ABB UniGear ZS1 User manual

ABB Power Distribution 1
ZS1
Air-insulated medium voltage switchgear, 12 kV/17.5 kV
Instruction manual BA 372/04 E

Your safety first – always!
•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
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 under operation condition of the switchgear or switchboard
the specified data are not exceeded.
•Keep the instruction manual accessible to all persons concerned with
installation, operation and maintenance.
•The user’s personnel are to act responsibly in all matters affecting safety at
work and the correct handling of the switchgear.
If you have any further questions on this instruction manual, the members of our
field organization will be pleased to provide the required information.
That's why our instruction manual begins with these recommendations:
WARNUNG
Anerkannte Regeln der Technik und Betriebsanleitungen
beachten !
Gefährliche Spannung
kann elektrischen Schock und Verbrennungen verursachen.
Vor Aufnahme von Arbeiten jeder Art dieses Gerät unbedingt freischalten,
erden und kurzschließen.
WARNING
Always observe the instruction manual and follow the rules
of good engineering practice !
Hazardous voltage
can cause electrical shock and burns.
Disconnect power, then earth and short-circuit before proceeding
with any work on this equipment.

4ABB Power Distribution
Contents Page
1 Summary 6
1.1 General 6
1.2 Standards and specifications 6
1.3 Operating conditions 6
1.3.1 Normal operating conditions 6
1.3.2 Special operating conditions 6
2 Technical data 7
2.1 Electrical data 7
2.2 Resistance to internal arc faults 7
2.3 Dimensions and weights 8
3 Panel design and equipment 9
3.1 Basic structure and variants 9
3.2 Enclosure and partitioning 9
3.2.1 Ventilation of the panels 9
3.3 Compartments in the panels 10
3.3.1 Busbar compartment 10
3.3.2 Circuit-breaker compartment 10
3.3.3 Withdrawable parts 10
3.3.4 Cable compartment 10
3.3.5 Control cabinet 11
3.4 Interlocks/protection against
maloperation 11
3.4.1 Panel internal interlocking 11
3.4.2 Interlocks between panels 12
3.4.3 Locking devices 12
3.5 VD4 circuit-breaker run on-block 12
4 Despatch and storage 21
4.1 Condition on delivery 21
4.2 Packaging 21
4.3 Transport 21
4.4 Delivery 21
4.5 Intermediate storage 21
5 Erection of the switchgear on site 23
5.1 Site requirements 23
5.2 Foundations 23
5.2.1 Foundation frame on concrete floor 24
5.2.2 Raised false floor 24
5.3 Erection of the panels 24
5.4 Installation of the busbars 25
Contents Page
5.5 Installation of the top mounted boxes 25
5.5.1 Voltage transformer for busbar metering 25
5.5.2 Earthing switch for busbar earthing 26
5.6 Pressure relief ducts 26
5.7 Connection of the cables 26
5.7.1 Power cables 26
5.7.2 Control cables 27
5.8 Earthing of the switchgear 27
5.9 Laying the ring circuits 27
5.10 Final erection work 27
6 Operation of the ZS1 switchgear 44
6.1 Start-up 44
6.1.1 Preparatory work 44
6.1.2 Start-up 44
6.2 Switching operations 45
6.2.1 Withdrawable circuit-breaker part 45
6.2.2 Withdrawable metering parts 46
6.2.3 Circuit-breaker 46
6.2.4 Tee-off earthing switch 48
6.2.5 Busbar earthing switch 48
6.2.6 Switch-disconnector 48
6.2.7 Insulating protection plate 49
6.2.8 Electrical/mechanical
annunciation/monitoring 49
6.2.9 Earthing and short-circuiting with
the earthing cable sets 50
6.3 Test procedures 50
6.3.1 Testing the off-circuit conditon 50
6.3.2 Testing for in-phase condition 51
6.3.3 Current and voltage testings 51
7 Maintenance 58
7.1 General 58
7.2 Inspection 58
7.3 Servicing 59
7.4 Repair 59
7.4.1 Switchgear in general 59
7.4.2 Replacement of complex functional groups 60
7.5 Testing withdrawable parts with
a VD4 type circuit-breaker 61

