UniGear type ZVCMedium voltage, arc-proof, air-insulated,fused vacuum contactor switchgear

PPoowweerr IITT

Installation, Operation and Maintenance Manual

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TABLE OF CONTENTS

1) INTRODUCTION................................................................................................................................................................2

2) STANDARDS AND SPECIFICATIONS .......................................................................................................................3

3) TYPE TEST REPORTS .....................................................................................................................................................3

4) TECHNICAL SPECIFICATION.....................................................................................................................................5

A) ELECTRICAL DATA.......................................................................................................................5B) INTERNAL ARC WITHSTAND...........................................................................................................5C) ENVIRONMENTAL DATA ................................................................................................................6

5) DIMENSIONS & WEIGHTS ............................................................................................................................................7

6) RECEIPT AND INSPECTION.........................................................................................................................................8

7) STORAGE AND INSPECTION.......................................................................................................................................9

A) SHORT TERM STORAGE (MAX FOUR WEEKS ONLY).............................................................................9B) LONG TERM STORAGE (ONE MONTH TO SIX MONTHS) .........................................................................9

8) BASIC STRUCTURE..........................................................................................................................................................9

A) COMPARTMENTS AND PARTITIONS..................................................................................................9B) INTERLOCKS AND LOCKING FACILITIES ..........................................................................................12

9) INSTALLATION................................................................................................................................................................13

A) FOUNDATION ............................................................................................................................13B) BOLTING PANELS TOGETHER.......................................................................................................13C) BUSBARS .................................................................................................................................13D) POWER CABLE CONNECTION.......................................................................................................14E) CONTROL CABLE CONNECTION....................................................................................................15F) EARTHING ................................................................................................................................15G) CONNECTING TO UNIGEAR TYPE ZS1...........................................................................................15

10) OPERATION...................................................................................................................................................................16

A) EARTH SWITCH..........................................................................................................................16B) CONTACTOR.............................................................................................................................16C) RACKING..................................................................................................................................17D) REMOVAL OF CONTACTOR TRUCK ................................................................................................18E) INSERTION OF CONTACTOR TRUCK ...............................................................................................18F) FUSE OPERATION......................................................................................................................18

11) MAINTENANCE............................................................................................................................................................19

A) GENERAL.................................................................................................................................19B) INSPECTION AND SERVICING ........................................................................................................19C) REPAIRS/REPLACEMENT.............................................................................................................21

i) Recommended Spare parts .........................................................................................................................................21ii) Corrosion Repair .........................................................................................................................................................21iii) Trip Coil Replacement ................................................................................................................................................21iv) Feeder Unit Replacement...........................................................................................................................................22v) Fuse Replacement........................................................................................................................................................22

12) TROUBLESHOOTING................................................................................................................................................23

We reserve all rights to this publication. Misuse, particularly including duplication and the makingavailable of this manual – or extracts – to third parties is prohibited. The information supplied is withoutliability. Subject to alteration.

© 2002 ABB Australia Pty Limited

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1) INTRODUCTION

UniGear type ZVC is three-phase, air-insulated indoor switchgear designed forthe operation, control and protection of motors and transformers at rated voltagesup to 7.2kV and rated current up to 400A. Other applications are possible andshould be referred to the manufacturer.

UniGear type ZVC’s combination of maximum accessibility at minimumdimension and innovative integration of components offers a lightweight cubiclewith small footprint providing greater utilisation of switchroom space.

The UniGear type ZVC enclosure is constructed from 2mm thick zinc coatedsteel sheet. The indoor, metalclad, IP4X design using vacuum switchingtechnology and epoxy resin enclosed conductors ensure long service life ispossible. An integral fault-making cable earthing switch is included and ALLoperations, ON-OFF-ISOLATION-EARTHING, are conducted with the front doorclosed to ensure maximum personnel protection in the event of an internal arcingfault and to avoid contamination and electrical deterioration of the switchgear.

UniGear type ZVC comprises a fixed portion for the connection of the mainbusbars and the outgoing cables. It houses fixed isolating contacts, currenttransformers and earthing switch. The low voltage control and protectionequipment is housed in a separate compartment mounted on top of the cubicle.A withdrawable truck mounted fused vacuum contactor with primary andsecondary isolating contacts is located in the fixed portion and is moved betweenthe isolated and service positions by rotation of a racking screw by a specialhandle provided with the switchboard. Widely available tag type fuses are usedas the short circuit protection device and two parallel fuses per phase can beaccommodated.

