

The magnets operate with active logics and there ore the lack

o auxiliar voltage leaves the interlocking sstem active in

saet condition.

1. UniGear ZS1Saet


17/9217

Standard safety interlocks (mandatory)

Type Description Condition to be met

1A Apparatus rack ing-in/out Apparatus in open position

B Apparatus closing Deined truck position

2A Apparatus rack ing-in Apparatus multi -contact plug plugged

B Apparatus multi-contact plug unplugging Truck in test position

3A Earthing switch closing Truck in test posit ion

B Apparatus racking-in Earthing switch in open position

4A Apparatus compartment door opening Truck in test posit ion

B Apparatus racking-in Apparatus compartment door closed

5A Feeder compartment door opening Earthing switch in ON position

B Earthing switch opening Cable compartment door closed

Note: Apparatus are circuit-breakers and contactors.

Keys (on request)

6 Apparatus racking-in lock Can onl be removed with the t ruck in the racked-out pos it ion

7 Earthing switch closing lock Can onl be removed with the earthing switch open

8 Earthing switch opening lock Can onl be removed with the earthing closed

9 Insert ion o the apparatus raking- in/out c rank lever Can alwas be removed

10 Insertion o the earthing switch operating lever Can alwas be removed

Padlocks

11 Apparatus compartment door opening

12 Cable compartment door opening

13 Insertion o the apparatus raking-in/out crank lever

14 Insertion o the earthing switch operating lever

15 Shutters opening or closing

Locking magnets (on request)

16 Apparatus racking-in/out Magnet energized

17 Earthing switch ON/OFF Magnet energized

Accessory devices

20 Shutters ail-sae

The device locks the shutters i n the closed pos ition when theapparatus is removed rom the compartment. The operator cannotopen the shutters manuall. The shutters can onl be operated bthe apparatus truck or the service trucks (please see the dedicatedchapter at page 28).

21 Apparatus-switchgear unit compatibilit matrixThe apparatus multi -contact plug and relati ve swi tchgear unit socketare equipped with a mechanical matrix, that disables apparatusracking-in into a switchgear unit with an inappropriate rated current.

22 Circuit-breaker mechanical operating mechanism

The apparatus compartment is equipped with a mechanical device,that enables circuit-breaker closing and/or opening directl b meanso the ront operating mechanism pushbuttons, keeping the door

closed. The controls can be operated with the circuit-breakers in theoperation and racked-out position.

Tpes o interlocks


18/9218

1. UniGear ZS1

Vacuum circuit-breaker

UniGear ZS1 switchgear can be fitted with the widest

range of apparatus available on the market today, and of

these the vacuum circuit-breaker now occupies a position

of prime importance in all sectors of primary distribution.

Vacuum circuit-breakers cover the whole range of

switchgear parameters and therefore the whole range of

applications.

Many years of experience gained in developing and using

vacuum interrupters is today reflected in the range of

ABB circuit-breakers, which stand out for their

exceptional electrical and mechanical characteristics,

extremely long life, low maintenance, compactness and

the use of highly innovative construction techniques.

ABB develops and produces a complete range of

interrupters for use in circuit-breakers and contactors and

for all medium voltage applications.

Figure 7: UniGear ZS1


19/9219

VD4 circuit-breakerThe VD4 medium voltage circu it-breaker inter rupters use

vacuum to extinguish the electric arc and as the insulating

medium.

Thanks to the unequalled proper ties o vacuum and the

breaking technique used, current interruption takes place

without arc chopping and without overvoltages. Restoration

o the dielectric properties ollowing interruption is extremel

rapid.

The VD4 circu it-breakers are used or protection o cables,

overhead lines, motors, transormers, generators and

capacitor banks.

PolesThe VD4 medium voltage circu it-breakers use vacuum

interrupters embedded in poles (1).

Embedding the interrupter in the pole makes the circuit-

breaker particularl sturd and protects the interrupter itsel

against shocks, deposits o dust and humidit.

The vacuum inter rupter houses the contacts and provides the

interruption chamber.

ABB circu it-breakers use the most advanced vacuum-

breaking techniques: with radial magnetic low or circuit-

breakers with medium-low ratings and with axialmagnetic low

or those with high breaking capacit.

Both techniques guarantee even distribution o the arc roots

over the whole surace o the contacts, allowing optimum

perormance at all current values.

The structure o a vacuum inter rupter is re lativel simp le. The

housing is made up o a ceramic insulator closed at the ends

b stainless steel covers. The contacts are made o purecopper and sintered chrome and are welded to the copper

terminals. A metallic bellows allows movement o the moving

contact-terminal group, at the same time guaranteeing that

the vacuum is maintained in the interrupter. The interrupter

components are welded in an environment under a ver

strong vacuum to guarantee a vacuum o less than 10 -5 Pa in

the interrupter.

This means that the interrupter does not an ionisable

material. In an case, on detachment o the contacts, an

electric arc is generated which onl consists o the melted

and vaporised material o the contact.

A metal lic shie ld is integrated inside the inter rupter to capturethe metallic vapours given o during interruption, as well as

or controlling the electric ield. The particular shape o the

contacts generates a magnetic ield which orces the arc to

rotate and to involve a much wider surace than that o a ixed

contact arc.

Apart rom limiting the thermal stress on the contacts, this

makes contact erosion negligible and, above all, allows

theinterruption process to be controlled even with ver high

short-circuit currents.

The electric arc remains supported b the external energ unt il

the current passes through its natural zero.

The ABB vacuum interrupters are zero current interrupters andare ree o an re-striking phenomena.

