ABB UniGear ZS1 User manual

UniGear ZS1
Installation, service and maintenance
instruction manual

1
Your safety first – at all times!
This is why our instruction manual begins with the following recommendations:
• Only install switchgear and/or switchboards in closed rooms suitable for electrical equip-
ment.
• Ensure that installation, operation and maintenance are only carried out by specialist
electricians only.
• Fully comply with the legally recognized standards (IEC or local), the connection conditions
of the local electrical utility and the applicable safety at work regulations.
• Observe the relevant information in the instruction manual for all actions involving
switchgear and switchboards.
• Danger!
Pay special attention to the hazard notes in the instruction manual marked with this warning
symbol.
• Make sure that the specified data are not exceeded under switchgear or switchboard
operating conditions.
• Keep the instruction manual accessible to all personnel involved in installation, operation
and maintenance.
• The user’s personnel must act responsibly in all matters affecting safety at work and correct
handling of the switchgear.
WARNING
Always follow the instruction manual and respect the rules
of good engineering practice !
Hazardous voltage
can cause electrical shocks and burns.
Disconnect power, then earth and short-circuit before proceeding
with any work on this equipment.
If you have any further questions about this instruction manual, the members of our field
organization will be pleased to provide the required information.
We reserve all rights to this publication. Misuse, and including in particular, duplication and
making this manual - or extracts thereof available to third parties is prohibited. We do not
accept any responsibility for the information provided, which is subject to alternation.

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Contents
Page
1. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Standards and specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.1 Normal operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.2 Special operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1 Main parameters for panels with circuit-breakers . . . . . . . . . . . 8
2.1.2 Main parameters for panels with NALF switch-disconnector . . 8
2.2 Resistance to internal arc faults . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.1 Dimensions and weights of 12/17,5 kV units . . . . . . . . . . . . . . 9
2.3.2 Dimensions and weights of 24 kV units . . . . . . . . . . . . . . . . . 10
2.3.3 Dimensions and weights of panels with the
NALF 12/17,5 kV switch-disconnectors . . . . . . . . . . . . . . . . 10
2.3.4 Dimensions and weights of panels with the NALF 24 kV
switch-disconnectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Panel design and equipment . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Basic structure and variants . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Enclosure and partitioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1 Ventilation of the panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Compartments in the panels . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.1 Busbar compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.2 Circuit-breaker compartment . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.3 Withdrawable parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.4 Cable connection compartment . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.5 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.6 Switch-disconnector and cable compartment
in the panel with switch-disconnector . . . . . . . . . . . . . . . . . . 17
3.4 Interlock/protection against erroneous operation . . . . . . . . . . 18
3.4.1 Panel internal interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.2 Door interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.3 Interlocks between panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.4 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.5 Internal interlocking of panel with
switch-disconnector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 Circuit breaker and contactor plug connector
coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 Fast recovery device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Ith Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4. Dispatch and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Condition on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 Intermediate storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6.1 Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6.2 Apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5. Assembly of the switchgear on site . . . . . . . . . . . . . . . . . 31
5.1 General site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.1 Method of installation A – Installation of the base irons . . . . . 32
5.2.2 Method of installation B – Fixing with anchoring bolts to
concrete floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2.3 Method of installation C – Fixing to a raised false . . . . . . . . . 32
5.3 Assembly of the switchgear panels . . . . . . . . . . . . . . . . . . . . 40
5.4 Installation of the bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4.1 Bushing of 12/17,5 kV panels . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4.2 Bushing of 24 kV panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.5 Fixing of the panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.6 Installation of the busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.6.1 Preparation of the material . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Page
5.6.2 Busbar compartment access . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6.3 Busbar installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.7 Installation of the top-mounted boxes . . . . . . . . . . . . . . . . . . 53
5.7.1 Voltage transformers for busbar metering . . . . . . . . . . . . . . . 53
5.7.2 Earthing switch for busbar earthing . . . . . . . . . . . . . . . . . . . 57
5.8 Pressure relief ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.8.1 Standard gas duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.8.2 Compact gas duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.8.3 Compact gas duct with top chimneys . . . . . . . . . . . . . . . . . . 63
5.9 Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.9.1 Power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.9.2 Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.10 Earthing the switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.11 Laying the ring circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.12 Final erection work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6. Operation of the switchgear . . . . . . . . . . . . . . . . . . . . . . . 71
6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1.1 Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2 Switching operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2.1 Withdrawable apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2.2 Circuit-breaker – type VD4 and Vmax . . . . . . . . . . . . . . . . . . 75
6.2.3 Circuit-breaker – type VM1 . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.2.4 Circuit-breaker – type HD4 . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.2.5 Vacuum contactor – type V-contact . . . . . . . . . . . . . . . . . . . 79
6.2.6 Withdrawable metering parts . . . . . . . . . . . . . . . . . . . . . . . . 80
6.2.7 Earthing switch – type EK6 and ST-VG-01 . . . . . . . . . . . . . . 80
6.2.8 Busbar earthing switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.2.9 Earthing and short-circuiting with earthing module . . . . . . . . 81
6.2.10 NALF type switch-disconnector . . . . . . . . . . . . . . . . . . . . . . 82
6.3 Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.3.1 Testing the off-circuit condition . . . . . . . . . . . . . . . . . . . . . . . 84
6.3.2 Current and voltage tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4 Service trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.1 Earthing truck without making capacity . . . . . . . . . . . . . . . . 85
6.4.2 Earthing truck with making capacity . . . . . . . . . . . . . . . . . . . 85
6.4.3 Power cable test truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.4 Isolation truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.1.1 Intervals for inspection, servicing and repairs . . . . . . . . . . . . 87
7.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.3.1 Maintenance in busbar compartment . . . . . . . . . . . . . . . . . . 89
7.3.2 Maintenance in cable compartment . . . . . . . . . . . . . . . . . . . 90
7.3.3 Maintenance in circuit breaker compartment . . . . . . . . . . . . 94
7.3.4 Maintenance in the low voltage compartment . . . . . . . . . . . . 95
7.4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.4.1 Switchgear in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.4.2 Replacement of complex functional groups . . . . . . . . . . . . . 98
7.5 Testing withdrawable parts . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.5.1 Motor-driven withdrawable parts . . . . . . . . . . . . . . . . . . . . . . 99
7.5.2 Checking correctness of dimensional settings . . . . . . . . . . . 99
7.5.3 Checking auxiliary switch setting on withdrawable parts . . 100
7.5.4 Checking the direction of rotation of the travel motors
on motor-driven withdrawable parts . . . . . . . . . . . . . . . . . . 100
7.5.5 Testing interlock condition . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.6 Tests on the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.6.1 Auxiliary switch settings on the earthing switch . . . . . . . . . 102
7.7 Spare parts, auxiliary materials and lubricants . . . . . . . . . . 102
7.7.1 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.7.2 Auxiliary materials, lubrificants . . . . . . . . . . . . . . . . . . . . . . 102
7.8 Operating accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8. Product quality and environmental protection . . . . . . . . 104

