ABB ZX0 User manual

•Greener
•Smarter
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—
PRODUCT MANUAL
PrimeGear ZX0
Gas-insulated medium voltage switchgear

04
05
08
11
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59
64
65
66
68
69
70
Your safety first - always!
Standards, regulations, notes, further
documents
1. Dispatch and storage
2. Installation of the switchgear at site
3. Commissioning
4. Operation
5. Test procedures
6. Service
7. Actions at the end of the service life
8. Overview of the busbar parts and assemblies
9. List of tools
10. Working materials, auxiliary materials and
accessories
11. Technical data
—
Table of contents

—
Your safety first - always!
4PrimeGear ZX0 PRODUCT MANUAL
That‘s why our instruction manual begins with
these recommendations:
•Operate the switchgear as prescribed for its
intended purpose.
•Ensure that the technical data on the name plate
and in the specification are not exceeded during
operation of the switchgear.
•Only install the switchgear in enclosed rooms
suitable for electrical equipment.
•With the aim of a smooth installation sequence
and ensuring a high-quality standard, have
installation at site performed by specially trained
personnel or managed and supervised by the
ABB Service Department.
•Ensure that installation, operation and
maintenance are only performed by specialist
electricians familiar with this manual.
•Comply in full of the legally recognized
standards (IEC/DIN VDE/GB), the connection
conditions of the local electrical utility and the
applicable safety at work regulations.
•Follow the instructions in the documentation
when performing any work on switching devices
and switchgear.
•Keep all documentation accessible to all persons
concerned with installation, operation and
maintenance.
•The user’s personnel bear unlimited responsibility
in all matters affecting safety at work and the
correct handling of the switchgear in accordance
with EN 50110 and national regulations.
•Always observe the five safety rules set out in
EN 50110 on establishing and securing the off-
circuit condition at the place of work for the
duration of work on the switchgear. Gas-insulated
switchgear are notable for maximum safety, as
the circuit breaker performs the earthing switch
function in conjunction with the three position
disconnector. The sequence of safety rules
therefore deviates from that proposed in the
standard as follows.
Isolate,
Check the off-circuit condition,
Earth and short-circuit,
Secure to prevent reconnection,
Cover or guard off adjacent live parts.
If you have any further questions on this manual,
the members of our field organization will be
pleased to provide the required information.

STANDARDS, REGULATIONS, NOTES, FURTHER DOCUMENTS 5
—
Standards, regulations, notes, further
documents
The relevant standards for switchgear over 1 kV and their switching devices
Switchgear
Switchgear
Circuit breaker
Disconnector and earthing
switch
Switch disconnector – fuse
combination
HRC - fuses
IEC
62271-1
62271-200
62271-100
62271-102
62271-105
60282
GB
GB/T 2011
GB 3906
GB 1984
GB 1985
Common specifications for high-voltage switchgear and
controlgear standards
High-voltage switchgear and controlgear, Part 200: A.C.
metal-enclosed switchgear and controlgear for rated voltages
above 1 kV and up to and including 52 kV
High-voltage switchgear and controlgear
Part 100: High voltage alternating current circuit breakers
High-voltage switchgear and controlgear
Part 102: Alternating current disconnectors and earthing switches
High-voltage switchgear and controlgear
Part 105: Alternating current switch-fuse combinations
High-voltage fuses - Part 1: Current-limiting fuses
Take particular account of the relevant standards listed below. Observe the national technical specifications and the accident
prevention regulations of the country in which the switchgear is operated and the safety data sheets for the used auxiliary
materials.
IEC 60364
IEC 61936
DIN EN 50110
National technical accident prevention regulations e.g. for electrical systems and equipment and SF6installations
Safety data sheets for auxiliary materials
Low-voltage electrical installations
Power installations exceeding 1 kV a.c.
Operation of electrical installations
Fundamental notes on this manual
Read the relevant sections of this manual through
in full before performing work, so as to ensure
correct handling.
Paragraphs in this manual are marked in
accordance with their significance. The markings
mean the following:
Hazard warning, meaning in this manual
that death or serious injury and
considerable damage may occur if the
actions described are not performed.
Important note, meaning in this manual
that injury and damage may occur if the
actions described are not performed.
Attention is drawn to further documents.
Note on safety
The internal arc classification to IEC 62271-200 |
GB 3906 confirms a tested degree of operator
protection. The information on accessibility of the
switchgear as required by IEC 62271-200 | GB
3906 can be found on the name plate of the
panels. The coding is as follows (example):