The rapid reduction o the current densit and ast

condensation o the metallic vapours, that happens at the at

the instant that the current passes through zero, allow the

maximum dielectric strength between the interrupter contacts

to be re-established within a ew milliseconds. Supervision o

the vacuum level is not necessar as the circuit-breaker poles

are sealed-or-lie and do not require an maintenance.

(1) Circui t-breakers up to 17.5 kV - 1250 A - 31.5 kA are made opolamide poles.

Figure 8: VD4 circuit-breaker with mechanical actuator


20/9220

Operating mechanismThe VD4 circuit-breaker is tted with a mechanical stored

energ tpe operating mechanism.

The trip ree mechanism allows opening and closing operations

independent o the operator.

The operating mechanism spring sstem can be recharged

either manuall or b means o a geared motor. The apparatus

can be opened and closed b means o the pushbuttons on

the ront o the operating mechanism or b means o electric

releases (shunt closing, shunt opening and undervoltage).

The circuit-breakers are alwas tted with an anti-pumping

device to eliminate the possibilit o simultaneous opening and

closing commands, closing commands with springs discharged

or with the main contacts not et in their run-end position.

TruckThe poles and operating mechanism are xed onto a metal

support and handling truck.

The truck is provided with a wheel sstem which makes

the operations or racking the apparatus into and out o the

switchgear unit possible with the door closed. The truck allows

ecient earthing o the circuit-breaker b means o the metallic

structure o the switchgear unit.The vacuum circuit-breaker truck can be motor-operated.

The racking-out and racking-in operations can be carried out

b means o electrical controls, either locall b the operator or

b a remote sstem.

Apparatus-operator interaceThe ront part o the circuit-breaker provides the user interace.

It eatures the ollowing equipment:

ONpushbutton.

OFFpushbutton.

Operationcounter.

Indicatorofthecircuit-breakeropenandclosedstate.

Indicatorofthechargedordischargedstateoftheoperating

mechanism springs.

Manualchargingdevicefortheoperatingmechanism

springs.

Overrideselectoroftheundervoltagerelease(optional).

eVD4 circuit-breakerThe eVD4 circuit-breaker is a complete plug and pla medium

voltage electrical eeder protection sstem. It is an evolution

o the traditional concept o a circuit-breaker that with a single

device, can carr out the breaking, measurement, protection,

control and communication unctions.

The eVD4 circuit-breaker is derived rom the VD4 series with its

renowned reliabilit and robust characteristics.

eVD4 integrates the ABB RelionfamilyRBX615series

protection device with combined current and voltage

sensors.

Withthisintegratedsolution,theMTTRMeanTimeto

RepairofthesystemmanagedbyeVD4ismuchlowerthan

traditional solutions. This makes the eVD4 the ideal solution

or all installations where a high degree o continuit o service

is required.

The eVD4 is available in ixed and withdrawable versions or

UniGear ZS1 switchgear and it is mechanicall

interchangeable with the VD4 circuit-breaker.

1. UniGear ZS1Vacuum circuit-breaker

Figure 9: eVD4 circuit-breaker with on bord sensors, protection and control unit RBX 615.


21/9221

VM1 circuit-breakerThe conventional mechanical stored energ tpe o operating

mechanism used on the VD4 circuit-breakers can be replaced

with an operating mechanism with magnetic actuator, creating

the VM1 series o circuit-breakers.

All the characteristics o the circuit-breakers described in

this chapter remain unchanged except or the operating

mechanism.

The operating mechanism is based on a greatl reduced

number o components:

Actuatorwithpermanentmagnets.Theheartoftheo perating

mechanism consists o the magnetic actuator which carries

out the closing and opening operations, and keeps the main

contacts in their positions taken up ater the operation.

The magnet transmits the operating mechanism to the

interrupters b means o a single transmission lever.

Electroniccontroldevice.Allthefunctions(trip,operation,

energ charging and watchdog) are carried out b the

integrated electronic controller. The circuit-breaker is tted

with a multivoltage direct and alternating current eeder.

Capacitors. The energ required to switch the operating

mechanism is provided b an incorporated capacitor

bank. The stored energ guarantees the complete O-C-O

reclosing sequence.

Positionsensors.Thepositionoft hecircuit-breakercontacts

is detected b means o electronic proximit sensors.

StandardsIEC 62271-100 or the circuit-breaker.

Figure 10: VM1 circuit-breaker with magnetic actuator


22/9222

Fig. 11: HD4 circuit-breaker

UniGear ZS1 switchgear can also be fitted with SF6 gas

circuit-breakers.

The ABB vacuum and gas series of circuit-breakers are

mechanically interchangeable and the same switchgear

unit can therefore take either type of apparatus. Only ABB

can offer apparatus representing both techniques for the

whole range of applications, voltage levels (12-17.5-24

kV), rated current (630...4000 A) and breaking capacity

(16...50 kA).

This makes it possible to specify the optimum solution

for the installation characteristics and the feeders to be

switched and protected.ABBs long practical experience shows that the two types

of circuit-breakers are equally valid and complementary.

HD4 circuit-breakerThe HD4 medium voltage circuit-breakers use

sulphurhexaluoride gas (SF6) to extinguish the electric arc

and as the insulating medium.

Thanks to the excellent properties o SF6 gas, interruption

o the currents takes place without arc chopping and

overvoltages. There is no restriking phenomenon ater

interruption and the dielectric properties ollowing interruption

are recovered extremel rapidl.

Gas circuit-breakers are available or all electric power

distribution applications. The are particularl recommended

or use on capacitor banks, motors, transormers insulated

in oil and in installations where components which are

particularl sensitive to dielectric and dnamic stresses are

installed (or example, old cables or transormers).

