ABB UniGear ZS2 UniSafe 36 Owner's manual

— UniGear ZS2 Installation, operation and maintainance instruction manual
—
MEDIUM VOLTAGE PRODUCTS
UniGear ZS2
Installation, operation and
maintainance instruction manual

—
ABB’s UniGear ZS2 is a
three-phase, metal enclosed,
air- insulated switchgear and
all units are factory-assembled,
type tested and suitable for
indoor applications up to 36 kV.
The switchgear is designed with a
withdrawable type vacuum / SF6
circuit breaker and fitted with a
single busbar system.

3
—
Table of contents
1. Your safety first – at all times! 4
2. Summary 6
2.1 General 6
2.2 Standards and specifications 6
2.3 Operating Conditions 6
3. Technical data 7
3.1 Electrical data 7
3.2 Resistance to internal arc fault 7
3.3 Dimensions and weights 7
4. Switchgear design and equipment 8
4.1 Basic structure and variants 8
4.2 Compartments in UniGear ZS2 11
4.3 Interlocks and protection against erroneous 16
operations
4.4 Control wiring plug connector coding 19
4.5 Instructions for floor-rolling version 20
circuit breaker
4.6 ICOG- Incoming and Outgoing type Switchgear 21
4.7 Ith Limiters 21
5. Dispatch and Storage 23
5.1 Condition on delivery 23
5.2 Packing 23
5.3 Transport at site 23
5.4 Delivery 23
5.5 Intermediate storage 23
5.6 Unpacking 24
5.7 General site requirements & Floor Layout 27
5.8 Foundations 28
6. Assembly of the switchgear panels 32
6.1 Installation of busbars 34
6.2 Cable connection 37
6.3 End covers 40
7. UniGear ZS2 Digital 41
8. Operation of the switchgear 43
8.1 Commissioning 43
8.2 Preparatory work 43
8.3 Switching Operation 43
8.4 Service Trucks 48
9. Maintenance 52
9.1 Maintenance strategies 52
9.2 Preventive Maintenance 53
9.3 Inspection 53
9.4 Servicing 53
9.5 Repair 55
9.6 Testing with withdrawable 55
9.7 Testing Interlock conditions 56
9.8 Spare parts, Auxiliary materials, Lubricants 57
10. Product quality and environmental protection 58

—
1. Your safety first - at all times
DANGER!
Pay special attention to the hazard notes in the instruction manual marked with
this warning symbol.
• Make sure that the specified criteria are not exceeded under switchgear
operating conditions.
• Ensure the instruction manual is accessible to all personnel involved in
installation, operation, and maintenance.
• The user’s personnel must act responsibly in all matters related to safety at work
and correct handling of the switchgear.
• Ensure that the switchgear or switchboard and accessories are stored in closed
room, free of dust and moisture till erection.
• Ensure that installation, operation, and maintenance are carried out by only
trained, qualified and authorized personnel
UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
To emphasize on safety, our installation, operation, and maintenance manual begins
with the following recommendations:
Only install switchgear in closed rooms suitable for electrical equipment. Ensure
that installation, operation and maintenance is only carried out by qualified
competent electricians only and the responsibilities after the ex-works delivery are
clarified. Fully comply with the legally recognized standards (IEC or local), the
connection conditions of the local electrical utility and the relevant safety at work
regulations.
Observe the relevant information in the instruction manual for all actions involving
switchgear. Using of safety clothes like safety gloves according to EN 388 Blade cut
resistance class 5, long sleeved work jacket or safety sleeves, safety shoes is
recommended during all activities done with 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.
• Do not override safety interlocks, either electrical or mechanical, during
operation and/or maintenance
WARNING
If you have any further questions about this instruction manual,
ABB’s field service team will be pleased to provide the required
information. We reserve all rights to this publication. Misuse,
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 change.
• Fully comply with the legally recognized standards
(IEC or local), regulations of the local electrical authority and stipulated safety
requirements
• Ensure that activities related to switchgear are carried out as per relevant
instructions and guidelines given in this manual, and applicable local safety
standards and work practices

6UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
2.1 General
ABB’s UniGear ZS2 is a three-phase, metal
enclosed, air- insulated switchgear and all units
are factory-assembled, type tested and suitable
for indoor applications up to 36 kV. The
switchgear is designed with a withdrawable
type vacuum / SF6 circuit breaker and fitted with
a single busbar system.
This manual does not contain any instruction
relevant to customer specific documents. In case
of special switchgear and apparatus
configurations, it is strongly recommended to
consult both this manual and relevant project
specific technical documents.
2.2 Standards and specifications
UniGear ZS2 switchgear complies with standard
and specifications prescribed on IEC publications
62271-200 and 62271-1 for factory-assembled,
metal enclosed and type tested high voltage
switchgears.
Additionally, the switchgear offers IP4X and IP2X
degrees of protection for the enclosure and for
partitions respectively, as prescribed by the IEC
publication 60529.
All other corresponding IEC publications, national
and 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, customized order specific
data furnished by ABB must also be taken into
account.
2.3 Operating conditions
2.3.1 Normal operating conditions
UniGear ZS2 switchgear is basically suitable for
normal operating conditions for indoor
switchgear in accordance with IEC 62271-200.
Among other considerations, the following
limiting values apply:
Ambient temperature
Maximum + 40°C
Maximum 24-hour average + 35°C
Minimum (according to "minus 5 indoor" class) - 5°C
The maximum site altitude is 1000 m above sea level.
Note: For higher altitude & ambient, please consult ABB
2.3.2 Special operating conditions
The switchgear is suitable for operation in the
Wda type of climate according to IEC 60721-2-1.
Special operating conditions must be discussed
with the ABB in advance.
For example:
• At altitudes above 1000 m, effects of the
reduction in dielectric strength of air on the
insulation level must be taken into account
(please refer to graph in Fig.1).
• Increased ambient temperatures must be
compensated for, in the design of busbars,
branch conductors and withdrawable parts.
Otherwise, the current carrying capacity will
be limited. Heat dissipation in the switchgear
can be assisted by fitting additional
ventilation facilities.
Note on any special climatic operating
condition:
When switchgear is operated in areas with high
humidity and/ or with major rapid temperature
fluctuations, there is a risk of dew deposits,
which must remain an exception in normal
operating conditions for indoor switchgear.
Preventive action (e.g. suitable ventilation and
proper air conditioning of the building or
housing, use of dehumidifying equipment, etc.)
must be taken into consideration in consultation
with ABB to avoid this condensation phenomenon
and any resulting corrosion
or other adverse effects.
Details like number of heaters, location and
temperature settings depend on the project, and
those details must be taken from customer order
document.
k 1,0
0,8
0,6
0,4
1000
2000 3000 4000 m 5000 H
—
2. Summary
—
Figure 1
Curve for determination of the altitude factor k in relation to altitude H