ABB Power Distribution 5
Contents Page
7.5.1 Motor-driven withdrawable parts 61
7.5.2 Checking the correctness of
dimensional settings 61
7.5.3 Checking auxiliary switch settings on
withdrawable parts 61
7.5.4 Checking the direction of rotation of
the travel motors on motor-driven
withdrawable parts 62
7.5.5 Testing of interlock conditions 62
7.6 Tests on the panel 63
7.6.1 Auxiliary switch settings on the
earthing switch 63
7.7 Spare parts, auxiliary materials,
lubricants 63
7.7.1 Spare parts 63
7.7.2 Auxiliary materials, lubricants 63
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

6ABB Power Distribution
1Summary
1.1 General
The metal-clad, three-pole air-insulated panels
without disconnectors from type ZS1 for rated
voltage of 12 kV and 17.5 kV are factory-
assembled, type-tested indoor panels. They are
designed as withdrawable switchgear and fitted
with single busbar systems. The withdrawable
breaker parts are preferably fitted with vacuum
circuit-breaker
Details of the technical design and configuration of
the switchgear, such as technical data, detailed
equipment lists, comprehensive circuit docu-
mentation etc., can be found in the relevant order
documents.
1.2 Standards and specifications
ZS1 switchgear comply with the standards and
specifications for factory-assembled and type
tested high voltage switchgear in VDE 0670, and
the relevant IEC publications 60298 and 60694.
In addition, in accordance with IEC 60529, the
panels have degrees of protection
• IP 4X (up to IP 55 possible) for the enclosure
• IP 2X for the partitioning.
All other relevant VDE specifications, especially DIN
VDE 0101, VDE 0105 and DIN VDE 0141, the
corresponding IEC publications, the national or
local workplace safety regulations and the safety
regulations for production materials are to be
followed during erection and operation of this
equipment. In addition, the order-related data and
instructions from ABB are to be observed.
1.3 Operating conditions
1.3.1 Normal operating conditions
The switchgear are basically suitable for normal
operating conditions for indoor switchgear and
controlgear in accordance with VDE 0670, Part
1000 (IEC Publication 60694). The following limit
values, among others, apply:
• Ambient temperature:
– Maximum + 40 °C
– Maximum 24 h average + 35 °C
– Minimum (according to – 5 °C
"minus 5 indoor class"
• Humidity:
VDE 0670 Part 6 amends the contents of VDE
0670 Part 1000 with respect to humidity as
follows: With indoor installation, it is assumed
that the humidity within the enclosure can reach
high values, but without condensation normally
appearing on the installed equipment. Con-
densation can be prevented by appropriate
design of the station building or switchgear
room.
• Site altitude:
– The maximum site altitude is up to 1000 m
above sea level.
1.3.2 Special operating conditions
Special operating conditions must be agreed by
the manufacturer and operator according to VDE
0670 Teil 1000. The ZS1-switchgear provides
opportunities to comply, for example, with the
following special operating conditions
• Increased ambient:
Conductors and switching devices to be
designed for a higher rated current.
• Increased humidity:
Heaters to be installed in the panels.
• Sites altitudes above 1000 m:
Design panels for higher insulation level in
consideration of the altitude factor k according
to figure 1/1.
Figure 1/1: Curve for determination of the altitude factor k in
relation to the altitude H
(Sourcee: ABB switchgear manual,
9th Edition, 1992)
0,4 1000 2000 3000 4000 5000m
0,6
0,8
1,0
k
H