PolesThe HD4 circuit-breaker poles use the autopuer breaking

sstem, combining the compression and sel-blast techniquesin a single solution.

The autopuer sstem is the most innovative technique in the

ield o gas circuit-breakers and originates rom high voltage

apparatus.

The combinat ion o the compression and sel-blast techniques

allows the best perormance to be obtained at all current

values. Both techniques are alwas present, but whereas the

ormer operates optimall in switching low currents, the latter

acts eectivel during operation at higher current values.

The autopuer technique allows the use o a smaller quantit

o gas than that required b circuit-breakers based on other

techniques. For the same reason, the gas pressure is also

considerabl reduced. The autopuer technique guarantees

the insulating withstand voltage and the breaking capacit up

to 30% o the rated value, even with zero relative pressure.

The whole range o HD4 circuit-breakers uses the same gaspressure or all rated voltage levels (12-17.5-24 kV). SF6 gas

pressure level monitoring is not necessar, since the circuit-

breaker poles are sealed-or-lie pressure sstems and are

maintenance-ree.

The are itted with a pressure contro l device or checking

that the characteristics are not altered due to transport or

incorrect operations.

1. UniGear ZS1Gas circuit-breaker


23/9223

Figure 12: HD4-HXA circuit-breaker

Operating mechanismThe HD4 circuit-breaker is i tted with a mechanical

storedenerg operating mechanism. This is trip ree and

thereore allows opening and closing operations independent

o the operator.

The operating mechanism spr ing sstem can be recharged

either manuall or b means o a geared motor. The operating

mechanism is o the same tpe or the whole series and has a

standardised range o accessories and spare parts.

All the accessor components can easil be replaced b

means o plug-socket connectors.

Opening and the closing o the apparatus can be carried

out b pushbuttons on the ront o the operating mechanism

or b electric releases (shunt closing, shunt opening and

undervoltage).

The circu it-breakers are a lwas itted with an anti -pumping

device to eliminate the possibilit o simultaneous opening

and closing commands, closing commands with springs

discharged or with the main contacts not et in their run-end

position.

TruckThe poles and operating mechanism are ixed onto a metal

support and handling truck.

The truck is provided with a wheel sstem which makes

the operations or racking the apparatus out o and into the

switchgear unit possible with the door closed.

The truck a llows eective earthing o the c ircui t-breaker b

means o the metallic structure o the switchgear unit.

Apparatus-operator interace

The ront panel o the c ircui t-breaker provides theuserinterace. It eatures the ollowing equipment:

ONpushbutton.

OFFpushbutton.

operationcounter

indicatorofthecircuit-breakeropenandclosedstate

indicatorofthechargedanddischargedstateofthe

operating mechanism springs

manualchargingdevicefortheoperatingmechanism

springs

overrideselectoroftheundervoltagerelease(optional)

LEDgaspressureindicator(optional)

HD4-HXAcircuit-breakerforhigh

unidirectional componentsThe range o HD4 circuit-breakers is extended b the HD4-

HXAversion.

This series o circuit-breakers maintains a ll the eatures

described in this chapter, but is notable or its abilit to switch

loads with strong unidirectional components.

Forbreakingcapacitiesof40kAorlower,HD4-HXA

circuit-breakers are able to switch loads with unidirectional

components IDC = 100%, up to service voltage 13.8 kV;

at 50 kA the unidirectional component percentage IDC isreduced to 50%.The can be used in all installations aected

b strong unidirectional components, but their natural ield o

application is ound in switching and protecting transormers

o the auxiliar circuits in power generating stations.

StandardsIEC 62271-100 or the circuit-breaker.

IEC 60376 or the SF6 gas.


24/9224

V-Contact VSC medium voltage contactors are apparatus

suitable for operating in alternating current and are

usually used to control feeders which require a high

number of operations per hour.

They are suitable for operating and protecting motors,

transformers and power factor correction banks.

Fitted with appropriate fuses, they can be used in circuits

with fault levels up to 1000 MVA.

The electrical life of V-Contact VSC contactors is defined

as being in category AC3 with 100,000 operations

(closing/opening), 400 A interrupted current.

V-Contact VSC contactorThe contactors cons ist o a monobloc o resin containing the

ollowing components:

vacuuminterrupters

movingequipment

magneticactuator

multivoltagefeeder

accessoriesandauxiliarycontacts.

The V-Contact contactors are provided in the ollowing

versions:

VSC7/Pforvoltagesupto7.2kV.

VSC7/PGforvoltagesupto7kVwith32kVpower

requenc withstand voltage.

VSC12/Pforvoltagesupto12kV.

VSC12/PGforvoltagesupto12kVwith42kVpower

requenc withstand voltage.

Both versions are available with an operating mechanism with

electrical or mechanical latching.

The V-Contact VSC contactors are mechanical l

interchangeable with the ormer V-Contact V/P contactor and

with the whole series o ABB circuit-breakers, the same

switchgear unit can thereore take both tpes o apparatus

without modiication.

A version o V-Contact VSC contactors is a lso used in the

UniGear MCC compact switchgear up to 400 A.

Operating mechanismDue to the magnetic actuator, V-Contact VSC contactors

need negligible auxiliar power in all conigurations (15W

inrush - 5W continuous).

The V-Contact VSC is available in three dierent

conigurations.

SCO (single command operation).

The contactor closes the suppl o auxiliar voltage to

the multivoltage eeder input, when the auxiliar is cut the

contactor opens.

DCO (double command operation).