7
—
3. Technical data
3.1 Electrical data
Table 1 : Main parameters for switchgear with
circuit breaker
Rated voltage (Ur) kV 36
Rated power frequency withstand
voltage (Ud)
kVrms 70
Rated lightning impulse withstand
voltage (Up)
kVpk 170
Rated frequency (fr) Hz 50
Rated current (Ir) of busbars A upto 3150
Rated current (Ir) of
circuit breaker branches
A upto 2500,
3150 (FC**)
Rated peak withstand current (Ip)* kA 78.75
Rated short-circuit breaking current
of circuit breaker
kA 31.5
Rated short-time withstand
current (Ik)*
kA 31.5
Rated duration of short circuit (tk)* s 3
*The short-circuit withstand capacity of components must be taken
into account separately. For individual circuit breaker data, see the
Instruction manual for the relative circuit breaker
** Forced Cooling
3.2 Resistance to internal arc faults
The fault withstand capacity is 31.5kA for 1s with
gas duct- IAC AFLR 31.5kA,1s 14kA for 1s with
absorber assembly - IAC AFLR 14kA 1s
Table 2 : Dimensions of 36kV units
(Refer notations in section 4.1)
Dimension Notation Metrics in
mm
Height A 2161# 2662 ##
Width
- Feeder switchgears up to 2500
A/ 3150A FC (up to 31.5kA)
B 1000/1200
Depth C 2200 / 2400 /
2600 /
2800/###
Height of the basic part of
Switchgear
D 2024
E 1700
#Height of the standard LV Compartment is 460 mm
## Including the height of the Gas duct
### Variable as per project requirement
Table 3 : Dimensions of 36kV units;
including withdrawable circuit breaker parts
Rated Current in A Mass in kg Approximate)
upto 1250 1300
1600 1500
2000 1500
2500/3150 1700
Table 3.1 : Variant Configurations - for Feeder
Current Rating in Amps Copper
Version
Aluminium
Version
630 Yes
1250 Yes Yes
1600 Yes
2000 Yes Yes
2500 Yes Yes
3150 (FC)* Yes Yes
*with Force Cooling
Variant Configuration for ICOG
Current Rating in Amps Copper
Version
Aluminium
Version
630 Yes
1250 Yes Yes

8UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
—
4. Switchgear design and equipment
4.1 Basic structure and variants
The basis for UniGear ZS2 switchgear is
an incoming or outgoing feeder panel
with circuit breaker. It is divided into
circuit breaker compartment 1, busbar
compartment 2, cable compartment 3,
low voltage compartment 4 for
secondary equipment. Apart from this,
there are variants for various operating
needs. Pictures in Fig. 3 to Fig. 12 show
examples of possible configurations
of a switchgear including electrical
equipment.
For busbar sectionalizing, two
switchgears are necessary, a coupling
switchgear with withdrawable circuit
breaker part and a bus riser switchgear
(may be with busbar metering and
earthing). In switchgear without busbar
sectionalizing, a direct bar connection
between the busbars
will be established. Further details about
installation and equipping the
switchgear can be obtained from
relevant order specific documents.
1. Circuit breaker compartment
2. Busbar compartment
3. Cable compartment
4. Low voltage compartment
—
Figure 2 - Basic Structure of ZS2
—
Figure 3 - Cross section of feeder unit 36kV, 630A -
1250A, 31.5kA, 2200 mm depth
—
Figure 4 - CCross section of feeder unit 36kV, 1600A/2000A/2500A,
31.5kA, 2600 mm depth

9
—
Figure 6 - Cross section of feeder unit 36kV, 3150A, 31.5kA with Forced
cooling , 2600 mm depth*
1030
F
F
SECTION F-F
SCALE 1 : 10
C/S of 2600mm depth panel (3150A FC)
—
Figure 9 - Cross section of Coupler Unit 36kV, 630A - 1250A, 31.5kA
—
Figure 7 - Cross section of Bus-Coupler unit 36kV, 2500A-
3150A , 31.5kA
—
Figure 10 - Cross section of Bus Riser with NC 1250-2500A (1000 mm),
36kV,31.5kA
1038
A
A
SECTION A-A
SCALE 1 : 10
—
Figure 5 - Cross section of feeder unit 36kV, 3150A, 31.5kA with
Forced Cooling, 2400 mm depth*
—
Figure 8 - Cross section of BusPT with measurement

10 UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
—
Figure 12 - Cross section of feeder unit with Line PT, 31.5kA,
2800 mm depth*
—
Figure 11 - Cross section of Bus Riser with forced Cooling
3150A (1000 mm), 36kV,31.5kA
C/S with IR Window details as optional feature
—
Figure 13 - C/S with IR Window details as optional feature
*=Can be varied as per customer requirement
A D
1
2
3
4
5
6
7
8
9
10
11
12
17
13
19
16
14
18
15
B
C
—
Figure 14 A. Busbar compartment
B. Circuit breaker compartment
C. Cable compartment
D. Low voltage compartment
1. Enclosure
2. Branch conductors
3. Busbars
4. Circuit breaker
5. Bushing
6. Earthing switch
7. Current transformer
8. Control wiring duct
9. Main earthing
10. Voltage transformer
11. Lower connection bar
12. Circuit breaker door
13. Metering door
14. Cable compartment door
15. Earth switch operating
mechanism
16. Pressure relief flap
17. Support insulator
18. Incoming cables
19. Phase barrier