Figure 1 Illustrates the main features of a typical UniGear type ZVC cubicle.

BusbarcompartmentContactor and HRCfuses compartment

Cable compartment

Low voltagecompartment

Busbars

Withdrawable fused contactor’scontacts

Vacuum contactor

HRC fuses

Instrument current transformer

Earthing switch

Auxiliary voltage transformer

Cable connection terminals

A

B

C

D

1

2

3

4

5

6

7

8

Figure 1

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2) STANDARDS AND SPECIFICATIONS

UniGear type ZVC switchgear cubicles comply with standards and specificationsfor factory assembled high voltage switchgear to IEC 60694 (AS 2650-1986).

Other relevant standards for components include:

IEC 60470 (AS1864-1976) Motor Starter & Contactor

IEC 60282-1 and 60644 Isolators (HV Fuses)

(AS1033.1-1990)

IEC 60129 (AS1306-1985) Earthing Switch

IEC 60529 (AS1939-1990) Degree of Protection

IP4X external closure

IP2X internal shutters &partitions

IEC 60298 (AS2086-1995) Arc fault containment

IEC 60044-1 (AS1675-1986) Current transformers

Special requirements in compliance with regulations issued by local authoritiesshould be checked with the manufacturers.

3) TYPE TEST REPORTS

TYPE TEST STANDARD CLAUSE TEST VALUE AUTHORITY REPORT NO. RESULT

SHORT TIME & PEAK

WITHSTAND CURRENT TEST

- Main Bus System IEC60298 6.5.101 50kA/3 sec Pehla 0047Ra OK

- Earthswitch IEC60129 6.5 12.0kA/1 sec Pehla 0049Ra OK

- Earthing circuit IEC60298 6.5.102 12.0kA/1 sec Pehla 0049Ra OK

OVERLOAD CURRENT IEC60470 6.103 6kA/1 sec Pehla 0048Ra OK

WITHSTAND TEST IEC60470 6.103 2.7kA/30 sec Pehla 0048Ra OK

VERIFICATION OF MAKING &

BREAKING CAPACITIES

- Earthswitch making IEC60265 6.107.1 31.5kA Peak Pehla 0051Ra OK

- Fused contactor making IEC60470 6.102.4 4kA - C x100 Pehla 0001Ma OK

- Vacuum contactor breaking (max) IEC60470 6.104 6kA SACE LBRP5158 OK

- Fused contactor breaking (max) IEC60470 6.102.5 3.2kA - O x25 Pehla 0001Ma OK

- Fused contactor breaking (min) IEC60470 6.102.5 90A - O x25 Pehla 0001Ma OK

VERIFICATION OF

CO-ORDINATION TEST WITH

4TYPE TEST STANDARD CLAUSE TEST VALUE AUTHORITY REPORT NO. RESULT

SCPD'S - CLASS 'a' ASSESSMENT

- Test duty A - 100% break IEC60470 6.106 50kA Pehla 0052Ra OK

- Test duty B - 100% make IEC60470 6.106 50kA/125kAp Pehla 0134Ra OK

- Test duty C - take over point IEC60470 6.106 4.6kA / 7.2kV Pehla 0052Ra OK

VERIFICATION OF INTERNAL

ARCING FAULT

- Load side IEC60298 Appx AA 50kA Pehla 0135Ra OK

- Line side IEC60298 Appx AA 50kA Pehla 0135Ra OK

- Main bus IEC60298 Appx AA 50kA/0.5 sec Pehla 0135Ra OK

DIELECTRIC TESTS

- Partial discharge IEC60298 6.1.9 < 100 pc ABB T & D TR-168 UNDERPREPARATION

- Lightning and switching IEC60298 6.1.6 40/60kV ABB TPT C1144 OK

impulse voltage test

- Power frequency withstand IEC60298 6.1.7 10kV/1 min ABB T & D TR-169 OK

voltage test - 10kV

- Power frequency withstand IEC60298 6.1.7 20kV/1 min ABB T & D TR-170 OK

voltage test - 20kV

- Power frequency withstand IEC60298 6.1.7 32kV/1 min ABB T & D TR-179 OK

voltage test - Special

POWER FREQUENCY

WITHSTAND VOLTAGE TEST

- Aux Circuit IEC60298 6.1.10 2kV/1 min ABB T & D TR-170 OK

TEMPERATURE RISE TEST IEC60298 6.3 TABLE 3 ABB T & D TR-175 OK

- Starter IEC 60694 (1/2/4/7AA) OK

TEMPERATURE RISE IEC60298 6.3 TABLE 3 Pehla

- Main busbars IEC 60694

MECHANICAL TESTS

- Earthswitch mechanical endurance IEC60129 6.102 1000 CO OPS. ABB T & D TR-176 OK