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Figure 1: Curve for determination of the altitude factor k in relation to the altitude H.
1. Summary
1.1 General
UniGear is the new name of the ZS1 switchgear in release 1.2 (ZS1.2). It is three-phase, metal-clad,
air insulated switchgear and all the units are factory-assembled, type-tested and suitable for indoor
applications up to 24 kV.
The units are designed as withdrawable modules and are fitted with a single busbar system. The
withdrawable parts are equipped with circuit-breakers and contactors.
Details of the technical design and configuration of individual switchgear, such as the technical data,
detailed equipment lists for the individual panels and comprehensive circuit documentation etc., can
be found in the relevant order documents.
Note
The UniGear ZS1 switchgear is indicated in the test reports and type test certificates with the
abbreviation ZS1.2
1.2 Standards and specifications
UniGear ZS1 switchgear panels comply with the standards and specifications for factory-assembled,
metal-enclosed and type tested high voltage switchgear to IEC publications 62271-200 and 60694. In
addition, in accordance with IEC 60529, the switchgear panels have the following degrees of
protection: IP4X for the enclosure and IP2X for the partitions.
All other corresponding IEC publications, national or local safety at work regulations and safety
regulations for production materials must be followed during erection and operation of these systems.
Above and beyond this, the order-related data from ABB must be taken into account.
1.3 Operating conditions
1.3.1 Normal operating conditions
The switchgear are basically suitable for normal operating conditions for indoor switchgear and
switchboards in accordance with IEC 60694. The following limit values, among others, apply:
Ambient temperature:
Maximum +40 °C
Maximum 24 h average +35 °C
Minimum (according to “minus 5 indoor class”) -5 °C
The maximum site altitude is 1000 m above sea level.
1.3.2 Special operating conditions
The switchgear are suitable for operation in the climate of Wda type according to IEC 60 721-2-1.
Special operating conditions must be discussed with the manufacturer in advance. For example:
• At site altitudes above 1000 m, the effects of the reduction in dielectric strength of the air on the
insulation level must be taken into account (please refer to diagram in figure 1/1).
• Increased ambient temperatures must be compensated for in the design of the busbars and branch
conductors as well as for the withdrawable parts, otherwise the current carrying capacity will be
limited. Heat dissipation in the switchgear panel can be assisted by fitting additional ventilation
facilities.
Note on any special climatic operating conditions
When switchgear are operated in areas with high humidity and/or major rapid temperature fluctua-
tions, there is a risk of dew deposits which must remain an exception in normal operating conditions
for indoor switchgear. Preventive action (e.g. fitting electric heaters) must be taken in consultation with
the manufacturer to avoid this condensation phenomenon and any resulting corrosion or other adverse
effects. The control of the heaters depends on the relevant project and details must be taken from the
order documents.