6PrimeGear ZX0 PRODUCT MANUAL




IAC AFLR 31.5 kA 1 sec
Duration of fault current
Level of fault current
Successfully tested accessibility of the area behind the switchgear
(R - rear)
Successfully tested accessibility of the area to the side of the
switchgear (L - lateral)
Successfully tested accessibility of the area in front of the
switchgear (F- front)
Switchgear installed in closed rooms with access restricted to
authorized personnel
Internal arc classification
The operator of the switchgear must
prevent access by personnel to non-arc
classified areas, for instance by issuing
instructions.
Within the ratings stated on the name
plate, the switchgear is safe for
operating personnel in accordance with
IEC 62271-200 | GB 3906 when all system
components are completely and properly
installed.
Commissioning, servicing and extension
work require special attention with regard
to safety (see also IEC 62271-200 | GB 3906).
Operator safety in accordance with IEC 62271-200
| GB 3906 assumes that the conditions stipulated
by ABB are complied with (see also Technical
Catalogue TK 1YHA000299).
The IAC qualification relies on a system consisting
of at least two panels.
You have chosen a gas-insulated switchgear of
series PrimeGear ZX0. This switchgear is notable
for the following features:
•Gas-insulated with hermetically sealed pressure
systems.
•Solid insulated busbar.
•Rated voltages up to 24 kV.
•Up to 1250 A and 25 kA.
•Single busbar design.
•Stainless steel encapsulations, manufactured
from laser cut sheet steel.
•Modular structure.
•Switchgear with a leakage rate of less than 0.1 %
per year.
•Integrated routine leakage testing of the panels
ex-works.
•Indoor installation.
•Wall mounting installation and free-standing
installation.
•Operator controls separate from low voltage
compartment.
•Operator controls on the panel accessible from
the outside.
Please observe further documents in addition to
this manual. The documents relevant to your
switchgear are part of the final documentation.
Installation checklist 1YHA000330
Order documents
•Single line diagram.
•Front view.
•Construction data if compiled specifically for
this order.
•Circuit diagrams.
•Earthing diagram – switchgear earth to station
earth (not part of ABB supply).
Instruction manuals
•Use of Air 1YHA000334
•Use of AirPlus 1YHA000300
•Use of SF6insulating gas 1YHA000333
•Circuit breaker VD4X0 1YHA000331
•Material supplement BA 509
Operating instructions and directions for
components, e.g.
•Surge arresters.
•Current and voltage transformers.
•Current and voltage sensors.
•Protection and control devices.
•Capacitive indicators.
•Solid insulated busbar.
•VT cable.

STANDARDS, REGULATIONS, NOTES, FURTHER DOCUMENTS 7
—
Fig. 3: Circuit breaker
panel, 1250 A, panel
width 600 mm,
example
configurations
In order to prevent accidents (particularly
injury to hands!) extreme care should be
taken during all repair work on the
operating mechanism, especially with
front plate removed.
The spiral spring in the spring energy storage
mechanism, for instance, retains a basic tension
which is independent of the charging and
discharging processes during switching, so as to
ensure correct function. This spring energy can be
inadvertently released if work is performed
incorrectly on the spring mechanism!
Wear appropriate work clothes and
protective gloves during the installation
work to avoid injuries particularly at
sharp-edged sheet metal parts of the
switchgear.
Use only chlorine-free cleansers for
cleaning of the switchgear.
1.0 Gas compartment
1.1 Circuit breaker pole
1.2 Circuit breaker operating mechanism
1.3 Outer cone bushing
1.5 Socket for capacitive indicator system
1.9 Current transformer
1.10 Gas density manometer
1.11 Gas filling valve
1.12 Cast resin bushing to busbar
1.13 Pressure relief disc
2.1 Busbar
2.3 Three position disconnector
2.4 Operating mechanism for three position disconnector
—
Fig. 3
7.1
6.5
6.0
6.6
2.1
1.10
1.11
6.10
1.5
2.4
1.9
3.1
3.2
3.3
3.6
1.12
2.3
1.1
1.0
1.13
1.3
3.5
3.0
7.0
6.5
6.0
6.6
2.1
6.10
1.5
2.4
1.9
3.1
3.2
3.3
3.6
1.10
1.11
1.12
2.3
1.1
1.0
1.13
1.3
3.5
3.0
3.0 Cable compartment
3.1 Cable connector
3.2 High-voltage cable
3.3 Cable clamp
3.5 Main earthing bar
3.6 Floor plate
6.0 Low voltage compartment
6.5 Secondary cable entry
6.6 Low voltage compartment door
6.10 Mechanism bay
7.0 Busbar cover
7.1 Pressure relief duct (optional, for pressure relief to the out side)