ABB Power Distribution 7
2Technical data
2.1 Electrical data
Rated voltage kV 12 17.5
Max. operating voltage kV 12 13.8
Rated power frequency withstand voltage kV 28 38
Rated lightning impulse withstand voltage kV 75 95
Isolation VDE/IEC List 2 VDE/IEC List 2
Rated frequency Hz 50/60 50/60
Rated current of the busbars ... 4000 ... 4000
Rated current of the tee-offs:
• Circuit-breaker A ... 4000 ... 4000
• Switch-disconnector A ... 1250 ... 1250
Rated impulse current of
the main conductor kA ... 125 ... 100
Rated short-circuit breaking current
of the circuit-breaker kA ... 50 ... 40
Rated short-time current 2) 3s kA ... 50 ... 40
Auxiliary voltage V DC1) 60, 110, 120; AC 110, 220
1) Special DC voltage on request.
2) 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.
2.2 Resistance to internal arc faults
The resistance to internal arcing faults is 50 kA 1s.
Criteria 1 to 6 of PEHLA Directive No. 4 (in con-
junction with VDE 0670 part 6 and IEC 60298) are
fulfilled. Depending on the configuration of the
panels and/or the switchroom conditions (e.g. low
ceiling height), additional measures may be
necessary to ensure compliance with criterion 5.

8ABB Power Distribution
2.3 Dimensions and weights
Rated voltage kV 12 17.5
Height2) Dimension a mm 2200 2200
Width Dimension b
• Tee-off current up to 1250 A (up to 31.5 kA) mm 650 650
• Tee-off current up to 1250 A (above 31.5 kA) mm 800 800
• Tee-off current 1600 A mm 800/1000 800/1000
• Tee-off current above 1600 A mm 1000 1000
Depth Dimension c mm 13001) 13001)
1) 1350 mm for rated tee-off currents of 4000 A
2) Height of the control cabinet is 705 mm
AV
a
bc
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
kg
Rated current Rated short-time current
A …31,5 kA …50 kA
…1250 800 850
1600 850 850
2000 1200 1200
2500 1200 1200
3150 1200 1200
4000 1400 1400

ABB Power Distribution 9
3Panel design and equipment
3.1 Basic structure and variants
(Figures 3/1 to 3/5)
The basis for the ZS1 panel is the incoming/
outgoing feeder panel with vacuum circuit-breaker
using insertion technology. It is divided into busbar
compartment A, circuit-breaker compartment B,
cable compartment C and the control cabinet for
the secondary equipment D. Apart from this, there
are variants for all operating needs. The pictures 3/
1 to 3/5 show possible configurations of a panel
including electrical equipment.
For a busbar sectionalizing, two panels are
necessary, the coupling panel with the
withdrawable circuit-breaker part and a bus riser
panel (optional with busbar metering and earthing).
When setting up the switchgear in two rows, the
busbar sectionalizing can be combined with a bar
connection between the two sets of switchgear. In
equipment without busbar sectionalizing, a direct
bar connection between the busbars will be
established.
With ZS1 panels it is possible to set up a double
busbar installation in accordance with the two
breaker method. This duplex arrangement is
possible both with back to back or front to front
positioning.
Apart from this, panels with fixed-mounted
switch-disconnectors of type C3 (e.g. for feed to
a station service transformer) are provided.
Depending on rated short-time current and the
ceiling height of the circuit-breaker compartment, a
pressure relief duct on the panel would perhaps be
required.
Further details about the installation and equipping
of the switchgear can be obtained from the order
documents.
3.2 Enclosure and partitioning
(Figure 3/5)
Enclosure and internal partitioning of the panels are
of high quality aluminium-zinc coated steel sheets,
2 mm thick. The three high voltage compartments
(busbar compartment circuit-breaker compartment
and cabel connection compartment) are equipped
with top-mounted, 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 almost
180°. Cable and circuit-breaker compartments
have their own doors equipped with sight glasses
made of security glass. Neighbouring panels are
partitioned from one another by the side walls of
each panel and the air cushion which remains
between these walls as a result of the design when
the panels are joined together.
In the case of the duplex version with a rated short-
time current of up to 31,5 kA a swivelling lever cap
is used instead of the three screw caps. The door
of the control cabinet has a catch fastener lock.
The enclosure is completed by top-mounted
pressure-relief flaps which are, according to the
rated tee-off conductor current, made of sheet
steel 49.2 or expanded metal 49.1 and below by
means of the floor-covering 17 made of sheet steel
which cannot be magnetized. The pressure-relief
flaps are secured with steel screws on one longitu-
dinal side and on the other longitudinal side with
plastic screws. In the case of internal overpressure,
the plastic screws are the point of rupture.
Part of the internal partitioning are the busbars-rear
wall 9.3, the intermediate wall 9, the mounting plate
12 with the shutters 12.1. and the horizontal
partition 20. The internal partitioning makes it
possible to have safe access to the circuit-breaker
and cable compartment even when the busbars
are live.
The control cabinet for the secondary equipment is
completely protected from the high voltage area
due to its steel-sheet casing.
On the front side, cover plates ensure a good
appearance and are mechanically and thermically
arc fault proof in case of such an event 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. The finishing coat is in the standard colour
RAL 7035 (special colours by agreement). The
stoving procedure completes the work and imparts
a notable insensitivity to impacts and corrosion.
3.2.1 Ventilation of the panels
(Figures 3/1, 3/5, 3/9)
For the purpose of ventilation in cases of certain
rated currents in the busbar and tee-off bars,
openings in the outer enclosure are necessary.
For incoming air to the circuit-breaker com-
partment, the horizontal partition is provided with
air-vents 20.2. The degree of protection IP4X and
safety in case of releases of hot gas caused by an
arc fault are provided by the flap 20.3 in the raised
false floor. In the case of outgoing air, the presssure
relief flaps are provided made of expanded metal
instead of clad metal sheets. The form and size of
the vents in the expanded metal provide the degree
of protection IP4X.
In the panel for tee-off rated current 4000 A, cross-
current blowers are installed for cooling purposes.