- Earthswitch & starter operation IEC60298 6.102 50 CO ABB T & D TR-181 OK

- Interlocks E/Sw/Starter IEC60298 6.102 25 Attempts ABB T & D TR-181 OK

- Fuse Striker Mechanism IEC60470 6.101.4 min/max energ ABB T & D TR-180 UNDERPREPARATION

DEGREE OF PROTECTION

- External surface IEC60470 5.13 IP4X ABB T & D TR-177 OK

- Internal barriers & partitions IEC60470 5.13 IP2X ABB T & D TR-178 UNDERPREPARATION

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4) TECHNICAL SPECIFICATION

a) Electrical Data

Rated Voltage kV 3.6 7.2Rated Frequency kV 50/60 50/60Rated Insulation Level kV 3.6/10/40 7.2/32/60Maximum Busbar Current A 4000Rated Current of Tee-Off A 400Rated Peak WithstandCurrent 3 sec

kA 130

Rated Short Time Current 3 sec kA 50Auxiliary Voltage:- Fused Contactor Feeder Unit- Mechanically Latched Trip

Coil

VV

100-250V AC/DC 48-60V DC 100-130V DC100-130V AC 220-250V AC

Earthing Switch Rated MakingCurrent

kA 31.5

Earthing Switch Short Timecurrent 1 sec

kA 12.5

HV Fuse type Tag type to BS2692-1986 type II454mm centres maximum

CT rated secondary current A 1Main Circuit Resistance:- Bus risers to top spout

bushing- Cable tags to bottom spout

bushing

µΩ

µΩ

40 ± 10

139 ± 15

b) Internal Arc Withstand

Accessibility type “A” restricted to authorised personnel only.Minimum ceiling height1 ≥ 4.0 mInternal Arc Fault rating is 40 kA/1 sec, and 50 kA/0.5 sec.

1 To use a lower ceiling height contact ABB for a solution

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c) Environmental Data

UniGear type ZVC is suitable for clean, dry indoor environmentscomplying with IEC 60694 (AS 1939) rated values.

Max ambient temperature +40°CMax 24 hour average ambient temp +35°CMinimum ambient temperature -5°CMaximum average relative humidity

Over 24 hour period 95%Over 1 month period 90%

The ambient air must not be significantly contaminated by dust, smoke,corrosive or combustible gases, vapour or salt.

Altitude category does not exceed 1000m

Special performance and operating conditions to meet customer needs cansometimes be provided. Refer to the manufacturer for details if equipment is tobe installed or operated in conditions exceeding the ratings above.

For technical data of individual components included as part of the switchgearrefer to the ABB Equipment list for the project, together with the associatedoperating instructions.

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5) DIMENSIONS & WEIGHTS

Maximum Weight of Panel without Truck : 275 kgMaximum Weight of Contactor Truck : 95 kgWeight of Palette and Both End Covers : 90 kg

Total Maximum Weight of Panel and Truck : 460 kg

Width (mm)

Height (mm)

LV Box Height (mm) 665

2200

325

865

2400

1060

2595

Height withArc duct (mm)

2670

A – Busbar compartmentB – Contactor and HRC fuses compartmentC – Cable compartmentD – Low voltage compartmentE – Gas exhaust duct

Depth (mm)

Power CableEntry

Control CableEntry

Bottom EntryFront Access

Bottom EntryFront Access

Arc Duct No

Bottom EntryRear Access

Bottom EntryFront Access

Yes/No

1124 1304

Top EntryRear Access

Top EntryFront Access

No

1304

Top EntryRear Access

Top EntryFront Access

Yes

1504

Bottom EntryFront Access

Bottom EntryFront Access

Yes

1304

Floor planPower cable:

Bottom entry

Top entry

Control Cable:

Bottom entry

Top entry

1124

1304

1304

1304

1504

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6) RECEIPT AND INSPECTION

UniGear type ZVC is shipped in groups of one, two or three cubicles. Thewithdrawable vacuum contactor is shipped inside the cubicle locked in theservice position. Loose items, usually comprising items such as service trolley(for removal of contactor from cubicle), door key, operating handles, connectingbusbars, connecting hardware and inter-cubicle wiring, accessories, spare parts,HV fuses are packed separately.