8PrimeGear ZX0 PRODUCT MANUAL
—
1. Dispatch and storage
1.1 Condition on delivery
The panels have been routine tested to IEC 62271-200
| GB 3906.
•In normal cases, the gas compartments have
been filled with insulating gas to the rated filling
pressure. When airfreighted, however, the panels
are delivered with reduced pressure.
•If airfreight with PrimeGear ZX0 panels is needed,
please contact ABB for further guidance.
•The individual parts of the busbars, the installation
material and accessories and the documentation
are packaged separately from the panels.
When the busbars are removed from the
packaging, do not lay them on their
silicone surfaces. As the copper is very
heavy, the silicone can be damaged even
if the components are incorrectly stored
for a short period only. Always use the
spacers supplied for storage.
1.2 Delivery
Check the consignment for completeness and
freedom from damage. Document any transport
damage found on the waybill and inform us of it
immediately. Take photographs of the damage.
1.3 Packaging
The panels have been prepared for transport by
the agreed method and for the desired duration
of any interim storage required. Details of the
length of preservation and the storage location
(indoors or outdoors) can be found in the order
documents. If the panels are packaged, they are
mounted on a pallet and secured to prevent them
from slipping.
The possible packaging methods are as follows:
•No packaging.
•Packaged in plastic sheeting.
•Packaged in plastic sheeting and surrounded by
protective cardboard.
•Heat sealed in plastic sheeting with drying
agent enclosed.
•Packaged in aluminum foil in transport crate
with drying agent enclosed.
1.4 Handling
The transport units are the panels.
Always handle the panels in the upright
position.
Take account of the weight of the transport
units when selecting the handling
equipment.
Due to the high centre of gravity of the
panels, there is a risk that the transport
units may tip over! Take all precautions to
protect personnel and the materials
transported. When using hydraulic lift
trolleys to transport panels of 450 mm
width or during positioning of the panels
on the foundation rails, there is a high risk
of them tipping. Therefore always fit lateral
support plates as shown in Fig. 1.4.3.1 to
prevent them from doing so.
Only ever handle the panels by
•forklift truck.
•trolley jack.
•crane, or.
•hydraulic lift trolley (Support plates required for
panels of 450 mm width!).
1.4.1 Handling by forklift truck or trolley jack
The panels must each be mounted on a
pallet and secured with straps. The pallet
must rest fully on the forks of the truck
or jack. The high centre of gravity means
there is a high risk of tipping. Avoid jerky
motions.



1.4.2 Handling by crane
•As shown in Fig.1.4.2.1, fasten one lifting
bracket each to the left and right of the roof
section and U shape parts of the panel module,
using two M12 X 30 cheese-headscrews with
dished washers & nuts and three M8 dished
washer & nuts in each case.
•Attach suspension ropes of a sufficient load
bearing capacity (see section 11, Technical data,
for the panel weights) and sufficient length to
the lifting brackets using shackles thread the
suspension ropes through the cutouts in the
rope guides. The ABB scope of supply does not
include suspension ropes and shackles.