10 ABB Power Distribution
3.3 Compartments in the panels
3.3.1 Busbar compartment
(Figures 3/5, 3/6, 5/8, 5/9, 5/11 and 5/12)
The busbars 3 have a D-shaped cross-section
made of copper or aluminium and are laid in
sections from panel to panel. According to the
current rating, single or double configuration is used.
They are held by the flat tee-off conductor 2 and the
busbar bushings 29 and/or 29.4. No special
connecting clamps are needed.
Busbars and tee-off conductors are insulated by
means of shrink-on sleeves. The bolt connections
in the busbar system are normally covered by insu-
lating covers 58, so that the entire configuration is
completely free of arc fault points of origin.
In conjunction with bushing plates 28 (or 28.2) and
29 and/or 29.4, panel by panel partitioning is
possible.
In switchgear with a short-time current more than
25 kA this partitioning may also be necessary for
reasons of stability.
3.3.2 Circuit-breaker compartment
(Figures 3/5, 3/7, 3/10 and 3/19)
The circuit-breaker compartment contains all the
necessary equipment for the mutual functioning of
the withdrawable breaker part and the panel. It is,
as the busbar compartment, metally partitioned on
all sides.
The isolating tulips 5 together with the fixed isolated
contacts are in the mounting plate 12. Also
included are the metal shutters 12.1 which cover
the insertion openings. The shutters are opened by
means of the actuating bars 13.16 of the
withdrawable breaker part using lever 38 when
inserting into the service position and are closed
when it is removed. In the test/disconnected
position of the withdrawable part, a partitioning by
separation is established in the main circuit current.
The connection of the control wiring which must be
established for test purposes need not be
interrupted when in the test/disconnected position.
The socket 10.1 for the control wiring is fixed-
mounted in the circuit-breaker compartment.
3.3.3 Withdrawable parts
(Figures 3/7, 3/8, 3/10, 3/11 and 3/21)
1. Withdrawable circuit-breaker parts
The withdrawable circuit-breaker forms a com-
plete module consisting of the circuit-breaker
type VD4, the withdrawable assembly 13.15, the
isolated contact arm 4.2 with the contact system
4.3 and the control wiring plug 10.2.
The withdrawable assembly 13.15 and the
circuit-breaker are coupled via a multipole
control-wiring plug connection 10.3.
The withdrawable assembly establishes the
mechanical connection between the panel and
the circuit-breaker. The fixed part is connected to
the panel by forking, form-coded on both sides.
The movable part with the circuit-breaker is
moved manually or by a motor by way of a
spindle, between the service or test
disconnected positions with the front doors
closed. Service and test disconnected positions
are exactly registered by means of auxiliary
switches, which register the final position reached
and the angular position of the spindle.
The earthing connection between the with-
drawable part and the panel is established by its
rollers and the travel rails 41 which are bolted
into the panel. The surfaces of all the parts of the
earthing circuit are zink-galvanized.
Withdrawable parts of the same design are
mutually interchangeable. In the case of the
withdrawable parts having the same dimen-
sions, but different equipping of the circuit-
breaker, the codification of the control wiring
plug prevents non-permitted connections
between the withdrawable part and the panel.
2. Other withdrawable parts
In place of the circuit-breaker, the withdrawable
part can also be fitted to act as a „disconnecting
device“ with a fixed current-bridge in VD4 pole-
casing, with a SF6 circuit-breaker or vacuum
contactor (both fabricated by ABB Sace).
The withdrawable part 95 is used in the metering
panel with a voltage transformer 95.1 with or
without HRC fuses as required. At the point of
contact of the movable contact-arms or the
HRC fuse cartridges and the voltage
transformer, dielectrically dense cast-resin
tubes have been used.
3.3.4 Cable compartment
(Figures 3/1, 3/4, 3/5, 3/12, 3/13)
The cable compartment contains current trans-
former 7, voltage transformer 8 and earthing switch
6 in each case according to the individual operating
requirements.
The cable compartment is constructed for the
installation of three current transformers. Should all
three current transformers not be required, dum-
mies will be installed instead with the same
installation and connection procedures.