11
4.1.1 Enclosure and partitioning
The enclosure and internal partitions of
UniGear ZS2 are made of 2 mm thick high quality
Aluminium Zinc coated steel sheets. Three high
voltage compartments (viz: busbar compartment,
circuit breaker compartment and cable
compartment) are equipped with top mounted
pressure relief flaps fixed with steel bolts on one
longitudinal side and breakable nylon bolt on the
other side. These pressure relief flaps open; when
over pressure happens in an event of any internal
arc fault. Pressure relief flaps are made of sheet
steel with wire mesh or plain sheet steel
according to the rated branch conductor current.
The circuit breaker compartment door is of
pressure resistant design for internal arc fault
and is also padlockable. It is provided with
security glass for inspection purposes which is
also tested for Internal arc. Sidewalls of each
switchgear serve as partition between adjacent
switchgears.
Please refer table below for cable and Busbars
access in FRCB & Cassette type structures
Access for FRCB
Structure
Cassette
Structure
Cable compartment Rear Front & Rear
Busbar compartment Rear & Top Rear & Top
The low voltage compartment for secondary
equipment is completely protected from the high
voltage area.
Compartmentalization is made by the following
internal partitioning: (Refer Fig. 14)
• The rear wall of the busbars compartment
• Intermediate wall between cable and circuit
breaker
• Mounting plate with metallic shutters
• Horizontal partition
The internal partitioning makes safe access to
circuit breaker and cable compartments possible
even when bus bars are live (LSC2B-PM).
End covers at lateral sides ensure good
appearance and are arc fault proof both
mechanically and thermally, in the event of an
internal arc fault at end switchgears.
Doors, end covers and rear covers are made of
high quality steel sheets, which undergo
thorough cleaning through 7 tank process before
powder coating. The finishing coat is of standard
RAL 7035 color shade. (Special color shades on
request and by mutual agreement).
The circuit breaker compartment and cable
connection compartment doors are pressure
resistant and has manual closing system or can
be fitted with screws respectively.
4.1.1.1 Ventilation of the switchgears
Ventilation is ensured in the switchgear through
pressure relief flaps, which offers IP4X degree of
protection. For use of UniGear ZS2 switchgear for
ambient temperatures above 40°C systems,
additional ventilation system is to be provided.
4.2. Compartments in UniGearZS2
4.2.1 Busbar Compartment
The busbar compartment has three copper
busbars of tubular cross-section laid in sections
between switchgears. They are held in place by
tubular branch conductors. Diameter and
thickness of busbars vary according to the
current rating.
Busbars and branch conductors are insulated and
connections are shrouded.
—
Figure 15B - Interpanel Busbar assembly
—
Figure 15A - Busbar compartment top view without top sheet

12 UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
—
Figure 15.1 - Top Jumper of 630A with Busbar of 1250A
M16X45 Hex
Bolt 1
M16 Conical
Washer 1
—
Figure 15.2 - Top Jumper of 630A with Busbar of 2500A
M16X80 Hex
Bolt 2
M16X50 Hex
Bolt 1
M16 Conical
Washer 5
M16 Hex Nut 2
—
Figure 15.3 - Top Jumper of 2000A with Busbar of 2000A
M12X70 Allen
Bolt 2
M12 Conical
Washer 4
M12 Hex Nut 2
—
Figure 15.6 - Top Jumper & BB 1250A
M12X60 Allen
Bolt 2
M12 Conical
Washer 4
M12 Hex Nut 2
M16 Hex Nut 2
—
Figure 15.5 - Top Jumper-2000A with Busbar 2500A for Al Solution
M12X80 2
M12 Conical
Washer 4
M12 Hex Nut 2
M16 Hex Nut 2
—
Figure 15.4 - Top Jumper-1250A with
Busbar 2500A for Al solution
M12X80 hex Bolt 1
M12 Conical
Washer 2
M12 Hex Nut 1
M16X90 Allen
Bolt 1
M16 Conical
Washer 2
M16 Nut 1
—
Figure 15.7 - Top Jumper-2500A
with Copper Busbar 2500A