DISPATCH AND STORAGE 9
1.1 Condition on delivery
The panels have been routine tested to IEC 62271-200
| GB 3906.
•In normal cases, the gas compartments have
been filled with insulating gas to the rated filling
pressure. When airfreighted, however, the panels
are delivered with reduced pressure.
•If airfreight with PrimeGear ZX0 panels is needed,
please contact ABB for further guidance.
•The individual parts of the busbars, the installation
material and accessories and the documentation
are packaged separately from the panels.
When the busbars are removed from the
packaging, do not lay them on their
silicone surfaces. As the copper is very
heavy, the silicone can be damaged even
if the components are incorrectly stored
for a short period only. Always use the
spacers supplied for storage.
1.2 Delivery
Check the consignment for completeness and
freedom from damage. Document any transport
damage found on the waybill and inform us of it
immediately. Take photographs of the damage.
1.3 Packaging
The panels have been prepared for transport by
the agreed method and for the desired duration
of any interim storage required. Details of the
length of preservation and the storage location
(indoors or outdoors) can be found in the order
documents. If the panels are packaged, they are
mounted on a pallet and secured to prevent them
from slipping.
The possible packaging methods are as follows:
•No packaging.
•Packaged in plastic sheeting.
•Packaged in plastic sheeting and surrounded by
protective cardboard.
•Heat sealed in plastic sheeting with drying
agent enclosed.
•Packaged in aluminum foil in transport crate
with drying agent enclosed.
1.4 Handling
The transport units are the panels.
Always handle the panels in the upright
position.
Take account of the weight of the transport
units when selecting the handling
equipment.
Due to the high centre of gravity of the
panels, there is a risk that the transport
units may tip over! Take all precautions to
protect personnel and the materials
transported. When using hydraulic lift
trolleys to transport panels of 450 mm
width or during positioning of the panels
on the foundation rails, there is a high risk
of them tipping. Therefore always fit lateral
support plates as shown in Fig. 1.4.3.1 to
prevent them from doing so.
Only ever handle the panels by
•forklift truck.
•trolley jack.
•crane, or.
•hydraulic lift trolley (Support plates required for
panels of 450 mm width!).
1.4.1 Handling by forklift truck or trolley jack
The panels must each be mounted on a
pallet and secured with straps. The pallet
must rest fully on the forks of the truck
or jack. The high centre of gravity means
there is a high risk of tipping. Avoid jerky
motions.
1.4.2 Handling by crane
•As shown in Fig.1.4.2.1, fasten one lifting
bracket each to the left and right of the roof
section and U shape parts of the panel module,
using two M12 X 30 cheese-headscrews with
dished washers & nuts and three M8 dished
washer & nuts in each case.
•Attach suspension ropes of a sufficient load
bearing capacity (see section 11, Technical data,
for the panel weights) and sufficient length to
the lifting brackets using shackles thread the
suspension ropes through the cutouts in the
rope guides. The ABB scope of supply does not
include suspension ropes and shackles.
Lifting brackets
M8 dished washers & Nuts
M12x30 cheese-head screw
with dished washers & nut
—
Fig. 1.4.2.1: Preparing a
panel for handling by
crane
—
Fig. 1.4.2.1

10 PrimeGear ZX0 PRODUCT MANUAL
—
Fig. 1.4.3.1: Support
plates fitted
—
Fig. 1.4.3.2: Hydraulic
lift trolley
1.4.3 Handling by hydraulic lift trolley
When moving panels of 450 mm width,
fit the lateral support plates supplied as
shown in Fig.1.4.3.1 to prevent them from
tipping. Remove the cover on the cable
termination compartment and bolt the
support plates to the side walls of the
cable termination compartment.
Attach hydraulic lift trolleys of sufficient capacity
to the front and rear of the panel in accordance
with the manufacturer’s instructions (Fig.1.4.3.2).
The high centre of gravity means there is
a high risk of tipping. Avoid jerky
motions!
1.5 Intermediate storage
•Store the panels in the upright position.
•Do not stack the panels.
•Protect the transport units from damage.
The conditions for optimum intermediate storage
without packaging or with basic packaging are
as follows:
•The storeroom must comply with the normal
operating conditions for a switchgear
installation (see IEC 62271-1 | GB/T 11022).
•Cover the unpackaged panels with protective
sheeting, remembering to preserve sufficient
air circulation.
•Prevent condensation on the panels by partially
opening the packaging and heating the
storeroom accordingly.
The conditions for optimum intermediate storage
with packaging and preservation are as follows:
•Check the packaging for damage.
•Store the transport units in a dry place protected
from the weather.
•Contact us if.
-the storage life of the preservation is exceeded.
-the packaging with preservation is damaged.
8 x Cheese head screw M 8 x 25
16 x Dished washer 8
8 x Nut M 8
2 x Support plate
—
Fig. 1.4.3.1
—
Fig. 1.4.3.2

