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ABB ZS1 Instruction Manual
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ABB ZS1 Instruction Manual

ABB ZS1 Instruction Manual

Air-insulated medium voltage switchgear, 12 kv/17.5 kv
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ZS1
Air-insulated medium voltage switchgear, 12 kV/17.5 kV
Instruction manual BA 372/04 E
ABB Power Distribution
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Summary of Contents for ABB ZS1

  • Page 1 Air-insulated medium voltage switchgear, 12 kV/17.5 kV Instruction manual BA 372/04 E ABB Power Distribution...
  • Page 2 Your safety first – always! That's why our instruction manual begins with these recommendations: • Only install switchgear and/or switchboards in enclosed rooms suitable for electrical equipment. • Ensure that installation, operation and maintenance are carried out by specialist electricians only. Comply in full with the legally recognized standards (DIN VDE / IEC), the •...
  • Page 3 Resistance to internal arc faults Laying the ring circuits Dimensions and weights 5.10 Final erection work Panel design and equipment Operation of the ZS1 switchgear Basic structure and variants Start-up Enclosure and partitioning 6.1.1 Preparatory work 3.2.1 Ventilation of the panels 6.1.2 Start-up...
  • Page 4 We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual – or extracts – to third parties is prohibited. The information supplied is without liability. Subject to alteration. © ABB Calor Emag Mittelspannung GmbH, 2001 ABB Power Distribution...
  • Page 5 The switchgear are basically suitable for normal The metal-clad, three-pole air-insulated panels operating conditions for indoor switchgear and without disconnectors from type ZS1 for rated controlgear in accordance with VDE 0670, Part voltage of 12 kV and 17.5 kV are factory- 1000 (IEC Publication 60694).

  • Page 6: Technical Data

    Special DC voltage on request. Take the short-circuit withstand capability of the instrument transformers into account separately. For data on the individual switching devices, see ABB switchgear handbook or the instruction manual for the switching device concerned, as listed under 7.1.
  • Page 7 The minimum ceiling height in the switchroom is 3000 mm. Further details of the switchroom design can be found in figures 5/1 to 5/4. Weights: Feeder panel (including withdrawable circuit-breaker part) Weight Rated current Rated short-time current …31,5 kA …50 kA …1250 1600 2000 1200 1200 2500 1200 1200 3150 1200 1200 4000 1400 1400 ABB Power Distribution...
  • Page 8 With ZS1 panels it is possible to set up a double The control cabinet for the secondary equipment is busbar installation in accordance with the two completely protected from the high voltage area breaker method.
  • Page 9 12. Also casing, with a SF6 circuit-breaker or vacuum included are the metal shutters 12.1 which cover contactor (both fabricated by ABB Sace). the insertion openings. The shutters are opened by means of the actuating bars 13.16 of the...
  • Page 10 If the secondary devices are not intended for door no control voltage is applied and cannot be installation, they are mounted on perforated metal closed (electromechanical interlock). sheet 37.3. This is stored folded-up to enable any ABB Power Distribution...
  • Page 11 The emergency manual switch is not locked! The blocking magnet is not installed in the case of a motor drive; busbar earthing switches or the withdrawable parts are electrically locked. The emergency manual switch is not locked! ABB Power Distribution...
  • Page 12 4 Incoming feeder 12 kV, 2000 A, 31,5 kA 9 Outgoing feeder 12 kV, 630 A, with switch- with busbar earthing switch in top mounted box disconnector and fuses ABB Power Distribution...
  • Page 13 1800 Figure 3/2: Erection of the ZS1 switchgear in two rows *) Make allowance for the floor thickness Busbar sectionalizing connection with insulated busbar capacitance grading device 1 Busbar sectionalizing 2500 A 2 Bus riser panel with withdrawable metering unit 1800 Dimension dependent on switchroom volume and short-circuit current.
  • Page 14 1300 1800 1300 a) Installation front to front 1200 2608 1200 b) Installation back to back Figure 3/4: ZS1 Duplex switchgear 12 kV, 1000 A, 31,5 kA Double busbar switchgear according to the two-breaker method ABB Power Distribution...
  • Page 15 49.1 49.2 12.1 20.3 20.2 Figure 3/5: ZS1 Feeder panel 12 kV, 1250 A, 31.5 kA A Busbar compartment Earthing switch B Circuit-breaker compartment Current transformer C Cable compartment Voltage transformer D Control cabinet Intermediate wall Busbar rear wall Mounting plate 12.1 Shutter...
  • Page 16 Figure 3/9: Circuit-breaker compartment with withdrawable part Figure 3/8: Circuit-breaker compartment with withdrawable part 2500 A in disconnected position 1250 A in disconnected position Horizontal partition with ventilation wall 10.2 Control wiring plug 20.2 Air vents 13.17 Front plate Mechanical circuit-breaker operation ABB Power Distribution...
  • Page 17 17.2 Reducer ring 16.1 Cable screen Cable connecting bar Floor covering 43.4 Lateral covering of the internal control wiring 17.2 Reducer ring Heating plate Main earthing bar 19.1 Connecting link 43.2 Lateral covering of the external control wiring ABB Power Distribution...
  • Page 18 10.4 Auxiliary switch for control wiring plug 37.4 Terminal-strip holder 37.4 Terminal-strip holder 37.5 Screw for terminal-strip holder 14.9 10.2 10.1 Figure 3/16: Mechanical plug interlock Figure 3/17: Lock for earthing switch manual mechanism. 10.1 Socket 14.9 Padlock 10.2 Plug Interlock lever ABB Power Distribution...
  • Page 19 VD4 auxiliary switches 13.9 Protective cap used during transport Test position indicator (remove before putting into service) Service position indicator 13.13 Lifting lug 10.3 Control wiring plug connection for the withdrawable (remove before putting into service) assembly ABB Power Distribution...