Each package in the shipment is secured to a pallet base and is clad to suitairfreight, sea freight, road freights or to customer requirements as appropriate.

Always lift from base using forks or slings.

2 Check all packages on the consignment note have been received. Checkthe consignment for signs of rough handling and damage to packaging,particularly to dessicant. Check the contents of each package against thepacking list and notify the manufacturer within seven days of any damageor discrepancies.

Equipment should be left on a pallet until it is delivered to the switchroom and isready for placing in its final position.

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7) STORAGE AND INSPECTION

If storage is required after ex-works delivery the consignee has responsibility toensure the receipt and inspection procedures outlined in section 6 above arecompleted.

a) Short term storage (max four weeks only)Return the equipment to its original packaging and store in dry conditionscomplying with manual section 4c. Make sure fresh packs of desiccantdrying agent are included in the packaging. Conduct weekly inspections toensure packing and storage conditions are unchanged.

DO NOT STACK PACKAGES; STORE IN THE UPRIGHT POSITION.

b) Long term storage (one month to six months)Unpack the equipment (Do NOT remove from pallet) and store in a dry,well ventilated room with conditions complying to manual section 4c.Store the cubicles in an upright position

DO NOT STACK PACKAGES; STORE IN THE UPRIGHT POSITION.

Loosely cover cubicles with plastic sheeting to prevent contamination.Adequate air circulation must be maintained to prevent corrosion. Performregular (weekly) check for any condensation.

8) BASIC STRUCTURE

The enclosure and partitions are manufactured from zinc coated sheet steel toprovide the highest degree of protection against corrosion. In addition, the frontdoors and the rear cover have a powder coat stoving enamel finish ABB standardcolour RAL 7035 light grey 50% gloss. Other colours are available as specialorder options.

a) Compartments and Partitions(Refer figure 3)

UniGear type ZVC component layout is categorised as metal cladcompartmented switchgear according to the definitions of IEC 60298. Theexternal enclosure and the internal partitions between compartments areearthed metal barriers providing absolute protection of personnel againstcontact with high voltage conductors.

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The cubicle comprises three high voltage compartments. On top of eachcompartment a pressure relief flap (1) is fitted to release internaloverpressure in the event of an arcing fault. A separate compartment forlow voltage equipment (2) is fitted on top of the cubicle at the front.External wiring to this compartment is housed inside the front of thecubicle in earthed metal wiring ducts (3).

Flat copper busbars are supported on the epoxy resin encapsulated riserconductors (4). These are located in the busbar compartment (5). Noadditional support is necessary to withstand the rated short circuit currentof the busbar system. Unit busbar lengths are factory installed betweencubicles in a shipping suite and are joined at the riser conductors.

The cable compartment (6) is arranged for front access terminating cablesentering through the glandplates in the bottom of the panel in the basicversion. Current transformers are installed on spout bushings (7) whichare integrated into the bus riser moulding. Cable connection tags (8) andearthing switch contacts (9) are segregated by epoxy resin phase barriers.The earthing switch (10) is manually operated using its handle inserted inits mechanism (11) at the front of the cubicle.

The contactor compartment (12) includes guide rails for the withdrawablefused contactor (13). The withdrawable contactor truck is locked to thecubicle with bar operated by a bit key (14) and moves between isolatedand service position on racking screw (15). Automatic metal shutters (16)cover the bus-side spout bushings (17) when the truck is in the isolatedposition (optional cable side shutters can be provided). Self-aligning tulipcontacts in the spout bushings connect with disconnecting contacts (18)when the truck is in the service position. Secondary contacts (19) areautomatically connected, via the plug on the rear of the truck, when thetruck is installed in the cubicle. Contactor operating mechanism (20) ismounted on the truck chassis and is connected to the vacuum interrupters(21) by a lever and pushrod assembly. The fixed contact of the interrupteris rigidly connected to resin encapsulated conductors in fuse module (22)while, the moving contact is connected by flexible conductor (23). Tagtype HRC fuses (24) complete the primary circuit. Control VT (25)(optional) with primary fuses is mounted to the chassis and connect toterminals on the load side of the main power fuses. A mechanical latchedoperating mechanism (optional), is resettable by energising the trip coil(26) or a manual pushbutton (27) fitted to the front of the panel.