INSTALLATION OF THE SWITCHGEAR AT SITE 11
—
2. Installation of the switchgear at site
2.1 Fundamental notes on installation work
2.1.1 Safety notes
In order to prevent accidents (especially
hand injuries!), extreme care is to be
exercised during all work on the operating
mechanism with the mechanism bay covers
removed.
In order to ensure correct function, the
spiral spring in the energy store of the
circuit breaker operating mechanism is
permanently subjected to a basic pre-
tension which is independent of the
charging and discharging processes during
switching. This spring energy can be
suddenly released if work is performed
incorrectly in the area of the stored energy
spring!
2.1.2 General site requirements
At the start of installation, the switchgear room at
site must be complete and fitted with lighting and
power for the installation work. It must also be
lockable, dry, and with good ventilation facilities.
All necessary provisions such as openings, ducts,
etc. for laying of the power cables must already
be in place. Compliance with the conditions for
indoor switchgear to IEC 62271-1 | GB/T 11022
must be ensured.
2.1.3 Tightening torques
Use DIN screws of tensile class 8.8. Use the
tightening torques stated in table 2.1.3.1. The
tightening torques apply to unlubricated screw
connections.
Please consult the manufacturer’s
installation instructions for the tightening
torques of cable connectors and surge
arresters.
2.1.4 Handling of insulating gases
Based on the parameter, the insulating gas is
either DryAir, AirPlus or SF6(Reference to table
11.1 )
In normal case, no gas work is required during
installation. Please contact ABB if gas work is
required in case of repairs.
See manual 1YHA000334 for details on
handling AirPlus.
See manual 1YHA000300 for details on
handling AirPlus.
See manual 1YHA000333 for details on
handling SF6. 1)
1) SF6is a fluorinated greenhouse gas with a GWP of 22800.
The maximum quantity per panel is 5 kg.
That corresponds to a CO2 equivalent of 205 t.
Each gas compartment has a gas leakage monitor, and
therefore regular leakage testing (to Fluorinated Gas
Regulation 517/2014) is not required.
2.2 Foundation frames
•When a raised false floor is used, load-bearing
sections of the floor frame serve as supports
for the panels. No additional foundation frame
is necessary.
The slabs of the raised false floor must
be fastened to the supporting frame.
•If there is a concrete floor a foundation frame is
required. Standard foundation frames supplied
by ABB must be embedded in the floor topping.
•In addition to a standard foundation frame for
conventional applications, a reinforced
foundation frame for earthquake applications is
also available. Both frames are made of
aluminum profiles. In conventional applications,
the panels are fixed in the upper slot of the
aluminum profiles by means of slot rods. In the
reinforced version, the panels are fastened with
slot rods in the lower slot of the profiles.
•For 450 mm, 500mm and 600mm wide panels,
a further version with a corresponding width is
available (see Fig.2.1.1).
Maintain the following evenness and

—
Table 2.1.3.1: Tightening torques
Nut on stud bolt
Steel screw in pulling nut
Other screws of tensile class 8.8
M 8
12.5
18 - 24
26
M 10
50
straightness tolerances when installing
the foundation frame or a raised false floor
•Evenness tolerance: ± 1 mm/m.
•Straightness tolerance: max. 1 mm/m, but max.
2 mm for the entire length.
Consult the order documents for the


position of the foundation bars in the
switchgear room.
If no standard ABB foundation frames are used,
observe the relevant construction and laying
drawings for the special frames.