  • Page 20: Despatch And Storage

    Condition on delivery • crane, At the time of despatch, the ZS1 panels are • fork-lift truck and/or factory-assembled, the withdrawable parts inser- • manual trolley jack.
  • Page 21 Note: Do not walk on the roof of the panels (rupture points in pressure relief devices)! ø 35 60° 1.18 Figure 4/1: Handling by crane Lifting lug 1.18 Marking on the centre of gravity ABB Power Distribution...
  • Page 22 Site requirements documents are compiled, the binding data On commencement of installation at site, the supplied by ABB Calor Emag must always be taken switchroom must be completely finished, provided into account! with lighting and site electricity supply, lockable, dry The stipulations of DIN 43 661 are also to be and with facilities for ventilation.
  • Page 23 5/9) • Enter jacking screws 60.8 and place steel strips For local erection of the ZS1 switchgear bolts of 60.4 below them. tensile strength class 8.8 are supplied in all cases. • Carefully align the foundation frame horizontally...
  • Page 24 Isoflex Topas NB 52. ABB Power Distribution...
  • Page 25 • M10 connection points earth connections of the cable screens. • The push-rod of the auxiliary switch must still have about 0,5 mm to go to the end position in the operated position. ABB Power Distribution...
  • Page 26 • Connect the earthing conductor coming from the earth electrode, preferably via a removable bolted link for testing purposes, to the main earthing bar 19 of the switchgear. ABB Power Distribution...
  • Page 27 14 Door 6 Control cabinet, optional 15 Busbar metering or busbar earthing 7 Absorber 16 Wall opening for pressure relief 8 Opening for ventilation 17 Pressure relief duct 9 Height of cable basement as required 18 Diverter ABB Power Distribution...
  • Page 28 650/800/1000 mm panel width: 650/800/1000 mm Section D - D Section C - C 1300 FT + 700 FT + 700 ZS1: > 25kA ZS1: > 25kA 1300 (80) 1075 (80) 1075 FT + 200 FT + 200...
  • Page 29 Control cabinet, optional 14 Door Absorber 15 Busbar metering or busbar earthing Opening for ventilation 16 Wall opening for pressure relief Height of cable basement as required 17 Pressure relief duct 10 Covering, site supply 18 Diverter ABB Power Distribution...
  • Page 30 Section C - C FT + 700 1300 FT + 700 FT + 200 FT + 200 ZS1: > 25kA ZS1: > 25kA 1300 1175 1175 Figure 5/4c: Switchgear with pressure relief to the outside, Figure 5/4d: Switchgear with pressure relif duct and diverter,...
  • Page 31 Figure 5/5: Assembly of the foundation 60.7 frame 60.1 Foundation frame part 60.2 Foundation frame part 60.8 60.3 Link 60.4 Steel strip 60.5 Bracket 60.6 Dowel 60.4 60.7 Bolt M10x25 60.8 Jacking screw h Screed height 50 to 60 mm 60.6 ABB Power Distribution...
  • Page 32 Aperture, for the main earthing bar Bore Lifting lug Threaded bush, for switchgear assembly 1.11 Bore, for control wiring bushing 24 Shim, to be inserted above the opening when bolting together panels without busbar partitioning ABB Power Distribution...
  • Page 33 Figure 5/9: Arrangement of the bushing plate and busbar bushings on the right-hand panel side wall in bus tie panels. View of the inside 28.2 Bushing plate 29.1 Busbar support for single conductor 29.2 Busbar support for double conductor 29.4 Busbar bushing ABB Power Distribution...
  • Page 34 Spacer plate, 15 mm thick “Junction“ bag group, part number GCE 800 6131R0103 “Junction“ bag group, part number GCE 800 6131R0104 “Junction“ bag group, part number GCE 800 6131R0105 “Junction“ bag group, part number GCE 800 6131R0106 ABB Power Distribution...
  • Page 35 Cutting location for tee-off conductor tee-off conductor system 2 x 100 x 10 system 2 x 100 x 10 Figure 5/12: Insulating covers for busbars Insulating cover 58.1 Support for cover 58.5 Lid (for 17.5 kV only) ABB Power Distribution...
  • Page 36 28 (observe the notes in section 5.5.1). 28.3 Partitioning (non-standard; equipment on request) Top mounted box with voltage transformer 79.1 Intermediate box 79.2 Conductor tube 79.3 Reducer ring ABB Power Distribution...
  • Page 37 28 (observe the notes in section 5.5.1). Tapped plate Tee-off conductor Connection bar Spacer plate, 8 mm thick 3.10 Spacer plate, 8 mm thick Spacer plate, 5 mm thick ABB Power Distribution...
  • Page 38 The figure shows the arrangement for the open position of the earthing switch. 78.4 Limit auxiliary switch for earthing switch ON 78.5 Limit auxiliary switch for earthing switch OFF ABB Power Distribution...
  • Page 39 Figure 5/17: Top mounted box with earthing switch for busbar earthing Top mounted box of the earthing switch Operating mechanism box 78.1 Operating shaft 78.2 Slide 78.4 Auxiliary switch ON 78.5 Auxiliary switch OFF 78.6 Blocking magnet ABB Power Distribution...