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2. Technical data
2.1 Electrical data
2.1.1 Main parameters for panels with circuit-breakers
Rated voltage kV 12 17.5 24
Rated power frequency withstand voltage kV 28 38 50
Rated lightning impulse withstand voltage kV 75 95 125
Rated frequency Hz 50/60
Rated current of busbars A …4000 …4000 …3150
Rated current of circuit-breaker branches A …4000 …4000 …2500
Rated peak withstand current 1) kA …125 …125 …80
Rated short-circuit breaking current of circuit-breaker kA …50 …50 …31,5
Rated short- time current 3 s 1) kA …50 …50 …31,5
1) The short-circuit withstand capacity of the instrument transformers must be taken into account separately.
For individual switching device data, see the instruction manual for the relative switching device, as
listed under 7.1.
Rated voltage kV 12 17.5 24
Rated power frequency withstand voltage kV 28 38 50
Rated lighting impulse withstand voltage kV 75 95 125
Rated frequency Hz 50/60
Rated current of busbars A ...4000 ...2500
Rated current of branches A ...630 ...630
Rated breaking current of switch-disconnector A ...630 ...630
(power factor = 0.7)
Rated short-time withstand current of
switch-disconnector 1s 1) kA ...25 ...20
Rated short-circuit making current kA ...40 ...38
Rated peak withstand current kA ...62.5 ...62.5
Auxiliary voltage V DC 24, 48, 110, 220;
AC 110, 230
1) The short-circuit withstand capacity of the instrument transformers must be taken into account separately.
2.1.2 Main parameters for panels with NALF switch-disconnectors
2.2 Resistance to internal arc faults
The fault withstand capacity is as follows: 12 kV - 50 kAx 1s
17.5 kV - 50 kA 1s
24 kV - 31,5 kA 1s
The switchgear units have been tested according to IEC 62271-200 standard (appendix AA, class A,
criteria 1 to 5) and also to PEHLA recommendation no. 4.
In individual cases, depending on the configuration of the switchgear panels and/or the switchgear
room conditions (e.g. low ceiling height), additional measures may be necessary to ensure compliance
with criterion 5.

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Dimension mm
Height A 2200/2595 1)
Width B
- Feeder panels up to 1250 A (31.5 kA) 5) 550
- Feeder panels up to 1250 A (up to 31.5 kA) 4) 650
- Feeder panels up to 1250 A (above 31.5 kA) 800
- Feeder panels 1600 - 2000 A 800 2)
- Feeder panels above 2000 A 1000
Depth C 1340/13903)
Height of the basic part of panel D 2100
E 1495
1) Height of the control cabinet is 705/1100mm (dimensions without gas-duct);
2) 1000mm available on request;
3) 12/17,5 kV-50kA the panel is always 1390mm depth;
4) Feeders equipped with vacuum contactor are 650mm wide up to the 50kA short-time current;
5) UniGear ZS1 550 series only.
The dimension must be verified according to the documentation of the relevant order.
Rated current Weight
AKg
...1250 800-850
1600 850-900
2000 850-900
2500 1200
3150 1200
4000 1400
2.3 Dimensions and weights
2.3.1 Dimensions and weights of 12/17,5 kV units
Weights of 12/17,5 kV panels (including withdrawable circuit-breaker parts)

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2.3.2 Dimensions and weights of 24 kV units
Rated current Mass
AKg
...1250 1000-1050
1600 1200
2000 1200
2500 1200
Weights of 24 kV panels (including withdrawable circuit-breaker parts)
Dimension mm
Height A 2325/2720 1)
Width B
- Feeder panels up to 1250 A 800 2)
- Feeder panels above 1250 A 1000
Depth C 1700
Height of the basic part of panel D 2200
E 1620
1) Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).
2) 1000mm available on request.
The dimension must be verified according to the documentation of the relevant order.
Dimension mm
Height A 2200/2595 1)
Width
- Outgoing and incoming panels with B 800
switch-disconnector 630 A
Depth C 1300/1340 2)
Height of basic part of panel D 2100
E 1495
1) Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).
2) The depth of panel with the switch-disconnector in combination with HD4 circuit-breaker panels is recommended at 1340 mm, in other
cases 1300 mm – always take into account the note 3).
3) The dimensions must be verified according to the documentation of relevant order.
2.3.3 Dimensions and weights of panels with the NALF 12/17.5 kV switch-disconnectors
Weights of 12/17,5 kV panel (including the switch-disconnector)
Outgoing and incoming panels of width 800 mm, approx. 750 kg.
2.3.4 Dimensions and weights of panels with the NALF 24 kV switch-disconnectors
Weights of 24 kV panel (including the switch-disconnector)
Outgoing and incoming panels of width 1000 mm, approx. 950 kg.
Dimension mm
Height A 2200/2595 1)
Width
- Outgoing and incoming panels with B 1000
switch-disconnector 630 A
Depth C 1520/1560 2)
Height of basic part of panel D 2100
E 1495
1) Height of the control cabinet is 705/1100 mm (dimensions without gas-duct).
2) The depth of panel with the switch-disconnector in combination with HD4 circuit-breaker panels is recommended at 1560 mm, in other
cases 1520 mm – always take into account the note 3)
3) The dimensions must be verified according to the documentation of relevant order.