A hinged, screw fixed steel door (28) provides access to the contactor andcable compartments. All operations, ON-OFF, isolation, earthing andemergency manual trip must be conducted with the door closed. Allindicators, such as ON-OFF, isolated or in-service, earthed and fuseblown can be seen with the door closed through viewing windows (29).

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Legend:1. Pressure Relief Flap2. Low Voltage Equipment Compartment3. Metal Wiring Ducts4. Riser Conductors5. Busbar Compartment6. Cable Compartment7. Current Transformers8. Cable Connection Tags9. Earth Switch Contacts10. Earth Switch11. Earth Switch Operating Mechanism12. Contactor Compartment13. Truck Guide Rails14. Withdrawable Fused Contactor Truck15. Racking Screw16. Shutters17. Spout Bushings18. Disconnect Contacts

19. Truck Secondary Contacts20. Contactor Operating Mechanism21. Vacuum Interrupters22. Flexible Conductor Connecting Items 21&2323. Fuse Module24. HRC HV Fuses25. Control VT (optional)26. Trip coil (optional - latched)27. Contactor Manual Trip Operator (where trip

coil fitted)28. Contactor and Cable Compartment Door29. Contactor and Earth Switch Viewing

Windows

Figure 3

27

29

2

22

24

13

23

11

21

20

26

6

28

8

15

14

12

1

4

18

17

7

16

25

19

9

10

5

3

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b) Interlocks and Locking FacilitiesA series of interlocks is provided to protect personnel, the switchgearitself and, to prevent dangerous situations and maloperation that mayotherwise lead to serious consequences. The individual effectiveinterlocks are as follows:

• The truck can only be moved from the test/isolated position into theservice position (and vice versa) when the fused contactor andearthing switch are open and the door is closed.

• The fused contactor can only be closed when the truck is fullyengaged in the test or service position.

• The door cannot be opened when the truck is in the serviceposition.

• For a mechanically latched fused contactor, with the truck in the testposition, and without control voltage, it is only possible to open (notclose) it manually.

• With the truck in the test/isolated position the voltage transformersecondary is isolated.

• The earthing switch can only be closed when the truck is in thetest/isolated position.

• With the earthing switch closed, the truck cannot be moved from thetest/isolated position into the service position.

• Details of any additional interlocks, e.g. in connection with ablocking magnet on the truck and/or earthing switch operatingmechanism, can be found in the project specific documents.

• Interlock plates (optional), can be fitted so that only trucks of acertain type (eg. fuse rating or contactor type) are able to beinserted into matching panels.

The switchgear is also provided with facilities for padlocking thecontactor/cable compartment door, the contactor truck racking shaftand the earth-switch operating shaft.

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9) INSTALLATION

a) FoundationLay switchroom floor with a tolerance of ±1mm per metre in alldirections under the switchboard including a metre in front of theswitchboard with a maximum ±3mm over the entire switchboard length.To achieve these tight tolerances or to meet seismic requirements (ifapplicable) we recommend using foundation frames. ABB can providefoundation frames if required.

b) Bolting Panels TogetherPrecisely lineup shipping sections as per the project specific GeneralArrangement drawing so that each section is not more than 2mm off inall planes.

Bolt together using M8x16 (7 off), M10x16 (12 off) and M10x20 (6 off)hex-head bolts (tensile 8.8) and Belleville washers to a tighteningtorque of 25 Nm for M8 and 50 Nm for M10. Quantities and lengths ofbolts may vary for non-standard designs.

c) BusbarsClean any greasy or sticky substance off the risers and busbars with asoft dry cloth. Access to the buswork is gained by removing thepressure relief flaps above the busbar compartment.

Install busbars supplied loose across each shipping section starting atbottom bar and then continue to work upwards (figure 4). Remember tofit the joining boots (if provided). Use M10 socket head bolts (tensile8.8), nuts, spacers (when required) and two Belleville washers per boltto a tightening torque of 50 Nm.