ABB Power Distribution 11
The fixed-mounted voltage transformers are
connected on the primary side with flexible,
completely insulated wirings which are inserted into
the transformers.
In certain circumstances it is possible to use
removable voltage transformers. They can be
equipped with HRC fuses as in the metering panel.
The earthing switch type EK6 can be used either
with manual or motor-operated mechanism. Its
switching position will be indicated by means of the
auxiliary switch both mechanically and electrically.
In the 650 mm wide panel, it is possible (according
to choice) to prepare for up to three parallel three-
core cables if required. In the standard version, the
intended equipping is a plastic cable with single
cable core protection. Intended maximum cross-
section is 240 mm2with push-on sealing ends.
In the 800 mm or 1000 mm wide panel up to six
parallel plastic cables can be connected also with
single cable core protection and push-on sealing
ends with a cross section of maximum 500 mm2.
An alternative could be the 650 mm wide panel
socket-contacts with inner cones for connection to
the cable plugs. Customer wishes regarding the
connections to bars or special cable or sealing-end
types must be considered during the order-
planning phase.
In place of the three cable cores, three surge
arrestors can be fixed-mounted. An alternative
would be, under certain conditions, to have these
in a withdrawable form.
In the Duplex version, the cable compartment is
modified as follows:
• In the back to back version, the connection
between the two panels consists of flat copper
bars.
• In the front to front version it consists of made-
up plastic insulated cables or insulated busbar
capacitance grading device, depending on the
current.
3.3.5 Control cabinet
(Figures 3/1, 3/5, 3/14 and 3/15)
The control cabinet is for all matters of control and
protection suitable for both conventional or modern
control technology.
Apart from the usual case, a control cabinet of 705
mm in height, there is also a 1100 mm high version
for especially comprehensive secondary techno-
logy, which has a panel height of 2595 mm.
If the secondary devices are not intended for door
installation, they are mounted on perforated metal
sheet 37.3. This is stored folded-up to enable any
subsequent changes to the wiring. In the lower part
of the control cabinet, three rows of terminal strips
are on the swivelling terminal strips holder 37.4 and
below these, auxiliary switch 10.4 for the control
wiring plug is easily accessible.
For doors in which devices with higher voltage than
that of low-voltage protection are installed, a
secure and complete protection conductor
connection must be established. The corrosion
protected hinge of the control cabinet corresponds
to these requirements (DIN VDE 0660 part 500).
Protection against contact to clamps and devices
corresponds to VGB 4.
Secondary wiring internal to 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. At the side of the
control cabinet are holes for sliding in the ring
conductors.
Detailed information about the secondary
technology and to the relevant material used in
each case can be obtained from the secondary
check-list pertaining to the order and the handbook
(switching book).
3.4 Interlocks/protection against maloperation
3.4.1 Panel internal interlocking
(Figures 3/5 and 3/8)
To prevent dangerous situations and maloperation,
a series of interlocks exist 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
in-between position, the switch is mechanically
interlocked, in the case of circuit-breakers with
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 in-between position, the
switch is mechanically interlocked, in circuit-
breakers with electrical release there is an
electrical interlock too.
• In panels with digital control technology, pre-
vention of maloperation of the switch basically
takes place by means of the panel’s software.
• In the service or test positions, the circuit-
breaker can only be switched off manually when
no control voltage is applied and cannot be
closed (electromechanical interlock).