7
3. Panel design and equipment
3.1 Basic structure and variants
The basis for the UniGear ZS1 panel is the incoming/outgoing feeder panel with SF6 ¹) or vacuum
circuit breaker using insertion technology. It is divided into busbar compartment, circuit-breaker
compartment, cable compartment and control cabinet for the secondary equipment. Apart from this,
there are variants for all operating needs.
For busbar isolation, two panels are necessary, the coupling panel with the withdrawable circuit-
breaker part and a bus riser panel (optional with busbar metering and earthing). In equipment without
busbar isolation, a direct bar connection between the busbars will be established.
The UniGear ZS1 switchgear includes also the variant of incoming/outgoing panel with the switch-
disconnector NAL-F with the stationary mounting of switch-disconnector. The panel is divided into
busbar compartment, switch-disconnector compartment including cables and control cabinet for the
secondary equipment.
The UniGear ZS1 panels can also be set up in two rows; back to back fixed together in so-called duplex
arrangement with a double busbar system.
Further details about installation and switchgear equipment can be obtained from the documents of
relevant order.
¹) For series 550 only vacuum breaker is available.
3.2 Enclosure and partitioning (Figure 2)
The enclosure and internal partitions of the panels are of 2 mm thick high quality galvanised steel
sheets.
The three high voltage compartments (busbar compartment, circuit-breaker compartment and cable
connection compartment) are equipped with top-mounted and secured pressure relief flaps.
These open in the case of overpressure due to an internal arc fault.
The front of the panel is closed off by pressure resistant doors which open to an angle of 130°.
Cable and circuit-breaker compartments have their own doors.
The circuit-breaker compartments can be equipped with inspection windows made of security glass.
Neighbouring panels are partitioned from one another by the side walls of each panel and, as a result
of the design, the air cushion remains between these walls when the panels are jointed together.
The enclosure is completed above by top-mounted pressure-relief flaps which, according to the rated
branch conductor current, are made of sheet steel or expanded metal and below by means of floor
covering 17, made of sheet metal which cannot be magnetized.
The pressure-relief flaps are secured with steel screws on one longitudinal side and on the other
longitudinal side with plastic screws.
In the case of internal overpressure, the plastic screws are the point of rupture.
Arc fault current limitation can be achieved by undelayed circuit-breaker release, carried out by
auxiliary switches operated by the pressure wave.
The switchgear can be equipped with the following systems:
• Ith limiter: the auxiliary switches 11.5 (figure 28) are operated by the pressure relief flaps. For units
over 25 kA (see chapter 3-7);
• Fast recovery device: the auxiliary switches are mounted on the pressure sensors and operated by
the sensor stroke pin (see chapter 3.6).
The necessary safety measures to counteract the effects of an internal arc fault must be ensured in
relation to the ceiling height. In individual cases, this may require additional operator protection
measures on the switchgear panels.
These measures include:
1. Mounting a pressure relief duct 50 on the top of the switchgear, with further channels leading out
of the switchgear room in a form appropriate for the design of the building. The shock wave and
arc discharge are channelled off in ducts (see chapter 5.8);
2. Mounting a pressure relief duct with blow-out apertures located above the duct at the ends of the
switchgear and pointing towards the centre of the switchgear (diverter duct). The shock wave and
arc discharge then emerge in an extremely attenuated form and in a location which is not critical
for the operating personnel.
The rear wall of the busbars of busbar compartment 84, intermediate wall 9, mounting plate 12 with
shutters 12.1/12.2 and horizontal partition 20, form part of the internal partitioning.
The internal metallic partitioning makes safe access to the circuit-breaker and cable compartments
possible even when the busbars are live.
The low voltage compartment for the secondary equipment is completely protected from the high
voltage area thanks to its steel-sheet casing.
On the end sides, cover plates ensure good appearance and are mechanically and thermally arc fault
proof should such an event occur in the end panel.
Doors and rear walls as well as the cover plates are thoroughly cleaned and treated against corrosion
before receiving a high quality double coating of paint.

8
The finishing coat is in the standard RAL 7035 colour (special colours by agreement). Stoving
completes the procedure and provides considerable insensitivity to impact and corrosion.
The circuit-breaker compartment and cable connection compartment doors are pressure resistant and
can either be fitted with screws or manual closing systems (central handle).
3.2.1 Ventilation of the panels
Openings in the outer enclosure are needed for the purpose of ventilation in the case of certain rated
currents in the busbars and branch bars.
For incoming air to the circuit-breaker compartment, the horizontal partition is provided with air-vents
20.2. IP4X degree of protection and safety in the case of any release of hot gas due to an arc fault are
provided by flap 20.3 in the horizontal partition 20.
For outgoing air, the pressure relief flaps 1.1 are made of expanded metal instead of flat steel sheets.
The shape and size of the vents in expanded metal provide the IP4X degree of protection.
In cases of higher ambient temperature (>40 °C) and/or increased frequency (60 Hz) it may be necessary
to install a fan in the horizontal partition. This is not standard. Please refer to figures 109, 110.
It is necessary to use forced fan ventilation in 3600 A and 4000 A panels for 12/17.5 kV rated voltage
and in 2500 A panels for 24 kV rated voltage.
A Busbar compartment
B Circuit-breaker compartment
C Cable compartment
D Low voltage compartment
1 Enclosure
1.1 Pressure relief flap
1.2 Control wiring duct
1.7 Pressure relief flap made of expanded
metal
2 Branch conductor
3 Busbar
5 Isolating bushing
6 Earthing switch
7 Current transformer
8 Voltage transformer
9 Partition – removable
10 Control wiring plug connector
12 Mounting plate
12.1 Top shutter
12.2 Lower shutter
13 Withdrawable part
14 Earthing switch operating mechanism
14.1 Operating shaft for earthing switch
Figure 2: Example of UniGear ZS1
14.2 Slide
15.1 Terminal rack
16 Cable sealing end
17 Floor cover – split
18 Spindle mechanism
18.1 Spigot on spindle
18.2 Hole in spindle for insertion lever
19 Main earthing bar
20 Horizontal partition, removable
20.2 Ventilation grid
21 Cable clamp
84 Partition
1.7
12.1
15.1
10
1.2
13
12.2
19
20.2
18
14
21
20
1.1
1
2
3
84
5
12
7
6
17
8
18
18.1
18.2
14
14.1
14.2
20.2
A
B
D
C16
1.2
9