13
4.2.2 Circuit breaker compartment
The circuit breaker compartment contains all the
necessary arrangements for the rack-in and rack-
out operation of the withdraw-able part inside
the switchgear. Like the busbar compartment,
it is metallic partitioned on all sides.
The socket for the control wiring is firmly
mounted inside the circuit breaker compartment.
The tulip isolating contacts together with the
fixed isolating contacts are located on H-frame
and fixed through spout bushing. The shutters
are opened by means of lever assembly (Fig.16)
when inserting circuit breaker into the service
position and are closed when the circuit breaker
is removed. In the test/disconnected position of
the withdrawable part, partitioning by separation
from service to test position is thereby
established in the main current circuit. Auxiliary
plug and socket with control wiring are to be
connected, when circuit breaker in the test/
disconnected position.
In the test position, the breaker would be
completely inside the switchgear with door
closed. The ON / OFF indication and CHARGED /
DISCHARGED condition of the closing spring of
circuit breaker can be observed through the
inspection window.
The switching operations are carried out with the
door closed. Emergency trip of the circuit breaker
is possible when circuit breaker is in the service
condition. (Emergency Trip arrangement).
—
Figure 17 - Circuit breaker compartment with withdrawable
part in Service position
—
Figure 16 - View into the circuit-breaker compartment.
1 Control wiring socket
2 Top shutter
3 Lower shutter
4 Left-hand travel rail
—
Figure 18 - Shutter Assembly and Lever mechanism
—
Figure 19 - Circuit breaker compartment with withdrawable part in
Test position
4 3 2 1

14 UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
4.2.3 Withdrawable parts
4.2.3.1 Withdrawable circuit breaker parts
The withdrawable assembly with the circuit
breaker and the switchgear are coupled via
a multi-pole control wiring plug connector.
The racking mechanism establishes mechanical
connections between the switchgear and circuit
breaker. The circuit breaker can be moved
between Test and Service positions by means of
the handle provided, with front door closed.
Service and Test positions are set precisely by
means of lead bolt arrangement to ensure that
the breaker reaches the final position. The Test
and Service position indication can be observed
on the low voltage compartment.
The moving part with the circuit breaker
is moved either manually or by a motor by
means of a spindle, between the service or test
positions with the front door
closed. Service and test 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 circuit breaker
and the switchgear is established throughout;
from Test position to Service position by means
of finger contact bolted with circuit breaker and a
travel rail connection arrangement which is
bolted on to the switchgear refer Fig.20.
Separate earthing provisions for circuit breaker
in Test and Service positions are available
on request.
—
Figure 20 - Scribe Earthing
1. Lever for manually charging the
closing spring.
2. Coupling lever for racking
in /out operation
3. Opening push button
4. Closing push button
5. Signaling device for circuit breaker
open/closed.
6. Signaling device for closing spring
charged/ discharged.
7. Operation counter.
8. Handles for operating the truck locks
(only for withdrawable circuit breakers).
The control wiring plug and socket are also coded
to prevent any erroneous connection between
incompatible withdrawable part and the
switchgear, though their dimensions appear
similar.
Thanks to the coding fitted in the control wiring
plug and socket!
—
Figure 21 - VD4 Circuit breaker operating element.
3
4
6
5
7
1
2
8