12 ABB Power Distribution
• Connecting and disconnecting of the control
wiring 10.2 is only possible in the test/
disconnected position of the withdrawable part.
• Switch-disconnector and the earthing switch
integrated therein are normally mechanically
interlocked from each other and in each case
only one of the two can be switched on.
• 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
interlock1)).
• If the earthing switch is on, the withdrawable part
cannot be moved from the test/disconnected
position to the service position (mechanical
interlock).
• Details of other possible interlocks e.g. in
connection with a blocking magnet on the
withdrawable part and/or earthing switch drive,
can be obtained from the relevant order
documents.
3.4.2 Interlocks between panels
(Figure 3/1)
• The busbar earthing switch can only be on when
all withdrawable parts in the busbar section,
which must be earthed, are in the test/discon-
nected position (electromechanical2) interlock).
• When the busbar earthing switch is on, the
withdrawable part in the earthed busbar section
cannot be moved from the test/disconnected
position to the service position (electromecha-
nical2) interlock).
3.4.3 Locking devices
(Figures 3/7, 3/17, 3/18 and 6/16)
• The shutters 12.1 can be secured independently
of each other with padlocks when the
withdrawable circuit-breaker part has been
removed.
• Access to the drive-shaft of the earthing switch
can be restricted with a padlock.
• Access to the circuit-breaker compartment and
the cable compartment as well as to the
withdrawable part controls can be restricted
with a padlock.
3.5 VD4 circuit-breaker run on-block
In case of any irregularity in the area of the inner
control mechanism and of the charging function of
the stored-energy spring mechanism, the run-on
block disables the immediately subsequent
switching operation.
This is a protective measure to prevent damage to
the circuit-breaker.
Release of the run-on block is described in
instruction manual BA 383/E.
________________________
1) The mechanical interlock is replaced by a blocking magnet in
the case of a duplex configuration.
In the case of a motor drive, the mechanical interlock or the
blocking magnet is replaced by electrical interlock of the
earthing switch. The emergency manual switch is not
locked!
2) 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 13
Figure 3/1: Panel variations
1 Outgoing feeder 12 kV, 1000 A, 31.5 kA
with firmly connected voltage transformers
2 Outgoing feeder 13,8 kV, 1250 A, 31,5 kA with
removable voltage transformers and 1100 mm high
control cabinet
3 Outgoing feeder 12 kV, 1250 A, 40 kA
with firmly connected voltage transformers, surge
arrestors and pressure relief duct
4 Incoming feeder 12 kV, 2000 A, 31,5 kA
with busbar earthing switch in top mounted box
5 Incoming feeder 12 kV, 4000 A, 40 kA
with insulated busbar capacitance grading device
6 Busbar sectionalizing 12 kV, 2500 A, 40 kA with
earthing switch
7 Bus riser 12 kV, 2500 A, with withdrawable metering
unit and earthing switch
8 Busbar metering 12 kV, 40 kA, with withdrawable
metering unit and busbar earthing switch
9 Outgoing feeder 12 kV, 630 A, with switch-
disconnector and fuses
2650
2600
2595
12 3
56
4
8
79