  • Page 40 Figure 5/18: Pressure relief duct Rear wall busbar compartment Rear wall panel 49.3 Pressure relief flap behind 49.4 Plastic screw 50.1 Rear wall pressure relief duct 50.2 Front wall pressure relief duct 50.3 Attachment strips 50.4 Discharge grating 50.5 Absorber grating ABB Power Distribution...
  • Page 41 Figure 5/19: Cable termination in panels up to 1250 A 16.1 Cable sealing ends 16.1 Cable screen 16.3 16.2 Figure 5/20: Cable termination with pluggable cable sealing ends 16.2 Cable sealing end, size 1 16.3 Cable sealing end, size 3 ABB Power Distribution...
  • Page 42 Figure 5/22: Auxiliary switch for I limitation. It may be necessary to move the auxiliary switches into their service position when the lifting lugs have been removed. 11.5 I limiter 49.2 Pressure relief flap, centre 49.4 Rupture bolt (plastic) ABB Power Distribution...
  • Page 43 • Set the protective devices in the panel to the Operation of the ZS1 switchgear required values, and check their functioning with The relevant work and operating procedures are to test equipment. be carried out carefully by trained specialists familiar •...
  • Page 44 • Carry out the procedure as described above for range between the service and test positions. For withdrawal, changing the order accordingly. deblocking, see section 7.5.5. ABB Power Distribution...
  • Page 45 Close breaker Open breaker – Move withdrawable part into test/disconnected position Test switching of the circuit-breaker without primary voltage can be carried out with the withdrawable part in the test position (with the control wiring plug fitted). ABB Power Distribution...
  • Page 46 Automatic charging On-Off Close breaker... Off-On-Off or auto- reclosing sequence automatically (re)charge Test switching of the circuit-breaker without primary voltage can be carried out with the withdrawable part in the test position (with the control wiring plug fitted). ABB Power Distribution...
  • Page 47 To (Figures 3/5, 3/13, 6/13 and 6/14) disengage the motor-operated mechanism, first Earthing switches of type EK6 are used in ZS1 move the operating lever further in the previously switchgear. The earthing switch has a snap-action...
  • Page 48 For indirect operation (by fuse or electrical release), the opening Emergency manual operation: operation results in different posi- If a fault occurs in the motor-operated mechanism, tions for the switch and mecha- the switch-disconnector and earthing switch can nism. ABB Power Distribution...
  • Page 49 VDE 0682 Part 415 or IEC 61243-5. The two systems differ in several respects, • Secure neighbouring live areas (e.g. including different voltage levels which constitute possibly the feeder cables) to prevent the display thresholds. The capacitive voltage inadvertent contact. ABB Power Distribution...
  • Page 50 Test procedure: procedure (only)! • Only use phase comparators which comply with • Disconnect any voltage transformers and cover the IEC and VDE standards and are of suitable with an insulating plate. ABB Power Distribution...
  • Page 51 Figure 6/4: Operation and annunciation via digital control system of the univeral key in the crank position Measuring sockets (LRM-system) 1.8 Screw-type door catch, on the doors of the high- 30.1 Protection cover for measuring socket voltage compartments Bay control and protection unit REF542 ABB Power Distribution...
  • Page 52 (non-standard equipment) with the service position withdrawable part in the service position 10.1 Control wiring socket 45.1 Mechanical push-button 10.2 Control wiring plug 45.2 Knob Interlock ABB Power Distribution...
  • Page 53 10.1 Control wiring socket at the correct height for the catch to engage 12.1 Shutter Earthing switch mechanism 124.1 Height adjuster 14.1 Operating shaft 124.2 Guide pin Right-hand travel rail 124.3 Catch 43.3 Duct cover, top right ABB Power Distribution...
  • Page 54 Figure 6/15: Panel with switch-disconnector and fuse assembly Figure 6/16: Lower shutter secured with padlock to prevent unauthorized operation Switch-disconnector 35.1 Switch-disconnector operating mechanism Lever for shutter operation Insulating protection plate Padlock 43.4 Duct cover for internal wiring ABB Power Distribution...
  • Page 55 Actuating bars (1 pair), removable Warning label 12.1 133.3 Figure 6/19: Earthing at the top contact pins in a 800 mm or 1000 mm wide panel 12.1 Shutter Test / earthing module 133.3 Insulating rod Warning label ABB Power Distribution...
  • Page 56 20.3 Flap 20.4 Leaf spring 20.5 Inspection opening Figure 6/22: Horizontal partition with additional ventilation facilities 20.6 Bracket checking of unimpedeed motion of the internal flap 20.3 20.7 Centrifugal fan 20.5 Inspection opening ABB Power Distribution...