9
3.3 Compartments in the panels
3.3.1 Busbar compartment
The busbars 3 (figure 2) have a flat cross-section made of copper and are laid in sections from panel
to panel. For higher rated currents (3150, 3600 and 4000 A), the busbars have a D-shaped cross-
section.
According to the current rating, either single or double configuration is used. They are held by flat
branch conductor 2 and, if installed, by busbar bushings 29. No special connection clamps are needed.
Busbars and branch conductors for 17.5 kV and 24 kV are insulated by means of shrink-on sleeves.
The bolt connections in the 17.5 kV and 24 kV busbars system are covered by insulating covers 58
(figure 3). The busbars for 12 kV units up to 2000 A are without any covers. Flat busbars 2500 A and
D-shaped busbars 3150, 3600 and 4000 A are insulated and the connections are covered.
By means of bushing plates 28 and busbar bushings 29 (figures 61, 62) partitions can be created
between panels. These partitions are necessary for higher rated short-time currents – see the following
table.
Rated voltageRated short-time withstand currentPartitions
25 kA No 1)
12/17,5 kV 31,5 kA Every third panel 2)
40 kA, 50 kA Every panel 3)
24 kV 25 kA, 31,5 kA No 1)
Marine version All ratings Every panel 3)
1) In these panels, busbar bushing and bushing plates don’t need to be mounted. The dynamic strength of the busbar system is sufficient.
2) In these panels, busbar bushing and bushing plates must be mounted in every third panel only when you have the sequence of 800
and 1000mm wide. If these panels are positioned between 650mm wide panel they don’t need bushings because the dynamic strength
of the busbar system is sufficient.
3) In these panels, busbar bushing and bushing plates must be mounted in every panel.
According to customer requirements, this separation into individual panels by means of busbar
bushings 29 and bushing plates 28 (figures 61, 62) can also be provided in switchgear panels where
it is not technically necessary.
Top-mounted boxes with busbar earthing switches, or busbar voltage transformers can be placed
above the units.
Figure 3: Example of insulating covers
58 58.5
3.3.2 Circuit-breaker compartment
The circuit-breaker compartment contains all the necessary equipment for reciprocal operation of the
withdrawable part and the panel. Like the busbar compartment, it is metallically partitioned on all sides.
The tulip isolating contacts 5, together with the fixed isolating contacts, are located in mounting plate
12 (figure 2).
The metal shutters 12.1/12.2, covering the insertion openings, are also included. The shutters are
opened by means of actuating bars 13.16 (figure 6) of the withdrawable circuit-breaker part when
inserting into the service position, and are closed when the latter is removed.
In the test/disconnected position of the withdrawable part, partitioning by separation is established in
the main current circuit. Connection of the control wiring, required for test purposes, need not be
interrupted when in the test/disconnected position.

10
In the test/disconnected position, the withdrawable part is still completely inside the panel with the door
closed. The ON/OFF pushbutton located on the circuit-breaker, and the mechanical indicators for ON/
OFF and CHARGED/DISCHARGED can be observed through an inspection window if the circuit
breaker is in service position.
The switching operations are carried out with the doors closed. Installation of an additional mechanical
switching device for manual operation of the circuit-breaker in the service position is also possible (see
fig. 7, 8).
The socket 10.1 (figure 4) for the control wiring is mounted fixed in the circuit-breaker compartment.
Figure 4: View into the circuit breaker compartment
10.1 Control wiring socket
12.1 Top shutter
12.2 Lower shutter
14 Earthing switch operating mechanism
14.1 Drive shaft
42 Right-hand travel rail
43.1 Duct cover, top left
43.3 Duct cover, top right
Figure 6: Withdrawable part of VD4 circuit breaker pole side
13.16 Actuating bars
13.16
10.2
13.1
18.1
14
10.1
12.1
43.3
12.2
42
14/14.1
Figure 5: Circuit breaker compartment open
Withdrawable part in disconnected position,
control wiring plug connector open
10.2 Control wiring plug
13.1 Withdrawable part
14 Earthing switch operating mechanism
18.1 Square spigot