14 ABB Power Distribution
Figure 3/3: Erection of the ZS1 switchgear in two rows,
Connection of the busbars in a bar duct
1200*)
1800
Figure 3/2: Erection of the ZS1 switchgear in two rows
Busbar sectionalizing connection with insulated
busbar capacitance grading device
1 Busbar sectionalizing 2500 A
2 Bus riser panel with withdrawable metering unit
1800
)
h
1)2
1) Dimension dependent on switchroom volume and short-circuit current.
2) Minimum dimensions are specified by the manufacturer.
*) Make allowance for the floor thickness
2
1

ABB Power Distribution 15
Figure 3/4: ZS1 Duplex switchgear 12 kV, 1000 A, 31,5 kA
Double busbar switchgear according to the two-breaker method
18001300 1300
50 50
1200 12002608
a) Installation front to front
b) Installation back to back

16 ABB Power Distribution
49.2
9.3
7
6
8
A B D
C
9
12.1
12 13
20
20.2
20.3
43
17
2200
49.1
AV
Figure 3/5: ZS1 Feeder panel 12 kV, 1250 A, 31.5 kA
A Busbar compartment
B Circuit-breaker compartment
C Cable compartment
D Control cabinet
6 Earthing switch
7 Current transformer
8 Voltage transformer
9 Intermediate wall
9.3 Busbar rear wall
12 Mounting plate
12.1 Shutter
13 Withdrawable circuit-breaker part
17 Floor covering
20 Horizontal partition
20.2 Air vents
20.3 Flap
43 Duct cover
49.1 Pressure relief flap,expanded metal
49.2 Pressure relief flap, steel sheet

ABB Power Distribution 17
Figure 3/6: Busbar compartment, busbar system without
partitioning
3 Busbar
9 Intermediate wall
49.2 Pressure relief flap
58 Insulating cover
Figure 3/7: Circuit-breaker compartment, without withdrawable part
10.1 Socket for control wiring
12 Mounting plate
12.1 Shutters
14.2 Slide in front of the earthing switch manual
operating mechanism
20 Horizontal partition
38 Lever for operating the shutters
41 Travel rail
43.1 Lateral covering of the external control wiring
Figure 3/8: Circuit-breaker compartment with withdrawable part
1250 A in disconnected position
10.2 Control wiring plug
13.17 Front plate
Figure 3/9: Circuit-breaker compartment with withdrawable part
2500 A in disconnected position
20 Horizontal partition with ventilation wall
20.2 Air vents
45 Mechanical circuit-breaker operation
14.2
20
41
12
38
43.1
49.2
9
58
3
12.1
10.1
10.2
45 20.2 20
13.17

18 ABB Power Distribution
13.15 13.16
4.3
4.2
Figure 3/10: Withdrawable part with circuit-breaker 1250 A
4.2 Insulated contact arms
4.3 Contact system
13.10 Pole tube cap
13.15 Withdrawable assembly
13.16 Actuating bar
Figure 3/11: Withdrawable part with metering unit
13.15 Withdrawable assembly
95 Withdrawable metering unit
95.1 Voltage transformer
95.2 Cast-resin tube
Figure 3/13: Cable compartment, panel width 1000 mm, with
connecting bars for six parallel cabels
6.1 Position indicator of the earthing switch
14 Manual mechanism of the earthing switch
17 Floor covering
17.2 Reducer ring
23 Cable connecting bar
43.4 Lateral covering of the internal control wiring
44 Heating plate
Figure 3/12: Cable compartment, width of panel 650 mm, with
earthing switch, voltage transformer and three parallel
single-conductor plastic cables.
(1.2) Control cable duct
16 Cable sealing ends
16.1 Cable screen
17 Floor covering
17.2 Reducer ring
19 Main earthing bar
19.1 Connecting link
43.2 Lateral covering of the external control wiring
6.1
23
44
14
43.4
17
17.2
13.10
95.2
13.15
95.1
17.2
17
19
(1,2)
16.1
16
43.2
19.1
95