Typical Busbar and Risermodule connections (3150A)

Figure 4

Joining boot(optional)

Busbar insulation(optional)

Busbar connection(left side)

Bus riser module

Busbar connection(right side)

Spacer

14

Replace pressure relief flaps ensuring the nylon bolts are used forfixing the rear of the pressure relief flap only.

d) Power Cable ConnectionRemove the contactor truck from the panel and remove the partitionplate between the contactor and cable compartments for easier accessby unscrewing the four socket head bolts (indicated by the red circleson figure 5). Remove the cable gland plates from the bottom of thecubicle and terminate the cables on the cable module using anappropriate HV cable termination kit. Cut gland plates to fit around thecable and refit to cubicle base. Connect the cable earth and seal anyremaining gaps with elastic sealing compound to prevent ingress of dirtor vermin.

With partitionplate fitted

Without partitionplate fitted

Figure 5

Gland plate

Partition plate

CableTermination

Module

Earth bar

Cable Screen

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e) Control Cable ConnectionFeed control cables through the smallentry gland (figure 6), which is in thefront left hand side of the cubicle baseplate. Run the cables up the verticalduct, through the grommets in the baseof the instrument compartment into theterminals nominated by the controlschematic.Provision for top control cable entry intothe instrument compartment is optional.

f) EarthingJoin the inter-panel earthing bar locatedin the front of the cable compartment(figure 6) between each shippingsection with the connecting link suppliedloose. Connect one point of this inter-panel earthing bar with the substationearth.

g) Connecting to UniGear type ZS1Where a UniGear type ZS1 panel isbolted to a UniGear type ZVCpanel, special transition busbarsand earthing bars will be suppliedloose. Bolt panels together asdescribed previously. Quantitiesand lengths of bolts may vary fordesigns other than this basic one.Three additional cover plates (figure7) required to seal the UniGear typeZS1 bus compartment are suppliedfor each UniGear type ZS1 toUniGear type ZVC transition.

For bolting alongside other designsof switchgear, contact ABB for thefeasibility of preparing the design.

Control Cable EarthingDuct Bar

Figure 6

UniGear typeZS1 cover

plates

Figure 7

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10) OPERATION

a) Earth switchEnsure the withdrawable contactor truck is inthe test position or removed from the panel.Remove the padlock from the blocking platecovering the earth switch operating screw. Tooperate the earth switch, ensure that thecontactor/cable compartment door isclosed, insert the operation handle in theearth switch operating hole and turn in thedirection indicated on the label (figure 8). Theearth switch status is shown in the labelwindow.

b) ContactorSwitching of the contactor is carried out viathe control features fitted to the instrumentcompartment. The contactor status isindicated on the front of the contactor (figure9) and can be viewed through the top viewingwindow. Switching operations can only becarried out with the withdrawable contactor inservice or in the test position. We highlyrecommend that all switching be donewith the front door closed.

For a mechanically latched contactor(optional), manual emergency tripping isachieved by using the special rod provided tooperate the emergency manual trip operator(figure 10) fitted on the withdrawablecontactor.

Figures 8, 9 & 10

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c) RackingTo rack the contactor truck from test positioninto service ensure the following:• The contactor truck is locked using the bit

key provided.• The contactor compartment door is closed• The earth switch is off• The contactor is off• The padlock is removed from the blocking

plate covering the racking hole.

Insert the racking handle in the rackinghole and rotate the handle 14 revolutionsclockwise (figure 11). While in service thecontactor compartment door cannot beopened and the earth switch cannot beclosed.

To rack the contactor truck out of serviceinto its test position please ensure thecontactor is off. Insert the racking handle inthe racking hole and rotate the handle 14revolutions anti-clockwise (figure 11).

Where a voltage transformer (installed on thecontactor truck) powers the control circuit,please note that this supply is active onlywhen the contactor truck is in service. Ifsupply is required to this circuit under otherconditions we recommend connecting atemporary test supply via terminals in theinstrument compartment

A truck position indication label (figure 12) isvisible through the top viewing glass. Pleasenote that the contactor cannot be closed whilethe truck is in an intermediate positionindicated by the yellow position indication.