15
—
Figure 22 - Withdrawable assembly for circuit breaker, with auxiliary switches
S8 Test position indicator
S9 Service position indicator
10.2 Control wiring plug connector for
Withdrawable assembly
18.1 Square spigot
18.2 Hole in spindle for insertion lever
spindle
4.2.3.2 Other withdrawable parts
The withdrawable part can also be fitted with
following trucks:
• Metering potential transformers trucks with
fuses. (Refer sec.: 7.3.4)
• Earthing truck without making capacity
(for main busbar system and power cables)
These earthing trucks are intended for fail-safe
temporary earthing in cubicles for UniGear ZS2
type indoor switchgear. This earthing truck is
suitable to earth a circuit which is in OFF
condition. This earthing truck can sense the
voltage even if put into a live circuit, which will
prevent further racking-in by means of an
interlock thereby ensuring safety of the operator.
It is recommended that the circuit to be earthed
be switched OFF before using this earthing truck.
Earthing trucks are available in two versions:
• For earthing the main busbar system
• For earthing power cables
For ensuring maximum safety to the operator
and highest plant reliability against accidental
switching on the circuit, during scheduled or
unscheduled maintenance, it is highly
recommended to withdraw the circuit breaker
entirely out the switchgear and shorting
the circuit with main earthing by means of
earthing truck.
—
Figure 23 - Low Voltage compartment
—
Figure 24 - Low Voltage compartment internal wiring
S8
S9
10.2
18.1
18.2

16 UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
4.2.4 Cable compartment
The cable compartment contains current
transformers, and fixed or withdrawable
potential transformers, and earthing switch
depending on requirements of the customer.
The EK6 ST-E type earthing switch can be used
with either a manual or mechanism. Its switching
position will be indicated both mechanically and
electrically by means of the auxiliary switch.
UniGear ZS2's cable compartment can
accommodate installation of current
transformers and other equipment like surge
arrestors, voltage detecting insulators (VDI), etc.
The fixed type potential transformers are
connected with suitable connectors on the
primary side, while the removable or
withdrawable type potential transformers are
fitted with HRC fuses.
The UniGear ZS2 Digital panel‘s cable
compartment is constructed for installation of 1
set of current sensors.
The UniGear ZS2 Digital panel‘s cable
compartment is constructed for installation of
1 set of current sensors (Figure-current sensor).
—
Figure - Current Sensors
The voltage sensors are connected on the
primary side with copper bar. Should voltage
sensors not be required, 2 set of insulators will be
installed in their place, using the similar
installation and connection procedures
(Figure-voltage sensors).
—
Figure -Voltage Sensors
• KEVA 36 B2x – voltage sensor with ratio
10000:1
• KECA 80 C260-ZS2 – current sensor with ratio
150mV@80A
4.2.4.1 Cable connections
UniGear ZS2 switchgear can accommodate up to
three numbers of parallel single-core cables,
of maximum cross-section of 630 sq.mm,
as standard arrangement. Other options may be
made available on special request.
4.2.5 Low Voltage compartment
The low voltage compartment is an independent
sheet metal box mounted on the switchgear for
housing control and protection equipment. It is
suitable for both conventional as well as
microprocessor control technology. The standard
height of the low voltage compartment is
460 mm, and upto 824 mm height can be made
available on request.
If secondary devices are not intended for door
installation, they are mounted inside the low
voltage compartment.
Provisions for inter-panel wiring are made inside
walls of the low voltage compartment.
IMPORTANT NOTE
In the case of any non standard cable
connections an agreement must be
reached between the customer and
ABB during the technical preparation
stage of the order.
4.3 Interlocks and protection against erroneous
operations
4.3.1 Standard safety Interlocks
UniGear ZS2 has series of interlocks provided as
described below to prevent hazardous situations,
erroneous operation to protect both personnel
and equipment:
• The circuit breaker can be moved into Test or
Service position only when the circuit breaker
and earthing switch are in OFF condition.
In intermediate positions, the circuit breaker
is mechanically and electrically interlocked
against ON and OFF operations.
• With circuit breaker OR instead of AND
earthing switch closed, insertion of the circuit
breaker towards the Service position is locked
and only half a turn of the crank in the
clockwise direction is possible.
• 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)
• Interlock will not allow racking of the circuit
breaker in absence of auxiliary power supply
• Connection and disconnection of the control
wiring plug from its socket is possible only
when the withdrawable part is in Test position
and with the door opened (Fig. 79)
• The earthing switch can be closed only if the
withdrawable part is in the Test/Disconnected
position or outside of the panel (mechanical
interlock)
• Details of other interlocks can be obtained
from customer specific order related
documents