11
45.2
45.1
45.3
Figure 7: Push button for mechanical ON/OFF breaker
operation with the door closed (on request).
If the withdrawable part is in the service
position, operation is carried out using the
knob which swings a push rod extension out.
45.1 Mechanical pushbutton
45.2 Turning knob
Figure 8: View of the push rod extension swung out by
the knob at the front, with the withdrawable
circuit-breaker part in service position and the
door open
45.3 Swivelling push rod
3.3.3 Withdrawable parts (Figure 2)
1. Withdrawable circuit-breaker parts
The withdrawable circuit-breaker forms a complete module consisting of the vacuum circuit-
breakers type VD4, Vmax or VM1, SF6 circuit-breaker type HD4, the withdrawable assembly 13.15
(figure 9), isolated contact arm 4.2 with contact system 4.3 and control wiring plug 10.2.
The withdrawable assembly 13.15 and the circuit-breaker are coupled via a multi-pole control
wiring plug connector 10.3 (figure 10).
The withdrawable assembly establishes the mechanical connection between the panel and the
circuit-breaker. The fixed part is connected to the panel by forking, which is form coded on both
sides. The moving part with the circuit-breaker is moved manually or by a motor by means of a
spindle, between the service or test/disconnected positions with the front doors closed.
Service and test disconnected positions are set precisely by means of auxiliary switches, which
register the final position reached and the angular position of the spindle.
The earthing connection between the withdrawable part and the panel is established by its rollers
and travel rails 42 (figure 4), which are bolted onto the panel.
Withdrawable parts of the same design are interchangeable. In the case where the withdrawable
parts have the same dimensions, but different circuit-breaker fittings, the control wiring plug coding
prevents any erroneous connections between the withdrawable part and the panel.
The coding is indicated in the order documents (figure 23).
2. Withdrawable contactor parts (Figures 2, 11, 12)
In place of the circuit-breaker type, the withdrawable part can also be fitted with the V-Contact VSC
type vacuum contactor.
V-Contact VSC is fitted with MV fuses 91.15 and can be used for rated voltage up to 12 kV.
All the data mentioned in this chapter for circuit-breakers also apply to the contactors.
3. Other withdrawable parts
The withdrawable part can also be fitted with the following trucks:
• metering voltage transformer truck with fuses;
• earthing truck without making capacity (for main busbar system and power cables);
• earthing truck with making capacity (for main busbar system and power cables);
• power cable testing truck;
• isolation truck;
• isolation truck with fuses;
• shutter lifting truck.

12
18.2 18.1 S9 S8 10.3
91.15
91.14
91.13
13.15
Figure 9: Withdrawable part with circuit-breaker, type
VD4, operating mechanism side
13.15 Withdrawable assembly
Figure 11: V-Contact VSC type vacuum contactor – front
view
91.13 Signalling device ON/OFF
91.14 Operating cycle counter
Figure 10: Withdrawable assembly for circuit-breaker,
with auxiliary switches
S8 Test position indicator
S9 Service position indicator
10.3 Control wiring plug connector for
Withdrawable assembly
18.1 Square spigot
18.2 Hole in spindle for insertion lever
spindle
Figure 12: V-Contact type vacuum contactor – pole side
91.15 MV fuses
91.13 Signalling device ON/OFF
91.14 Operating cycle counter
3.3.4 Cable connection compartment (Figure 2)
The cable compartment contains current transformers 7, fixed and withdrawable voltage transformers
8, and earthing switch 6, according to individual operating requirements in each case.10
The cable compartment is constructed for installation of three current transformers. Should all three
current transformers not be required, dummies will be installed in their place, using the same
installation and connection procedures.

13
The voltage transformers mounted fixed are connected on the primary side with flexible, fully- insulated
cables which are inserted in the transformers.
The removable voltage transformers are fitted with HRC fuses. The EK6 type earthing switch can be
used with either a manual or motor-operated mechanism.
Its switching position will be indicated both mechanically by indication on the shaft and electrically by
means of the auxiliary switch. Earthing switch in 550 series cannot be equipped with a motor-operated
mechanism.
Three surge arrestors can be mounted fixed, instead of one position of single-core cables.
Cable connection of 12/17.5 kV units
In the 550 and 650mm wide panel, up to three parallel plastic cables can be connected with single-
core cable protection and push-on sealing ends with a maximum cross-section of 630mm².
In the 800 or 1000mm wide panel, up to six parallel plastic cables can be connected with single-core
cable protection and push-on sealing ends with a maximum cross-section of 630mm².
Customer requests regarding connections to bars, three-core cables, special cables or sealing ends
of different types must be considered during the order-planning stage.
Cable connection of 24 kV units
In the 800mm wide panel, up to three parallel plastic cables can be connected with single-core cable
protection and push-on sealing ends with a maximum cross-section of 500 mm².
In the 1000mm wide panel, up to six parallel plastic cables can be connected with single-core cable
protection and push-on sealing ends with a maximum cross-section of 500 mm².
For more information regarding cable connection, see chapter 5.9.
For detailed information about cable connections, please make reference to the figures
102...106.
The cable connections are supplied without screws, washer and nuts; the supply of this
material, according to the cable termination, is at Customer charge.
3.3.5 Control cabinet (Figures 2, 4)
The control cabinet is, for all control and protection aspects, suitable for both conventional or
microprocessor control technology.
The height of the control cabinet is 705/1100mm. For details, see chapter 2.3.
If the secondary devices are not intended for door installation, they are mounted on DIN RAILS. They
enable any subsequent changes to the wiring. In the lower part of the control cabinet, there are three
rows of DIN RAILS on the swivelling DIN RAIL holder and, below these, there is an easily accessible
auxiliary switch for the control wiring plug.
Secondary wiring inside the panel is in a duct on the right side of the panel. The left side of the panel
is for the external wiring. The ducts are covered with steel sheet metal 43.1, 43.2. There are holes for
sliding in the ring conductors at the side of the control cabinet.
3.3.6 Switch-disconnector and cable compartment in the panel with switch-disconnector
The switch-disconnector and cable compartment is merged. The switch-disconnector is mounted
stationary and connected to busbars. The interconnection to the busbar compartment is carried out
by means of bushings, which secures the separation of busbar compartment from all other switchgear
compartments.
The switch-disconnector and cable compartment is also separated from other compartments by
means of metal partitions.
The switch-disconnector can optionally contain an integrated earthing switch. The switching positions
of the integrated earthing switch type E can be indicated by an auxiliary switch.
Closing and opening of the switch-disconnector is performed manually by means of a lever with the
door closed. On request the device can be also mounted for motor operation of switch-disconnector.
The switch-disconnector can consequently be operated not only locally but also remotely. The earthing
switch is always operated locally by means of the operating lever.
The switchgear is constructed for the use of one-core cables as standard. The cable compartment
usually contains supporting insulators for fastening cables. On request the cable compartment can
contain the instrument current transformers instead of supported insulators. If all three current
transformers are not required, the relevant insulators are installed instead of them.
Cable connection in the panels for 12 kV, 17.5 kV and 24 kV:
In the panel with switch-disconnector 1 plastic one-core cable can be connected on each phase with
the cross-section up to 240mm² as standard.
Important note
In the case of any atypical cable connections an agreement must already be reached between
customer and manufacturer in the technical preparation stage of order.