ABB Power Distribution 19
Figure 3/14: Control cabinet
37.3 Perforated sheet
37.4 Terminal-strip holder
Figure 3/15: Control cabinet, terminal-strip holder swung upwards
10.4 Auxiliary switch for control wiring plug
37.4 Terminal-strip holder
37.5 Screw for terminal-strip holder
37.5
10.4
37.4
37.4 37.3
Figure 3/16: Mechanical plug interlock
10.1 Socket
10.2 Plug
32 Interlock lever
Figure 3/17: Lock for earthing switch manual mechanism.
14.9 Padlock
14.9
10.2
10.1
32

20 ABB Power Distribution
Figure 3/21: Withdrawable assembly for the withdrawable part with
auxiliary switches
S8 Test position indicator
S9 Service position indicator
10.3 Control wiring plug connection for the withdrawable
assembly
Figure 3/20: Pole side of a withdrawable part with circuit-breaker of
the high current type VD4
13.9 Protective cap used during transport
(remove before putting into service)
13.13 Lifting lug
(remove before putting into service)
Figure 3/19: View of the circuit-breaker compartment with the
withdrawable part removed and the shutters open
4.1 Contact pin
5 Isolating tulip
12.1 Shutter
43.3 Duct covering of the internal control wiring (above)
12.1
5
4.1
Figure 3/18: Lock for the circuit-breaker and cable compartment
14.9 Padlock
43.3
S 9 S 8 10.3
13.13
13.9
14.9

ABB Power Distribution 21
4Despatch and storage
4.1 Condition on delivery
At the time of despatch, the ZS1 panels are
factory-assembled, the withdrawable parts inser-
ted into the service position and the doors closed.
The factory-assembled panels are checked at the
works for completeness in terms of the order and
simultaneously subjected to routine testing
(normally without AC voltage testing of the busbars)
to VDE 0670 part 6 or IEC publication 60298, and
thus tested for correct structure and function.
The busbars are not assembled. The busbar
material, fasteners and accesssories are packed
separately.
4.2 Packaging
According to the kind of transport and country of
destination, the panels remain unpackaged or are
welded in foil and packed in seaworthy crates. To
protect against moisture, a drying agent is
provided:
• Panels with basic packaging or without pack-
aging.
• Panels with seaworthy packaging or similar
(including packaging for containerized ship-
ments):
– Sealed in polythene sheeting,
– Transport drying agent bags included,
– Moisture indicator included,
– When aluminium composite sheeting is used,
a sight window is fitted for checking.
• Observe the directions for use of the drying
agent bags to DIN55 473. The following applies:
– Coloured indicator blue: contents dry,
– Coloured indicator pink: contents moist (rela-
tive humidity above 40%).
4.3 Transport
(Figure 4/1)
The transport units normally comprise individual
panels, and in exceptional cases small groups of
panels or panels assembled back to back. The
panels are each fitted with four lifting lugs.
Transport panels upright. Take account of the high
centre of gravity. Only ever carry out loading
operations when it has been ensured that all
precautionary measures to protect personnel and
materials have been taken and using a
• crane,
• fork-lift truck and/or
• manual trolley jack.
Loading by crane:
• Fit lifting ropes of appropriate load capacity with
shackles (opening width above 30 mm,
fastening bore diameter 30 mm)
• Maintain an angle of at least 60°from the hori-
zontal for the ropes leading to the crane hook.
4.4 Delivery
The responsibilities of the consignee when the
switchgear arrives at site include, but are not
limited to, the following:
• Checking the consignment for completeness and
freedom from damage (e.g. also for moisture and
ist detrimental effects). in cases of doubt, the
packaging must be opened and then properly
resealed, fitting new drying agent bags, when
intermediate storage is necessary.
• If any short quantities, defects or transport
damages are noted:
– To be documented on the respective
shipping document.
– Notify the relevant carrier or forwarding agent
immediately in accordance with the relevant
liability regulations .
Note:
Always take photographs to document any major
damage.
4.5 Intermediate storage
Optimum intermediate storage as far as this is
necessary at all – without detrimental consequen-
ces depends on compliance with a number of
minimum conditions for the panels and assembly
materials
1. Panels with basic packaging or without
packaging:
• A dry well-ventilated store room with a climate
in accordance with IEC 60694.
• The room temperature must not fall below
-5°C.
• There must not be any other unfavourable
environmental influences.