12 PrimeGear ZX0 PRODUCT MANUAL
—
Fig. 2.1.1: Foundation
frames, top view
2.1 Fundamental notes on installation work
2.1.1 Safety notes
In order to prevent accidents (especially
hand injuries!), extreme care is to be
exercised during all work on the operating
mechanism with the mechanism bay covers
removed.
In order to ensure correct function, the
spiral spring in the energy store of the
circuit breaker operating mechanism is
permanently subjected to a basic pre-
tension which is independent of the
charging and discharging processes during
switching. This spring energy can be
suddenly released if work is performed
incorrectly in the area of the stored energy
spring!
2.1.2 General site requirements
At the start of installation, the switchgear room at
site must be complete and fitted with lighting and
power for the installation work. It must also be
lockable, dry, and with good ventilation facilities.
All necessary provisions such as openings, ducts,
etc. for laying of the power cables must already
be in place. Compliance with the conditions for
indoor switchgear to IEC 62271-1 | GB/T 11022
must be ensured.
2.1.3 Tightening torques
Use DIN screws of tensile class 8.8. Use the
tightening torques stated in table 2.1.3.1. The
tightening torques apply to unlubricated screw
connections.
Please consult the manufacturer’s
installation instructions for the tightening
torques of cable connectors and surge
arresters.
2.1.4 Handling of insulating gases
Based on the parameter, the insulating gas is
either DryAir, AirPlus or SF6(Reference to table
11.1 )
In normal case, no gas work is required during
installation. Please contact ABB if gas work is
required in case of repairs.
See manual 1YHA000334 for details on
handling AirPlus.
See manual 1YHA000300 for details on
handling AirPlus.
See manual 1YHA000333 for details on
handling SF6. 1)
1) SF6is a fluorinated greenhouse gas with a GWP of 22800.
The maximum quantity per panel is 5 kg.
That corresponds to a CO2 equivalent of 205 t.
Each gas compartment has a gas leakage monitor, and
therefore regular leakage testing (to Fluorinated Gas
Regulation 517/2014) is not required.
2.2 Foundation frames
•When a raised false floor is used, load-bearing
sections of the floor frame serve as supports
for the panels. No additional foundation frame
is necessary.
The slabs of the raised false floor must
be fastened to the supporting frame.
•If there is a concrete floor a foundation frame is
required. Standard foundation frames supplied
by ABB must be embedded in the floor topping.
•In addition to a standard foundation frame for
conventional applications, a reinforced
foundation frame for earthquake applications is
also available. Both frames are made of
aluminum profiles. In conventional applications,
the panels are fixed in the upper slot of the
aluminum profiles by means of slot rods. In the
reinforced version, the panels are fastened with
slot rods in the lower slot of the profiles.
•For 450 mm, 500mm and 600mm wide panels,
a further version with a corresponding width is
available (see Fig.2.1.1).
Maintain the following evenness and

straightness tolerances when installing
the foundation frame or a raised false floor
•Evenness tolerance: ± 1 mm/m.
•Straightness tolerance: max. 1 mm/m, but max.
2 mm for the entire length.
Consult the order documents for the
—
Fig. 2.1.1
position of the foundation bars in the
switchgear room.
If no standard ABB foundation frames are used,
observe the relevant construction and laying
drawings for the special frames.
600 mm 500 mm 450 mm
Rear
Front

INSTALLATION OF THE SWITCHGEAR AT SITE 13
—
Fig. 2.2.1.1: Preparing
reinforced foundation
frames
2.2.1 Installation of standard foundation frames
Standard foundation frames are delivered to site
completely preassembled.
Installation principle
The foundation frames are bolted together at the
front and rear. Vertical alignment is affected by
jacking screws. Brackets are used to fasten the
frames to the floor. The foundation frames are
finally embedded in the floor topping to provide
their load bearing capacity.
Detailed description of installation
•If reinforced foundation frames are to be
installed, slide six slot rods per frame into the
lower slots prior to installation and fix each
with a cheese head screw (Fig. 2.2.1.1). Do not
remove the protective film from the profiles.
•For the further process of assembly, observe
Fig. 2.2.1.2.
•Position the foundation frame sections in the
correct locations on the concrete floor.
•Align the foundation frame vertically with the
four screws (1), taking account of any deviation
in floor level in the direction of the foundation
frames which are still to be laid.
•Fasten the brackets (2) of the foundation frame
to the floor, using one knock-in anchor (5) and
one screw (3) with dished washer (4) for each
bracket.
•Slide one slot rod (6) into the front slot of the
front section and one into the rear slot of the
rear section. Fasten the slot rods in position by
inserting the grub screws.
•Place the following foundation frame in the
correct position on the floor, allowing the
inserted slot rods to slide into the sections of
the frame to be installed. Bolt the foundation
frames together with two M 8 x 100 cheese
head screws (7) and nuts and washers. Tighten
the grub screws in the slot rods.
•Align the foundation frame vertically as
described above and fasten it to the floor.
•Install the following foundation frames in the
same way.
•Earth the completely assembled frame. Further
details on this can be found in the order
documents.
When applying the floor topping, carefully
fill under the foundation frame with
topping material.