Figure 11

Figure 12

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d) Removal of Contactor TruckEnsure that the contactor truck is in testposition, and the earth switch is closed. Openthe contactor compartment door and move acontactor trolley in front of the panel ensuringthat its hinged part is locked into the holes inthe partition plate under the contactor truck.Unlock the contactor truck using a bit key(figure 13) and pull the contactor truck ontothe trolley using the handle on the front of thecontactor truck. Lock the contactor truckonto the trolley and unhinge the trolley fromthe partition plate. The trolley and thecontactor truck can now be moved away fromthe panel.

e) Insertion of Contactor TruckOpen the contactor compartment door andmove a contactor truck and trolley in front ofthe panel ensuring that its hinged part islocked into the holes in the partition plateunder the contactor truck. Unlock thecontactor truck using a bit key (figure 13) andpush the contactor off the trolley into thepanel. Lock the contactor truck into the panel,unhinge the trolley from the partition plate andremove the trolley.

f) Fuse OperationWhen any fuses are healthy the fuse conditionindication label (figure 14) is green. On fuse operationthis label changes to “BLOWN” on a red background.An adjacent label (figure 15 – typical fuse rating) fittedon the truck shows the fuse rating.

Figure 13

Figures 14 & 15

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11) MAINTENANCE

a) GeneralMaintenance serves to preserve trouble-free operation and achieve thelongest possible working life of the switchgear. It comprises thefollowing closely related activities:

Inspection: Determination of the actual conditionServicing: Measures to preserve the specified conditionRepairs/Replacement: Measures to re-establish the specifiedcondition.

Note: Maintenance work must be carried out in a careful manner bytrained personnel familiar with the characteristics of the individualswitchgear installation, in accordance with all relevant safety regulationsto AS/IEC and of other technical and statutory authorities, together withother overriding instructions. It is recommended that ABB servicepersonnel are called in to perform servicing and repair work, and forsome of the work described in greater detail, this is essential.

The inspection and servicing intervals for some of theequipment/components (e.g. parts subject to wear) are determined byfixed criteria such as switching frequency, length of service and numberof short-circuit breaking operations. For other parts, the length of theintervals may depend, for example, on the different modes of operationin individual cases, the degree of loading, and also environmentalinfluences (including pollution and corrosive atmosphere).

The equipment operating instructions must also be observed togetherwith this instruction manual in the individual cases concerned.

Further details can be taken from the technical documentation for theswitchgear installation (including, for example any agreed specialoperating conditions).

b) Inspection and servicingInspection and servicing of the switchboard should be carried outapproximately every one to five years, depending on the operatingconditions and local environment. We recommend logging allswitchgear maintenance.

The inspection should include but not be limited to the following:

• Electrically isolate the area where work is to be carried out andsecure it against reconnection.

• Check the installation for abnormalities of any kind, dirt and theeffects of other environmental influences.

• Check the function of the switch equipment, the controls, interlocks,protection, indicators and other devices.

• Check the surface condition of the isolating contact system for anydamage and retighten the fixing screws. The tulip contacts are

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fixed with hexagon socket head cap screws M10. After cleaning,lightly grease the contact faces.

• Contact parts which are corroded or show signs of other damage oroverheating should be removed and replaced.

• Check all switchgear accessories and the auxiliary equipment suchas indicating lamps and the anti-condensation heaters.

• No external discharge may occur on the insulating material surfacesof equipment at operating voltage. This can, for example, bedetected by characteristic noises, a clearly perceptible smell ofozone, or visible glowing in the dark.

Basic servicing activities, and those which may be found necessaryduring inspections, including the following:

• Carefully clean the unit, and in particular the insulating materialsurfaces, when they are found to be dirty. Remove dry dustdeposits using a soft dry cloth. For more strongly adhering deposits,e.g. sticky/greasy dust, use a cloth soaked in slightly alkalinehousehold cleaner. Wipe off with clean water and dry carefully.Alternatively, use a safety cleaner with a fluoride hydrocarbon base(check for compatibility with plastics and elastomers) Do not useeither trichlorethane, trichlorethylene, or carbon tetrachloride.

• Should external discharges occur as a result of condensation,application of a thin silicone film on the surface concerned is ofteneffective as a temporary remedy. It is advisable to seek advicefrom ABB on permanent solutions to such unusual problems.

• Close the contactor and measure the distance between the nut andthe washer on the moving end of the vacuum bottle. For newvacuum bottles this gap is 1mm. When this gap is reduced to zeroplease contact ABB to arrange refurbishing of the truck.

• Check that the bolt connections at the contact points in the busbarsystem and the earth connections are tight, and that the rackingoperation functions correctly.

• Replenish the grease on the contact points and mechanism of thetruck racking system. When lubrication is inadequate or missing,thoroughly clean the areas concerned and regrease with IsoflexTopas NB52.