The contactor closes the suppl o auxiliar voltage to the

multivoltage eeder closing input and opens when opening

input is supplied; anti pumping unction is supplied as a

standard.

DCO coniguration is also available, on request, with a

delaed undervoltage unction. This unction enables

automatic opening o the contactor when the auxiliar

voltage level drops below IEC deined levels.

Opening can be delaed rom 0 to 5 seconds (customer

setting b dip switches).

All conigurations are suitable or 1,000,000 mechanical

operations.

FusesThe contactor is itted with medium voltage uses or

protection o the operated eeders.

Coordination between the contactor, uses and protection unit

is guaranteed in accordance with the IEC 60470 Standards

or apparatus in class C.

The use-holder rame is usua ll preset or installation o a set

o three uses per phase with average dimensions and tpe o

striker, according to the ollowing Standards:

DIN43625.

BS2692.

Figure 13: V-Contact VSC contactor

1. UniGear ZS1Vacuum contactor


25/9225

Maximum load currents of the fuses

Feeder Transformers Motors Capacitors

Rated voltage Fuse Maximum load Fuse Maximum load Fuse Maximum load

3.6 kV 200A 160A 315A 250A 450A 360A

7.2 kV 200A 160A 315A 250A 355A 285A

12 kV 200A 160A 200A 160A 200A 160A

Figure 14: Fuse according to DIN Standards

Electrical characteristics

VSC7/P VSC12/P

Rated voltage kV 7.2 12

Rated insulation voltage kV 7.2 12

Rated power requenc withstand voltagekV 1min

20 (3) 28 (3)

Rated lightning impulse withstand voltage kV 60 75

Rated requenc Hz 50/60 50/60

Rated short-time withstand current kA (1) 50 50

Peak current kA 125 125

Internal arc withstand current (2) kA 1s 50 50

Maximum rated current o the contactor A 400 400

(1) Limited b the uses.

(2) The internal arc withstand values are guaranteed in the compartments on the suppl side o the uses (busbars and apparatus) b the structure o the switchgear and on the load side (eeder)

b the limiting properties o the uses.

(3) VSC7/PG or 32 kV power requenc withstand voltage and VSC12/PG or 42 kV power requenc withstand voltage are available on request in a dedicated panel.

Maximum performances of the contactor with fuses

3.6 kV 7.2 kV 12 kV

Motors kW 1,000 1,800 3,000

Transormers kVA 2,000 2,500 2,500

Capacitors kVAR 1,000 1,800 3,000

The ol lowing uses can be applied:

DINtypewithalengthof192,292and442mm

BStypewithalengthof235,305,410,454and553mm.

The use-holder rames are i tted with a device or automatic

opening when even just one use blows.

This same device does not allow contactor clos ing when even

a single use is missing.

The ABB range o uses or transormer protection is ca lled

CEF, whereas CMF is or motors and capacitors.

StandardsIEC60470forthecontactor

IEC60282-1forthefuses


26/9226

The UniGear panels can be fitted with ABB NAL type

switch-disconnectors.

These units are used to switch and protect feeders and

transformers or the auxiliary services transformers in sub

and power station.

The NAL switch-disconnectors are medium voltage

air-insulated apparatus consisting of a fixed support to

which the post insulators are applied (top and bottom),

the system of contacts (fixed and moving) and latching

pliers (of the fuses or of the insulating bars).

NAL-NALF switch-disconnectorThe switch-d isconnector is itted with two sstems o moving

blade contacts, the main one (through which the load current

passes with the switch in the closed position) and the arc-

breaking one (through which the current passes during the

opening and closing operations).

This solution means the main contacts are not stressed and

thereore keeps the electrical characteristics o the apparatus

unchanged.

During switch-disconnector opening air is compressed b

the pistons contained in the top insulator clinders. At the

moment o opening and separation o the contacts, a blast o

compressed air is emitted through special nozzles, so the arc

is cooled and deionised.

This leads to a gradual increase in the arc res istance which

causes its extinction. The movement o the p istons is

snchronised with the arc-breaking contacts o the switch-

disconnector -this guarantees the highest inlow o air at the

moment o separation o the contacts and there b ensures

reliable arc extinction.

The unit can be itted with insu lating bars (NAL switch-

disconnector unit) or with medium voltage uses (NALFswitch-

disconnector unit with uses).

The NALF switch-disconnector is i tted with an automatic

release mechanism or use tripping and uses uses in

accordance with DIN 43625 Standards. The ABB range ouses or transormer protection is CEF. Each unit is itted

with an earthing switch with making capacit or earthing the

cables.

Switch-disconnector control, like that o the earthing switch,

is carried out manuall rom the switchgear ront panel.

The position o both items o apparatus can be seen directl

rom the ront o the switchgear through an inspection

window.

The switchgear panel can be itted with a set o three current

transormers or with measurement sensors.

The Disconnector Feeder unit (DF) consists o two power

compartments: busbars and switch-disconnector/cables.The latter contains both the switch-disconnector and the

connection terminals o the power cables.

Figure 15: NALF switch-disconnector

1. UniGear ZS1Switch-disconnector


27/9227

Segregation between the power compartments takes place

automaticall with earthing switch closure. An insulating

shutter creates complete separation between the ixed

contacts o the switch-disconnector, making the top ones

inaccessible to the operators. This makes maintenance

operations on the cables and uses possible, keeping the

remainder o the switchgear in operation.

UniGear ZS1 panel with ixed switch-disconnector is classiied

LSC-2A because the cable and apparatus compartments are

not phisicall segregated.

The switch-disconnector, earthing switch and access door

to the cables compartment are interlocked with each other

to guarantee maximum saet or the personnel and correct

operation.