14
1) In the case of a motor operator, the mechanical interlock or the locking magnet is replaced by an electrical interlock of the
earthing switch. The manual emergency switch is not locked!
2) The locking magnet is not installed in the case of a motor operator; busbar earthing switches or the withdrawable parts are
electrically locked. The manual emergency switch is not locked!
3) This interlock is not available for motor-operated withdrawable apparatus as a mechanical device.
3.4 Interlock/protection against erroneous operation
3.4.1 Panel internal interlocking (Figure 2)
To prevent hazardous situations and erroneous operation, there is a series of interlocks to protect both
personnel and equipment:
• The withdrawable part can only be moved from the test/disconnected position (and back) when the
circuit-breaker and earthing switch are off (i.e. the switch must be off beforehand.) In the
intermediate position, the switch is mechanically interlocked. When the circuit-breakers have an
electrical release, the interlock is also electrical;
• The circuit-breaker can only be switched on when the withdrawable part is in the test or service
position. In the intermediate position, the switch is mechanically interlocked. When the circuit-
breakers have an electrical release, the interlock is also electrical;
• In panels with digital control technology, prevention of malfunction of the switch can also be achieved
by means of the control terminal (i.e. REF542
plus );
• In the service or test positions, the circuit-breaker can only be switched off manually when no control
voltage is applied and it cannot be closed (electromechanical interlock);
• Connecting and disconnecting the control wiring plug 10.2 (figure 5) is only possible in the test/
disconnected position of the withdrawable part;
• The earthing switch 6 can only be switched on if the withdrawable part is in the test/disconnected
position or outside of the panel (mechanical interlock ¹);
• If the earthing switch is on, the withdrawable part cannot be moved from the test/disconnected
position to the service position (mechanical interlock);
• Optionally there can be interlocking on shutters to prevent opening them manually. If it is applied
then a shutter device needs to be ordered;
• Details of other possible interlocks, e.g. in connection with a locking magnet on the withdrawable
part and/or earthing switch drive, can be obtained from the relevant order documents.
3.4.2 Door interlocking (Figures 13 to 20)
The panels can be equipped with the following interlocks (all optional):
• The apparatus (circuit-breaker or contactor) cannot be racked-in if the apparatus compartment door
is open (figure 13, 14). ³);
• The apparatus compartment door cannot be opened if the apparatus (circuit-breaker or contactor)
is in service or in an undefined position (figure 15, 16);
• The earthing switch cannot be operated if the cable compartment door is open (figure 17, 18);
• The cable compartment door cannot be opened if the earthing switch is open (figure 19, 20).
Warning
It is important that when the front doors (circuit-breaker and cable) are supplied with
screws, these screws are all fixed properly in order to guarantee the interlocks and the
safety of the personnel in case of internal arc.
3.4.3 Interlocks between panels
• The busbar earthing switch can only be closed when all the withdrawable parts in the relative busbar
section are in the test/disconnected position (electromechanical interlock ²);
• When the busbar earthing switch is closed, the withdrawable parts in the earthed busbar section
cannot be moved from the test/disconnected position to the service position (electromechanical
interlock ²).
3.4.4 Locking devices (Figure 2)
• The shutters 12.1/12.2 can be secured independently of each other with padlocks when the
withdrawable circuit-breaker part has been removed;
• Access to the operating-shaft 14.1 of the earthing switch can be restricted with a padlock;
• Access to the circuit-breaker racking slot can be restricted with a padlock;
• Access to the circuit-breaker compartment and the cable compartment can be restricted with a
padlock.