A
A
6 x Cheese head screw M 10 x 50
6 x Washer
6 x Slot rod
Section A-A
Washer 10
Slot Rod
Cheese head screw M 10 x 50
—
Fig. 2.2.1.1

14 PrimeGear ZX0 PRODUCT MANUAL
1
front
Rear
A
A
6
7
1
2
1
5
3
55 ± 5
< 3
2
4
*
*
Section A-A
Top of finished floor
Floor topping
*: Only in the case of reinforced foundation frames.
—
Fig. 2.2.1.2: Installation
of the floor frame
—
Fig. 2.2.1.2

INSTALLATION OF THE SWITCHGEAR AT SITE 15
—
Fig.2.3.1 location of gas
density manometer
—
Fig.2.3.2 Gas density
manometer
2.3 Assembly of the switchgear
2.3.1 Preparatory work
2.3.1.1 Checking the gas pressure in the gas
compartment
Each panel contains a gas compartment and is
fitted with a filling connector (Fig. 2.3.1.1.3). The
filling connector is located in the operating
mechanism bay behind the operator controls on
the panel.
Each panel contains a gas density manometer and
is located in the right up corner of drive cabinet.
Check the pressure in each gas compartment
before aligning and connecting the panels.
The reading must be in the green area of
the instrument’s scale. If it is not, or if
the site altitude is above 1000 m, please
contact ABB.

—
Fig.2.3.1
—
Fig.2.3.2

16 PrimeGear ZX0 PRODUCT MANUAL
—
Fig. 2.3.1.3.1: Cast resin
bushing
—
Fig. 2.3.1.3.2: Cast
resin busbar bushings
with stud bolts:
Specified dimensions
for assembled stud
bolts
2.3.1.2 Greasing the foundation bars
When a standard foundation frame supplied by
ABB is used, remove the protective film. Grease
the top surfaces of the foundation frame or
raised false floor beams. This facilitates erection
and alignment of the panels.
2.3.1.3 Preparing the panels
•Remove the covers from the cable termination
compartments on all panels.
Fitting the stud bolts for the solid-insulated
busbars
•The stud bolts are part of the busbar supply.
Use original stud bolts only.
•For 1250 A cast resin bushings, use M16/M12
stud bolts.
•Screw the stud bolts into the cast resin.
bushings on the panels until the stop is reached
(Fig.2.3.1.3.1). Tighten the stud bolts with a
torque wrench. The torque for 1250 A cast resin
bushings is 10 Nm.
•Measure the length of the stud bolts projecting
from the cast resin bushings. See Fig.2.3.1.3.2
for the specified dimensions.
1250 A
79 ±2 mm
Cast resin bushing
to busbar
—
Fig. 2.3.1.3.1
—
Fig. 2.3.1.3.2

washer 8.5 x 30 x 3 and 1 x dished washer 8) and
M 8 x 16 cheese head screws to the previously
positioned T-nuts (Fig. 2.3.2.1a and Fig. 2.3.2.2).
•Use six fastening points for panels of 450 mm,
500 mm and 600 mm width, twelve for panels
of 900 mm (Fig. 2.3.2.1).
When the cable VT is used
•For wall mounting or free-standing installation,
before panel connection, the pressure relief plate
for the cable compartment shall be removed to
have access to fasten the rear side screw on the
floor frame (Fig.2.3.2.1b and Fig.2.3.2.1c ).
When the plug-in VT is used
•For wall mounting or free-standing installation,
fasten the rear side screw on the floor frame
from the front side of panel.(Fig.2.3.2.1d ).
When a special foundation frame or raised false
floor is used
Fasten the panels in accordance with the
instruction documents supplied.
INSTALLATION OF THE SWITCHGEAR AT SITE 17