Each switchgear panel is itted with an auxiliar compartment,

where the instruments and auxiliar cabling are housed.

All the switchgear panels are access ible rom the ront and

maintenance and service operations can thereore be carried

out even when the switchgear is wall-mounted.

Standards

IEC60265-1fortheswitch-disconnector

IEC60282-1forthefuses

Electrical characteristics

Rated voltage kV 12 17.5 24

Rated insulation voltage kV 12 17.5 24

Rated power requenc withstand voltage (1) kV 1 min 28 38 50

Rated lightning impulse withstand voltage kV 75 95 125

Rated requenc Hz 50/60 50/60 50/60

(1) Limited b the uses.

(2) The internal arc withstand values are guaranteed in the compartment on the suppl si de o the uses (busbars) b the structure o the switchgear and on the load side (cabl es)

b the limiting properties o the uses.

NALF switch-disconnector unit with fuses

Rated short-time withstand current kA (1) ...25 ...25 ...20

Peak current kA ...100 ...100 ...63

Maximum rated current o the uses A 100 63 63

Internal arc withstand current (2) kA 1 s ...40 ...40 ...25

Selection table of the fuses for protection transformers

Transformerrated voltage

[kV]

Transormer rated output (kVA)Fuse rated

voltage[kV]25 50 75 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000

CEF Fuse-link In [A]

3 16 25 25 40 40 50 63 80 100 125

3.6/7.25 10 16 25 25 25 40 40 50 63 80 100 125

6 6 16 16 25 25 25 40 40 50 63 80 100 125

10 6 10 16 16 16 20 20 25 31.5 40 50 63 80 100 12512

12 6 6 10 16 16 16 20 20 25 40 40 50 63 80 100 125

15 6 6 10 10 16 16 16 20 20 25 40 40 50 63 80 100 125 17.5

20 6 6 6 10 10 16 16 16 20 20 25 31.5 40 50 63 8024

24 6 6 6 6 10 10 16 16 16 20 20 25 40 40 50 63 80

The tab le was calculated acco rding to standards IEC 6 0787 and IEC 6 2271-105 (or opera ting voltages up t o 24 kV ). The ollowing t ransormer work condit ions were as sumed:

Maximumlong-lastingoverload150% Magnetizinginrushcurrent12Induring100ms

Transformershort-circuitvoltageaccordingtoIEC60076-5

Standardambientworkingconditionsoffuses

The tab le above de tail s the r ated current o a parti cular use l ink o r a gi ven l ine voltage and transor mer rating. For d ierent cri teria , the use selecti on mus t be recalculated .

The gi ven l imits o the rated curren t o use are not mandator or use in the NALF di sconnector / NAL wi thout use tr ipping ss tem. Rated current values o t he cor responding uses or these

applications are given in the ABB catalogue FUSES.

(1) GB/DL version is available with higher request in dielectric characteristics.


28/9228

The UniGear ZS1 range is equipped with all the service

trucks needed for service maintenance activities.

The trucks are divided into four different types:

Earthing without making capacity

Earthing with making capacity

Cable test

Isolation

Earthing truck without making capacitThese trucks carr out the same unction as the earthing

switches without making capacit.

The there ore have no capacit to earth live circu its in ault

conditions.

The are used to ensure an addi tional ixed earth, as is

required b certain installation service and maintenance

procedures, as a urther saet guarantee or personnel.

The use o these trucks require the removal o the apparatus

(circuit-breaker or contactor) rom the switchgear and its

replacement with the truck.

The switchgear panels preset or use o the earthing trucks

must be provided with a ke lock which, when activated,

prevents their racking-in.

This truck is available in two versions:

Earthingofthemainbusbarsystem.

Earthingofthepowercables.

The earthing truck o the main busbars, during the racking-

in phase, onl lits the top shutter and earths the contacts

connected to the top branch connections (and thereore to the

main busbar sstem) b means o the switchgear structure.

The earthing truck o the power cables, dur ing the racking-

in phase, onl activates the bottom shutter and earths the

contacts connected to the bottom branch connections (and

thereore to the power cables) b means o the switchgear

structure.

These trucks can also be used in the bus-tie unit . In this case,

the earth one o the two sides o the main busbar sstem.

Earthing truck with making capacitThese trucks carr out the same unction as the earthing

switches with making capacit.

The cons ist o circu it-breakers provided with top (ear thing o

the main busbars) or bottom (earthing o the power cables)

terminals onl. The contacts without terminals are short-

circuited b means o a copper bar and connected to earth b

means o the apparatus truck.

The keep all the characterist ics o the circuit-breakers, such

as ull making and breaking capacit on live circuits under

ault conditions.

The are used to ensure extremel eective earthing on

circuits stressed b a ault. The allow opening and closing

operations to be carried out rapidl with electric remote

control.




The switchgear panels preset or use o the earth ing trucks

must be provided with a ke lock which, when activated,

prevents their being racked-in.

Figure 16: HD4 service truck

1. UniGear ZS1Service trucks


29/9229

This truck is available in two vers ions:

Earthing o the main busbar sstem.

Earthing o the power cables.

The earthing truck o the main busbars, during the racking-

in phase, onl lits the top shutter and presets the contacts

connected to the top branch connections (and thereore to

the main busbar sstem) or closing to earth b means o

operating mechanism.

The earthing truck o the power cables, dur ing the racking-

in phase, onl activates the bottom shutter and presets the

contacts connected to the bottom branch connections (andthereore to the power cables) or closing to earth b means

o operating mechanism.