17
A B
—
Figure 25 -
A) Closed position of door’s handle;
B) Not closed position of door’s handle.
4.3.2 Door interlocking
UniGear ZS2 is equipped with the following door
interlocks:
• The circuit breaker can be racked in from Test
to Service position only when door is closed.
(Fig. 25.1)
• The circuit breaker compartment door cannot
be opened if the circuit breaker is in Service or
in any undefined positions (Fig 25.2)
• The compartment door cannot be opened
if the earthing switch is open.
4.3.3 Interlocks between switchgears
The interlock between the switchgears can be
achieved by using the electrical schematic
controls.
Lock Condition
1AApparatus
racking-in/out Apparatus closed
B Apparatus closing Undefined truck position
2
AApparatus
racking-in
Apparatus control wiring
connector unplugged
B
Apparatus control
wiring connector
plug-out
Truck in service or undefined
position
3
AEarthing switch
closing
Truck in service or undefined
position
BApparatus
racking-in Earthing switch closed
Note: Apparatus are circuit breakers
—
Figure 25.1 - Circuit breaker compartment door enabling device
—
Figure 25.2 - Circuit breaker truck enabling slot

18 UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
4.3.4 Locking devices
• The main circuit's metallic shutters can be
padlocked independently when the
withdrawable circuit breaker has been
removed from switchgear. (Fig 25.4)
• Access to the circuit breaker racking slot can
be restricted with a pad lock.
• Access to the circuit breaker compartment
can be restricted with a padlock.
• Access to the operating-shaft of the earthing
switch can be restricted with a key lock.
(optional feature on request)
Note: For any padlock provision, padlock of
Ø6mm can be used.
—
Figure 25.5 - CB/Cable compartment door enabling device
Electromechanical door interlock for CB and cable
compartment
—
Figure 26 - Push button for mechanical ON/OFF breaker operation
with the door closed.
If the withdrawable part is in the service position, operation is carried
out using the knob which swings a push rod extension out.
26.1 Mechanical pushbutton
26.2 Turning knob
26.3 Handle
26.2
Turning knob
26.1
Mechanical
push
button
26.3
Handle
—
Figure 25.3
—
Figure 25.4
—
Figure - E&S Lock Arrangement