• Replenish the grease on the sliding and bearing surfaces in thecubicles – including the shutters, the interlock and guide systems,the spindle mechanisms and the switch truck wheels. Wherenecessary, thoroughly clean and regrease with Isoflex Topas NB52lubricant.

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c) Repairs/ReplacementUniGear type ZVC is maintenance free switchgear. Please contactABB in the event of an equipment failure for replacements.

i) Recommended Spare parts• Complete truck• Trip coil• Feeder unit• Fuses

ii) Corrosion RepairRepair work is to be carried out immediately after a defect has beendiscovered. All rust is to be removed from damaged paintwork areas onsteel sheet and other steel parts mechanically. Lightly grind thesurrounding paint coat and carefully degrease the entire area. Thenimmediately apply an anti-rust primer and, after an appropriatehardening period, apply the topcoat. The total dry film thicknessshould be approx. 60 um.

Only use suitable and compatible paint products. Topcoat is standardcolour light grey RAL 7035 or the relevant special colour.

iii) Trip Coil Replacement (figure 16)Undo the three screws (1) attaching the microswitches’ mounting plateto the truck traverse (on the left-hand side of the truck looking from thefront). Slide trip coil out of the trip operating mechanism (2), disconnectits wires and remove the two screws holding it to the mounting plate(3). Fit the new trip coil reversing the steps taken in the removalprocess.

Trip Coil

(1) Remove thesethree screws

Figure 16

(2) Slide trip coil outof operating mech.

(3) Remove thesetwo screws

MountingPlate

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iv) Feeder Unit Replacement (figure 17)Undo the two screws holding the feeder unit to the truck (on the right-hand side of the truck looking from the front). Remove feeder unit fromthe truck and disconnect its wires. Fit the new feeder unit reversing thesteps taken in the removal process.

v) Fuse Replacement (figure 18)If a fuse is blown we recommend that all fuses on the truck arereplaced. Unbolt the four screws connecting each fuse to the mouldingand remove each fuse. Replace with new fuses ensuring that the fuse’sstriker pin is nearest the front of the truck and the majority of the fuse isfacing into the moulding. Where two fuses per phase are used, thefuses are fitted, in the same way, back-to-back.

Feeder Unit

Remove thesetwo screws

Figure 17

Fuses

Remove thesefour screws (for

each fuse)

Fuse striker tothis end (front)

Figure 18

SINGLE FUSE

PARALLEL FUSE25NM

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12) TROUBLESHOOTING

a) Truck cannot enter cubicle.

i) Inhibited by current interlockSelect contactor truck of correct current rating.

ii) Racking mechanism not closed against the front of the truck.Rotate racking handle to the anti-clockwise stop.

b) Truck cannot be locked in cubicle.

i) Earth switch open.Close earth switch.

c) Truck cannot be racked in.

i) Handle not fully engaging the racking screw shaft.Push firmly on the handle. Maintain positive forward pressure on thehandle during rotation.

ii) Truck locking bars not fully extended.Rattle the truck in position and make sure the key spindle pops out atthe clockwise stop.

iii) Shutters padlocked.Remove padlocks.

iv) Front door not completely closed.Tighten door screws.

v) Earth switch is closed.Open earth switch.

vi) Racking hole padlockedRemove padlock.

d) Truck cannot be removed from cubicle.

i) Truck not fully in isolated/test positionRotate racking handle to anti-clockwise stop.

ii) Truck locked in cubicleUnlock truck.

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e) Vacuum contactor cannot be closed.

i) Racking operation not completed. (mechanical and electrical block)Rotate handle fully to stop.

ii) Secondary control plug damaged.Check secondary control plug for damage.

iii) No control supply available.Check control fuses.

iv) Fuse blown auxiliary switch not reset.

v) Vacuum contactor auxiliary switches inoperative.Check operation of auxiliary switches. Replace if necessary.

vi) Open circuit close coil.Contact ABB to replace close coil.

f) Earth switch cannot be closed

i) Earth switch operating hole cover is padlocked.Truck is not fully in isolated/test position.

25

ABB Australia Pty LimitedBapaume Road Moorebank 2170 NSWAustraliaLocked Bag 7315 Liverpool BC NSW 1871Phone +61 (0) 2 9821 0111Fax + 61 (0) 2 9602 2454Internet address: www.abb.com.au

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