These trucks can also be used in the bus-tie unit . In this case,

the earth one o the two sides o the main busbar sstem.

Power cable test truckThese trucks allow the insu lation tests on the power cables to

be carried out without accessing the eeder compartment or

disconnecting the cables rom the switchgear.




The truck, dur ing the racking- in phase, onl activates the

bottom shutter and, b means o the connectors it is itted

with, allows connection o the test apparatus cables.

This truck can onl be used in the incoming/outgoing eeders

with the door open.

Isolating truckThe isolating t ruck allows the top switchgear contacts to

be connected directl to the bottom ones. Connection

is made extremel sae b using the poles o the circuit-

breakers to insulate the connection busbars rom the

external environment. In the incoming/outgoing eeder units

it connects the main busbar sstem to the power cables,

whereas in the bus-tie, to the two sides o the busbar sstem.

This truck has its application in UniGear switchgear or

making incoming/outgoing eeders without a circuit-breaker

in radial networks, or making cable connections between

two items o switchgear placed in ront o each other, in

making interconnection units and in creating the bus-tie riser

coniguration with double insulation (in this case, both the

units are made up o bus-ties, the ormer itted with a circuit-

breaker and the latter with an isolating truck).

The switchgear panels preset or use o the isolating trucks

must be itted with a ke lock which, when activated, prevents

their being racked-in.

Main busbar sstem earthing

truck, without making capacit.

Power cable earthing truck,

without making capacit.

Cable test truck.

Main busbar sstem earthing

truck, with making capacit.

Power cable earthing truck,

with making capacit.

Isolating truck.


30/9230

The UFES (Ultra Fast Earthing Switch) is an innovative

design of an extremely fast-acting earthing switch,

grounding all 3 phases within less than 4 ms after

detection of an internal arc fault.

The extremel short operating time o the primar switching

element, in conjunction with rapid and reliable detection o

ault current and light, ensures that an internal arc ault is

extinguished nearl immediatel ater its ormation. Thermal

and mechanical damage inside o the protected switchgear

sstem are thus eectivel prevented.

Figure 17: Electronic device for measurement,

logic and tripping, type QRU1

Figure 18: Primary switching element type U1

Electrical maximum characteristics in UniGear ZS1 IEC

Rated insulation voltage (rms) (1) kV 12 17.5 24

Rated power requenc withstand voltage (rms) kV 28 38 50

Rated lightning impulse withstand voltage (peak) kV 75 95 125

Rated requenc Hz 50/60 50/60 50/60

Rated short-time withstand current (rms) (1) kA 50 50 31.5

Rated short-circuit making current kA 125 125 80

Rated duration o short-circuit s 3 3 3

(1) GB/D L version i s avai lable wit h higher request i n die lectr ic characte risti cs (42 kV) and sho rt-time wi thstand curren t (4 s ).

The UFES is avai lable to ul il a variet o applications in the

UniGear ZS1 switchgear:

Busbar installation with top-housing box

Cable compartment installation (12/17.5 kV 50 kA version)

Unbeatable advantages in case o an arc ault event

Drastic reduction o repair costs: no damages on the

switchgear equipment to be expected. No exchange o the

ault panel.

Greatl increased sstem availabilit: ater inspection and

elimination o the ault reason the switchgear can be takeninto service again within shortest possible time.

Greatl increased operator saet or human mal-operation

under maintenance conditions.

1. UniGear ZS1Ultra Fast Earthing Switch


31/9231

0.0 20.0 40.0 60.0 80.0 100.0 120.0

I(t)

Time in ms

Short-circuit current In

DC component

Arcing time wi th UFES

Finalclearingoffaultcurrentbyupstreamcircuit-breaker-80ms+timex

Reaching time or tripping criteria

0 10 20 30 40 50 60 70 80 90 100

1.6

1.4

1.2

1.0

0.8

0.6

0.4

0.2

0

Time in ms

Overpressure in bar

Pressure curve with UFES (4 ms) Pressure curve without UFES

Reaching time or tripping criteria

0.0 5.0 10.0 15.0 20.0 25.0

I(t)

Time in ms

0.0 5.0 10.0 15.0 20.0 25.0

I(t)

Time in ms

0.0 5.0 10.0 15.0 20.0 25.0

I(t)

Time in ms

0.0 5.0 10.0 15.0 20.0 25.0

I(t)

Time in ms

0.0 20.0 40.0 60.0 80.0 100.0 120.0

I(t)

Time in ms

UFES

CT

CB

1.

QRU

Ik

UFES

CT

CB

2.

QRU

Ik

UFES

CT

CB

3.

QRU

Ik

UFES

CT

CB

4.

QRU

Ik

UFES

CT

CB

5.

QRU

Ik

(Optional)

tTC

+ < 4 ms

tTCtTC

Figure 19: In rare cases, failure inside a switchgear cubicle due either to a

defect, an exceptional service condition or mainly by human mal-operation

may initiate an internal arc. The faster the arc will be interrupted, the less

destruction on the switchgear equipment will occur.

Figure 20: Avoidance of the severe effects of an internal arc fault, such as

- Rapid temperature rise (up to 20,000 C)

- Rapid pressure rise (see figure)

- Burning of materials

by fastest possible extinction.

Figure 21: Event sequence description

1. Internal arc formation.2. Arc detection by the electronic device (light and current).

3. ~ 1-2 ms after detection: Tripping signal to the UFES primary switching elements

4. ~ 3-4 ms after detection: Bolted 3-phase earthing by operation of the UFES primary switching elements.

Interruption of the arc voltage: Immediate extinction of the arc.