  • Page 57: Maintenance

    • Inspection is primarily to constitute a visual and with other overriding instructions. It is re- check for grime, corrosion and moisture: commended that ABB service personnel be called in – Effects of high temperature on the main to perform servicing and repair work, and this is circuits, necessary for some of the work detailed below.
  • Page 58 716. rotor. • Observe the manufacturers’ directions and in d) Check the unimpeded function of the wind particular ABB Instruction manual BA 1002/E vane and microswitch by starting the fan and BA 1006/E on safety at work. several times. • Wipe down after cleaning, using clean water, e) The wiring to the removable horizontal and dry properly.
  • Page 59 13.25 must be 2 must not be changed by the improper use of force. The distance between roller 13.24 and angle lever 13.92 must be 0.5 mm. – Loosen bolts 13.91.2 or 13.92.1 for any necessary adjustment. ABB Power Distribution...
  • Page 60 14.2 then fitted) immediately after the In test operations, the withdrawable part must be toggle spring mechanism has passed the moved by hand with the crank fitted with the motor dead centre position during rotation to the power switched off. OFF position. ABB Power Distribution...
  • Page 61 Do not forcibly move blocked withdrawable service position when the circuit-breaker is open parts! The blocking magnet Y0 is only present on and the earthing switch is open. manually operated withdrawable parts. ABB Power Distribution...
  • Page 62 Standard colour RAL 7035 must be operated immediately after the dead • 1kg-box GCE9014060R0103 centre position of the toggle spring mechanism • Spray tin GCE0007895P0100 is reached in the closing process and the automatic quick-closing process has started. ABB Power Distribution...
  • Page 63 Contact arm removed Contact system Internal tension springs 10.3 Control wiring plug connector for withdrawable (4.5) Socket head bolt assembly Insulating sleeve 13.2.1 ON push rod Arbor 13.24 Roller 13.26 Lever 13.92 Angle lever Hand crank ABB Power Distribution...
  • Page 64 11.3 Auxiliary switch Q8S1, earthing switch OFF 11.4 Auxiliary switch Q8S2, earthing witch ON 11.4 Auxiliary switch Q8S2, earthing switch ON 14.1 Operating shaft 14.1 Operating shaft (earthing switch) 14.2 Slide 14.6 Blocking disc 14.3 Cam plate, adjustable 14.7 Cam ABB Power Distribution...
  • Page 65 13.24 Roller 13.25 13.25 13.26 Lever 13.26 Lever 13.27 13.27 13.90 Travel motor 13.91 Link rod 13.91 Link rod 13.91.1 Bolt 13.91.2 Bolt 13.91.1 Bolt 13.91.2 Bolt 13.92 Angle lever 13.92 Angle lever 13.92.1 Bolt 13.92.1 Bolt ABB Power Distribution...
  • Page 66 ABB Power Distribution...
  • Page 67 ABB Calor Emag Mittelspannung GmbH ABB Sace T.M.S. S.p.A Oberhausener Straße 33 Petzower Straße 8 Via Friuli, 4 D-40472 Ratingen D-14542 Glindow I-24044 Dalmine Phone: +49(0)21 02/12-12 30, Fax: +49(0)21 02/12-19 16 Phone: +39 035/395111, Fax: +39 035/395874 E-Mail: calor.info@de.abb.com E-mail: sacetms.tipm@it.abb.com...