19
Keys (on request)
6 Apparatus racking-in lock
7 Earthing switch closing lock
8 Earthing switch opening lock
9 Insertion of the apparatus raking-in/out crank lever
10 Insertion of the earthing switch operating lever
Can only be removed with the truck in the racked-out position
Can only be removed with the earthing switch open
Can only be removed with the earthing closed
Can always be removed
Can always be removed
Accessory devices
18 Shutters fail-safe
19 Apparatus-switchgear unit compatibility matrix
20 Circuit-breaker mechanical operating mechanism
The device locks the shutters in the closed position when the apparatus is
removed from the compartment. The operator cannot open the shutters
manually. The shutters can only be operated by the apparatus truck or the
service trucks.
The apparatus multi-contact plug and relative switchgear unit socket are
equipped with a mechanical matrix, that disables apparatus racking-in into
a switchgear unit with an inappropriate rated current.
The apparatus compartment is equipped with a mechanical device, that
enables circuit-breaker closing and/or opening directly by means of the
front operating mechanism Push Buttons, keeping the door closed. The
controls can be operated with the circuit-breakers in the operation and
racked-out position.
Locking magnets (on request)
16 Apparatus racking-in/out
17 Earthing switch ON/OFF
Magnet energized
Magnet energized
—
T
ypes of interlocks
Standard safety interlocks (mandatory)
Type Description
1A Apparatus racking-in/out
B Apparatus closing
2A Apparatus racking-in
B Apparatus multi-contact plug unplugging
3
A Earthing switch closing
B Apparatus racking-in
4A Apparatus compartment door opening
B Apparatus racking-in
5A Feeder compartment door opening
B Earthing switch opening
Condition to be fulfilled
Apparatus in OFF position
Defined truck position
Apparatus multi-contact plug plugged
Truck in test position
Truck in test position
Earthing switch in OFF position, Earthing sw.
Operating handle cover in closed position.
Truck in test position
Apparatus compartment door closed
Earthing switch in ON position
Cable compartment door closed
Note: Apparatus is circuit-breakers.
Padlocks
11 Apparatus compartment door opening
12 Cable compartment door opening
13 Insertion of the apparatus raking-in/out crank lever
14 Insertion of the earthing switch operating lever
15 Shutters opening or closing
It is necessary to use padlocks with 5-8 mm hasp diameter
4.4 Control wiring plug connector coding
The connection between low voltage
compartment and circuit breaker is established
by a multi-pin control plug and socket. It is
recommended to ensure connecting the
secondary plug and socket before rack-in of the
circuit breaker from test to service position.
The control wiring plug and socket are also coded
to prevent any erroneous connection between
incompatible withdrawable part and the
switchgear, though their dimensions appear
similar.
Thanks to the coding fitted in the control wiring
plug and socket!

Table 4: Control wiring plug connector coding table
Panel rated current Revets position assembly in apparatus Hole open position in panel
B1 B2 B3 B4 B5 B6 B1 B2 B3 B4 B5 B6
1250A VD4 circuit breaker 0 0
1600A/2000A VD4 circuit breaker 0 0 0 0
2000A VD4 circuit breaker 0 0
2500A VD4 circuit breaker 0 0 0 0
1250A VD4 isolating truck 0 0 0
1600A/ 2000A VD4 isolating truck 0 0 0 0 0
2500A VD4 isolating truck 0 0 0 0
20 UNIGEAR ZS2 INSTALLATION, OPERATION AND MAINTAINANCE INSTRUCTION MANUAL
—
Figure 27 - Push button assembly for emergency ON/OFF arrangement
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
27.1
Swiveling
push rod
—
Figure 28 - Control wiring plug connector
1 Bore for actuating pin of the control wiring plug for
controlling the auxiliary switch
2,4 Centering striking tabs
3 Control wiring socket
2
3
4
1
4.5 Instructions for floor-rolling version
circuit breaker
In floor-rolling circuit breaker version, the circuit
breaker is mounted on a trolley equipped with
nylon wheels those roll on the ground, and
thereby making the handling of circuit breaker
easier.
The door of circuit breaker compartment and
cable compartment are unified to form a single
door, instead of two separate doors.
The circuit breaker compartment door is of
pressure resistant design for internal arc fault
and is also pad lockable. It is provided with
security glass for inspection purposes.
4.5.1 Handling of floor-rolling circuit breaker
4.5.1.1 Racking-in from Test to Service position
A ramp arrangement is provided in the
switchgear, as an integral part, to facilitate easy
insertion of the floor rolling circuit breaker into
switchgear; with the circuit breaker in switched
OFF condition. Refer Fig. 29.
The trolley must be pushed completely inside the
switchgear as far as possible, till the
Test position, and secured in place.
This is performed as follows:
• while pushing the circuit breaker, gently slide
handles of the traverse towards the square
spigot of the spindle mechanism at the center
of the circuit breaker
• on reaching the Test position of the circuit
breaker, release handles of the racking
mechanism or traverse
• locking flanges at both ends of the traverse
are to be aligned with slots provided on both
guide rails mounted on sidewalls of the
switchgear
Auxiliary power plug and socket with control
wiring are to be connected when the circuit
breaker is in Test/Disconnected position.
Manual insertion from the test/disconnected
position to the service position:
• Close the front door