15
A
A
B
B
Figure 13: Circuit-breaker compartment door enabling device (A)
Figure 14: Circuit-breaker truck enabling slot (A)
Figure 16: Circuit-breaker compartment door locking pin (B)
Figure 15: Circuit-breaker compartment door locking device (B)

16
C
C1
C2 Pin ON Pin OFF
D
D
Figure 17: Cable compartment door enabling device (C)
Figure 18: Cable compartment door enabling slot (C1) and earthing switch enabling pin (C2)
Figure 19: Cable compartment door locking device (D)
Figure 20: Cable compartment door locking pin (D)

17
200.1
200
205.1
205
215
Figure 21: Switch-disconnector compartment – open
position. Insulating plate in the isolating
distance of switch-disconnector 200 Switch-
disconnector
200.1 Position indicator of switch-
disconnector
205 Insulation partition wall
205.1 Movable insulation plate
3.4.5 Internal interlocking of panel with switch-disconnector
To prevent hazardous situations and erroneous operation, there is a series of interlocks to protect both
personnel and equipment:
• The switch-disconnector can only be switched on if the earthing switch is off. The earthing switch
can only be switched on if the switch-disconnector is off. The switch-disconnector and earthing
switch are mutually mechanically interlocked;
• The door of the lower cable HV part on the panel can only be opened if the earthing switch is on.
During closing of the earthing switch the insulating plate 205.1 (figure 21) is automatically inserted
in the isolating distance of the switch-disconnector, which increases safety. This plate is automati-
cally removed again during opening of the earthing switch;
• The earthing switch can only be operated if the cable compartment door is closed;
• If the control voltage is not connected, the switch-disconnector can only be opened and closed
manually. Manual operation of switch-disconnector and earthing switch can be prevented if the
slides 201.2 and 208.1 of the operating openings are locked up;
• In the panels with digital control techniques the protection against erroneous operation is basically
carried out by means of panel software. But the earthing switch is operated locally by means of
operating lever 215 (figure 22). The mechanical interlock between the switch-disconnector and
earthing switch is still in operation;
• Details of other possible interlocks, e.g. in connection with a locking magnet on the switch-
disconnector, can be obtained from the relevant order documents.
Warning
• The door of the upper HV part on the panel can only be opened if the off-circuit condition of
the switch disconnector is verified. This means that the off-circuit condition must be
unconditionally verified both on the upper and lower contacts of switch disconnector.
Figure 22: Preparation for the operation of earthing
switch in panel with the switch-disconnector.
Operating lever prepared for the operation
OFF.
215 Operating lever
3.5 Circuit breaker and contactor plug connector coding
The control wiring plug connector coding allows withdrawable parts for switching devices to be
assigned to particular panels. This ensures, for example, that withdrawable parts with different rated
currents or different control wiring circuits can only be used in the panels they are intended for.
Coding pins are fitted in the control wiring sockets 10.1 (figure 23) or control wiring plugs 10.2 (Figure
5), and engage with the corresponding bores of the relevant plug 10.2 or socket 10.1 when the two parts
are connected.
The plug connector coding is order-related, and is noted in the relevant wiring documentation.

18
Figure 23: Control wiring plug connector coding, shown for a 58 pole connector
10.1 Control wiring socket
10.4 Centring strinking tabs
10.5 Bore for actuating pin of the control wiring plug for controlling the auxiliary switch
Coding
The corresponding coding designation for the control
wiring plug is given in brackets (10.2)
The coding pins can be fitted in the control wiring
socket (10.1) and/or in the control wiring plug (10.2).
Basic design
The number of sockets is optional, but the basic
assignment is 1, 8, 10, 20, 21, 31, 33 and 40.
Sockets and pins can be mixed as required in the
control wiring socket (10.1) and control wiring plug
(10.2).
Circuit-breakers and contactors Plug pin coding (apparatus) Socket hole coding (panel)
12-17.5 kV 650 mm 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6
400 A V •• ••
630 A VD4 VM1 HD4 •• ••
1250 A VD4 VM1 HD4 VD4 VM1 HD4 ••
1600 A VD4 VM1 HD4 VD4 VM1 •• • •
2000 A VD4 VM1 ••
2500 A VD4 VM1 HD4 ••••
3150 A VD4 VM1 HD4 •• ••
3600 A VD4 VM1 HD4 •• ••
4000 A VD4 VM1 HD4 •• ••
Isolating trucks Plug pin coding (apparatus) Socket hole coding (panel)
12-17.5 kV 650 mm 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6
400 A
630 A 17.12.32
1250 A •• ••
1600 A 17.20.50
2000 A •• • •
2500 A 17.25.50 ••• •
3150 A •• ••
3600 A 17.32.50 •• ••
4000 A •• ••
Circuit-breakers Plug pin coding (apparatus) Socket hole coding (panel)
24 kV 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6
630 A VD4 VM1 HD4 VD4 VM1 •• ••
1250 A VD4 VM1 HD4 VD4 VM1 ••
1600 A VD4 VM1 HD4 •• • •
2000 A VD4 VM1 HD4 ••
2500 A VD4 VM1 HD4 ••••
Isolating trucks Plug pin coding (apparatus) Socket hole coding (panel)
24 kV 800 mm 1000 mm B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6
630 A
1250 A 24.12.25 •• ••
1600 A
2000 A 24.25.25
2500 A ••• •