Controlled fault current flow via UFES primary switching elements to earth potential.

5. Final clearing of the fault current by the upstream circuit-breaker.


32/9232

i

t

160 kA

80 kA

(31.5 kA x Hx2)

lnk perm.

= 31.5 kA

lnk

= 31.5 kA lnk

= 31.5 kAT1 T2

l = l1+l

2

l1

l2

l1

l2

Short-circuit currents too high?

The IS-limiter, a switching device with extremely short

operating time, solves the problem.

The rising g lobal demand or energ requires more power ul

or additional transormers and generators, and an increasing

interconnection o the individual suppl networks.

This can lead to the permissible short-circuit currents or the

equipment being exceeded causing severe dnamic or

thermal damage or even complete destruction.

The replacement o ex ist ing switchgear and cable connections

b new equipment with a higher short-circuit strength is otentechnicall impossible or uneconomical or the user.

The use o IS-limiters reduces the short-circuit current in both

new sstems and expansions o existing sstems, thus saving

cost.

A short-circuit downstream rom an outgoing eeder breaker is

assumed. The oscillogram shown below indicates the course

o the short-circuit currents in the irst hal wave.

A short-circuit current o 31.5 kA can low to the ault location

through each transormer. This would result in a total short-

circuit current o 63 kA, which is twice as much as the

switchgear capabilit.

The course o the current through the IS

limiter in such an

event is shown below as current i2.

It can be seen that the IS-limiter operates so rapidl, that

there is no contribution via the transormer T2 to the total

peak short-circuit current (i1+i2). Thereore, a switchgearwith a rating o 31.5 kA is suitable or this application.

i = i1+i

2

whithout Is-limiter

Current i = i1+i

2

at the ault location

i = i1+i

2

with Is-limiter

Single line diagram

o a bus tie or a

sstem with

lnk

= 31.5 kA

and with anlS

- limiter

Technical Data

Rated voltage kV 12.0 17.5 24.0 36.0/40.5

Rated current A1250/2000/2500/

3000/40001)1250/2000/2500/

3000/40001)1250/1600/2000/

25001)/3000 1)1250/2000/25001)

Interrupting current kARMS

Up to 210 Up to 210 Up to 140 Up to 140

1) with cooling an

1. UniGear ZS1IS-limiter: ault-current limitation

Figure 22: IS-limiter application diagram Figure 23: I

S-limiter


33/9233

110 kV

40 MVA8%

10 kV/31.5 kA 10 kV/40 kA

OptionA

OptionC

OptionB

10 kV/16 kA

10 kV/25 kA

I kT

= 15 kA

IkG

= 3 kA

T1

A B CIS-1

IT1

T2

IS-2

IT2

T3

IT3

OptionD

31.5 MVA

12%

Potential applicationsSuch a ast switching device caters or a variet o applications

which cannot be ullled b conventional switches. The most

important o these are presented below.

Advantages o all IS-limiter applications:

Reductionofshort-circuitcurrentsatthefaultlocation

Noupgradingoftheexistingswitchgear.

Option A, igure 24Coupling-parallel operation o two sstems.

Advantages:Improvingpowerquality

Increasingthereliabilityofthesystem

Reductionofthenetwork-impedance

Optimalloadflow

Option B, igure 24IS-limiter in the generator eeder to protect the high voltage sstem.

Advantages:

Generatorcanbeconnectedindependentoftheshort-

circuit capabilit o the sstem

Existingbusbarsystemdoesnotneedtobechanged

Noneed forexp ensiveg enerator breaker

Option C, igure 24IS-limiter and reactor connected in parallel.

Advantages:

Avoidcopperlossesofthereactor

Avoidvoltagedropoverthereactor

Noelectro-magneticfieldofthereactor

Option D, igure 25

Station service suppl and public network.Advantages:

Private/industrialgeneratorfeedercanbeconnectedtothe

(ull loaded) grid

SelectivetrippingoftheIS-limiter (I

S-limiter will operate onl

or short-circuit aults in the grid)

Option E, igure 26I in the case o two I

S-limiters being installed in a switch-

board selective tripping is required, a measurement o the

total current becomes necessar.

Advantage: The IS-limiter trips as ollows:

Short-circuit in section A: Onl IS-limiter no. 1 trips.

Short-circuit in section B: IS-limiter no. 1 and no. 2 trip.

Short-circuit in section C: Onl IS-limiter no. 2 trips.

Figure 24: Three possible applications of IS-limiters in one figure

(Option A, B, C)

Figure 26: Use of more than one Is-limiter with selectivity (Option E)

Figure 25: Is-limiter in connecting point with a public supply network

(Option D)


34/9234

Block tpe current transormersThe block tpe current transormers are epox resin insu lated

and used to suppl the measurement devices and protection

instruments. These transormers can have a wound core or a

bushing bar with one or more cores, with perormance and

accurac classes suitable or the installation requirements.

The conorm to the IEC 60044-1 Standards.

Thei r dimensions are in accordance with the DIN 42600

Narrow Tpe Standard, in the Medium and Long Size versions

up to 2500 A, where the are o the toroidal tpe in the

range o currents rom 3150 A to 4000 A (KOKS tpe).

The current transormers can also be provided with a

capacitive socket or connection to voltage signalling devices.

The current transormers are normal l itted on the load

side o the apparatus compartment or measurement o the

phase currents o the switchgear unit. Fitting on the suppl

side o the apparatus compartment is also possible (busbar

applications) or measuring the busbar currents or or realising

particular protection schemes. The ABB range o current

transormers is designated TPU.