—
Fig.2.3.2.7: Fitting
guide pins
—
Fig. 2.3.2.1: Fastening
points for panels of
various widths
2.3.2 Erection of the panels
•Set up the furthest panel precisely at the
specified position.
Screw two guide pins to each of the upper brackets
of the busbar compartments on the side of the
panel to be extended, using nuts and dished
washers (see Fig.2.3.2.7).
Guide pins are only to be fitted to one of the panels
at the joint between two panels. The guide pins
remain in the relevant position after erection of
the panels and must not be removed.
Lightly grease the guide pins for better sliding.
When the standard foundation frame is used
•Insert M 8 T-nuts through the holes in the floor
plates into the slots in the foundation frame
sections. Join the floor plates using washers (1 x
A
—
Fig. 2.3.2.1a
—
Fig.2.3.2.7
Section A-A, simplified
450 mm 500 mm 600mm 450mm 500mm 600mm
Floor frame
T-nut M 8
washer, 8.5 x 30 x 3
Dished washer
Cheese head screw,
M 8 x 16

18 PrimeGear ZX0 PRODUCT MANUAL
—
Fig. 2.3.2.2: Fastening
the panel to the
conventional
foundation frame
Slot in the foundation frame section Fastening of the panel to the foundation frame T-nut, M 8
—
Fig. 2.3.2.2
—
Fig. 2.3.2.1b
Remove the
pressure relief
plate from rear
side of panel
—
Fig. 2.3.2.1c
Fasten from here
to the floor frame
—
Fig. 2.3.2.1d
Fasten the rear side screw on the floor
frame from the front side of panel

INSTALLATION OF THE SWITCHGEAR AT SITE 19

—
Fig. 2.3.2.3 a: View into
the cable compartment
of an example panel,
Fastening of the panel
on the reinforced
foundation frame
—
Fig. 2.3.2.3 b:
Fastening points of
the panels at the
corresponding
panel widths in case of
reinforced frames
Fastening of the panels when using the reinforced
standard foundation frame
•To fasten the panels, use bars for each panel as
a support, screws M 10 x 50 and washers (Fig.
2.3.2.3 a). Refer to Fig. 2.3.2.3 b for the position
and number of fastening elements.
6 x Washer 10
6 x Cheese head screw M 10 x 50
3 x Bar
—
Fig. 2.3.2.3 a
Section A-A, simplified
When a special foundation frame or raised false
floor is used
Fasten the panels in accordance with the
instruction documents supplied.
—
Fig. 2.3.2.3 b
450 mm 500 mm 1200 mm 600 mm
4
50 mm 500 mm 1200 mm 600 mm
6 x Washer 10
6 x Cheese head screw M 10 x 50
3 x Bar 390 mm

20 PrimeGear ZX0 PRODUCT MANUAL

—
Fig. 2.3.2.4: Fastening
points for panel to
panel bolting
•Carefully slide the panel to be installed up to the
panel which is already in place.
Apply drawing or pressing tools to a large
area on the panel directly above the floor
(for instance by using a wooden beam
between the tool and the panel) so as to
avoid damage to the panel.
•Check the position of the panel and align the
panel to the precise dimensions if necessary.
•Fasten the low voltage compartments, the
operating mechanism bays and the cable
termination compartments of the two panels
together at the points provided (Fig.2.3.2.4)
using screws and nuts.
•In Fig.2.3.2.4, point 1 and 2 are for panel
connection; point 3 is for end cover connection.
•Fit the coupling link at the rear of the panels.
•Fasten the panel to the foundation frame as
described above.
•Measure the centre to centre distances L of the
adjacent cast resin busbar bushings (Fig.2.3.2.5)
for all three phases. The specified dimensions
for distance L can be found in table 2.3.2.1.
•If the measured dimension L deviates from that
specified, correct the position of the panel.
1)
1)
1)
1)
1)
1)1)3)
3)
1)
1)
1)
3)
2)
1) Rivet nut, M 8 (installed on the left side of panel)
Cheese head screw, M 8 x 35 (fastened on the
right side from adjacent panel)
Dished washer, 8 (fastened on the right side from
adjacent panel)
2) Cheese head screw, M12 x 50 Nut M12, 2 x dished
washer, panel connection spacer 2RJA026473P0001
3) Rivet nut, M8 (installed on the left side of panel
for end cover connection)
—
Fig. 2.3.2.4