Ring core current transormersThe toroidal transormers are o the epox res in insulated tpeand are used to suppl measurement and protection devices.

These transormers can eature either a closed or openable

core.

The can be used both or measuring phase currents or or

detecting the earth ault current.

The conorm with the IEC 60044-1 Standards.

Figure 28: TPU 1250 A

Figure 29: TPU 2500 A

Figure 27: Toroidal current transformer Figure 30: KOKS 3150 A

1. UniGear ZS1Instrument transormers


35/9235

Voltage transormersThe voltage transormers are o the epox resin insu lated tpe

and are used to suppl measurement and protection devices.

The are available or ixed assembl or or installa tion on

removable and withdrawable trucks.

The conorm with the IEC 60044-2 Standards.

Thei r dimensions are in accordance wi th the DIN 42600

Narrow tpe Standard.

These transormers can have one or two poles, with

perormance and precision classes suited to the unctional

requirements o the instruments connected to them.

When the are installed on removable or withdrawable trucks

the are itted with medium voltage protection uses.

The withdrawable t rucks also allow replacement o the uses

with the switchgear in service. Truck racking-out with the

door closed automaticall operates closure o a metallic

segregation shutter between the live parts o the switchgear

and the instrument compartment.

Fixed voltage transormers can be installed directl on the

main busbar sstem in a dedicated compartment (busbar

applications).

The ABB range o voltage transormers is designated TJC,

TDC,TJP.

Figure 31: VT truck with fuses

Figure 32: Single pole VTs - type TJC

Figure 33: Double-pole VTs - type TDC

Figure 34: Single-pole VTs with fuse - type TJP


36/9236

1. UniGear ZS1Measurement sensors

Figure 35: Linearity of advanced ABB sensors and example of output signal waveforms compared to conventional saturated CT

Electronic instrument transormersFuture or measuring currents and voltages in intelligent

UniGear is a low-power instrument transormer (according to

present IEC standards the belong to the group o Electronic

instrument transormers) called a sensor or short. These

products replace conventional instrument transormers o

both block and ring core tpes.

The characterist ic eature o advanced ABB sensors is

the level o output signal, which is ull adapted to it new

microprocessor-based equipment without the need o having

unnecessar power.

The analogue output s igna l level depends on the principle

used and can be:

IntherangeofmVforcurrentsensor(typicalvalueis150

mV at rated primar current).

Intherangeofvoltsforvoltagesensorswherethedivision

ratio is 1:10000 (e.g. output 1/3 V or 10 000/3 kV

nominal sstem voltage at primar/input side).

The UniGear ZS1 can be itted with KEVCD block tpe sensor

KEVCDisblocktypesensorwithshapethatconforms

to DIN size standard. Two versions could be selected:

one providing current measurement together with voltage

indication capabilit or second one, providing, in addition

to these, also voltage measurement possibilit. All

measurements/sensings or each phase is realized within a

single bod, so there is no need or additional devices.

Characteristics o the sensorsConstruction o current and voltage sensors is done without

the use o erromagnetic core. This act results in several

important beneits or the user and the application:

sensorbehaviorisnotinfluencedbynon-linearityand

width o hsteresis curve; that results in accurate and

linear response over a wide dnamic range o measured

quantitites

singledevice/sensorcouldbeusedforbothprotectionand

or measurement purposes (no need or a separate design/

product)

therearenohysteresislosses,sosensorsarehaving

excellent requenc response also at requencies dierent

rom the rated one, thus providing ver precise input to

protection unctions, allowing more precise ault analsis

and eicient ault location.

sensorsdonothavedangerousstatesinoperation(no

problem to keep output short-circuited or let open),

resulting in high saet or surrounding devices and

personell. The output signal remains ver low even in ault

situations o the network.

theuseofsensorsdisablethepossibilityofrelated

erroresonance phenomena, thus even more increasing the

saet and reliabilit o the power network; urthermore,

there is no need or additional protection equipment, special

burden or wiring.


37/9237

Figure 36: KEVCD block type current and voltage sensor

ABB sensors are connected to the measurement and

protection evaluation devices b means o shielded cables

and connectors, providing a high degree o immunit to

electromagnetic disturbances.

Accurac o these sensors is veri ied and tested including the

cabling, so precise inormation is assured up to the evaluation

device.

Beneits o the sensorsDue to the linear response and wide dnamic range, sensors

are much more standardized devices (compared to a number

o dierent designs o CTs and VTs). Thereore, it is mucheasier to select the appropriate design (it simpli engineering

tasks) and there could be also reduction in spare parts on

user side.

Signiicantl decreased power consumption during operation

o sensors due to negligible losses introduced b sensors

(no iron = no hsteresis losses; less winding and negligible

output current = small losses in sensor winding) results in

huge savings or lost energ and minimized temperature rise

(thus improving temperature conditions and ageing within

application). It also results in signiicantl lighter devices,

having weight onl a raction o that provided b conventional

CTs or VTs. Thereore, no special machines/tools are neededto car them and transport costs can be smaller.

Fast connection o sensors to IEDs without an tools and

material needed simpli and reduce assembl eort.


38/9238

1. UniGear ZS1Measurement sensors

Current sensorThe current sensor is based on Rogowski Coil principle.

Rogowski Coil work in the same manner as conventional iron-

core current transormers (CTs). The main dierence between

Rogowski Coils and CTs is that Rogowski Coil windings are

wound over a non-magnetic core, instead o over an iron

core. As a result, Rogowski Coils are linear since the non-

magnetic core cannot saturate. Rogowski Coils produce

output voltage (U

Documents

Catalogue UG ZS1 RevF 2012 09 En