ABB UniGear ZS2 UniSafe 36 User manual

UniGear type ZS2 UniSafe 36
Installation and maintenance instructions for
MV arc-proof air insulated metal-clad switchboards
This Manual contains general information needed for receiving, installation, commissioning,
operation and maintainence of the switchboards.
The trade name of switchboards are referred as UniGear type ZS2 after june2004

Installation and maintenance instructions UniGear type ZS2 UniSafe-36 1YTW571780-012 Rev:E 01-2005 en Page: 2 of 25
CONTENTS
0INTRODUCTION ........................................................................................................................................................... 3
1PRODUCT DESCRIPTION ............................................................................................................................................ 4
1.1 Ratings...................................................................................................................................................................4
1.2 Typical sections....................................................................................................................................................4
1.3 1200mm width version ..........................................................................................................................................5
2INSTALLATION INSTRUCTION ................................................................................................................................. 6
2.1 Floor......................................................................................................................................................................6
2.2 Space requirement .................................................................................................................................................8
2.3 Unpacking and transport .......................................................................................................................................9
2.4 Cubicle’s erection................................................................................................................................................10
2.5 Busbar assembly..................................................................................................................................................11
2.6 Through Earth Bar...............................................................................................................................................15
2.7 Cables termination...............................................................................................................................................16
2.8 Final Tightening ..................................................................................................................................................17
2.9 Control Cables.....................................................................................................................................................17
2.10 End covers...........................................................................................................................................................18
2.11 Cleaning ..............................................................................................................................................................18
3PUTTING INTO SERVICE .......................................................................................................................................... 18
4OPERATING INSTRUCTION...................................................................................................................................... 19
4.1 Earthing Switch ...................................................................................................................................................19
4.2 Circuit Breaker, HD-4 W 36 ...............................................................................................................................21
4.3 Withdrawable Voltage Transformer....................................................................................................................23
4.4 Fixed Voltage Transformer, cable circuit............................................................................................................23
5MAINTENANCE INSTRUCTION ............................................................................................................................... 24
5.1 General ................................................................................................................................................................24
5.2 After Sale ............................................................................................................................................................24
6DOCUMENTATION REFERENCE ............................................................................................................................. 24

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0 INTRODUCTION
DOCUMENTATION DELIVERED WITH THE PRODUCT
Single line dwg.
Front view,
Foundation plan,
Panel sectional view,
Circuit diagram,
Terminal list,
Components list (electrical),
Packing list,
Other order-bound documents (if any)
The actual switchgear may have technical-constructional variations according to installation-requirements o
f
the order. So, it is necessary to consult both this manual and up-dated order-
b
ound technical documentation
during the lifetime of switchboards:
! FOR YOUR SAFETY
Make sure that the room is suitable for the installation of switchgear
Make sure that the personnel are provided with this manual and are aware of all the relevant information.
Make sure that the ratings are not exceeded while the switchgear is in service
ACCESS ZONES
Switchgear is not intended to be accessible to unauthorised people.
The access zone for operators is the front of the switchgear. All operations must be made with the doors
closed. Only skilled and authorized personnel are allowed to open switchgear doors etc.
LOCAL RULES
All operations described in this manual should be carried out by trained and specialized personnel.
The valid country standards and regulations and the safety procedures of the user organisation should also
be followed.
CONTROL ON RECEIPT
On receipt the switchgear must be unpacked and checked. Damages from transportation or other
irregularities must be notified and reported to the related ABB office.
Identity No. and ratings of switchgear can be seen on the rating plate on inner side of LVC.
The switchgear are only supplied complete with the accessories specified in the order form confirmed by
ABB.
The documents enclosed in the packing are:
Shipping labels.
This Instruction Manual (accompanied with order-bound instruction when necessary)
The test certificate (traceable reference to factory test-records)
The electrical diagram(s).
STORAGE
The packing is normally intended for transport and not for storing purpose. Packing suitable for storage can
be supplied upon request.

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1 PRODUCT DESCRIPTION
1.1 Ratings
Rated values of Switchgear acc. to IEC 62271-200 appear on the nameplate which is inside the L.V.
compartment door.
The typical panels are Internal arc tested 25kA/1s, acc to IEC 60298 annex-AA, accessibility AF-LR,
criteria 1...6.
Rated values of apparatus (Circuit breaker, Earthing switch, CT, VT etc) appear on the respective
component.
Ratings apply for use in normal service conditions described in IEC 60694 para2.1.1, summarized as foll:
- The ambient air temperature does not exceed 40degC. The minimum ambient air temperature is –5degC.
- The altitude does not exceed 1000m. above sea level
- The ambient air is not significantly polluted by dust, smoke, corrosive and/or flammable gases, vapours or
salt.
-Degree of protection of persons against approach to live parts and contact with moving parts is: Enclosure:
IP4X, Partitions: IP2X
1.2 Typical sections
Fig:1.2.1 Circuit Breaker Feeder, 1250A Fig:1.2.2 Busbar Metering /Earthing/Direct cable
Fig:1.2.3 1250A Sectionalizer Fig:1.2.4 1250A Busriser, /Metering

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Fig:1.2.5 Metering
Complementary pair
Fig:1.2.6 Circuit Breaker Feeder, 1600-2000-2500A
Width: 2x1000mm (including metering)
Fig:1.2.7 1600-2000-2500A Sectionalizer Fig:1.2.8 1600-2000-2500A Busriser
1.3 1200mm width version
Fig:1.3.1 C.B.Feeder 630-1250-1600-2000-2500A

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2 INSTALLATION INSTRUCTION
! CAUTION! Make sure that the cubicle can not be dropped or tilted during unpacking,
transportation or assembly.
CAUTION! The encapsulating sheet steel of cubicles may have sharp edges inside and on the roof.
2.1 Floor
Check the floor regarding openings for the cables according to figure 2.1.1 and/or 2.1.2
Check the floor level. The deviations in height for the supporting surface to the cubicles must be less than
2mm/m. Otherwise the cubicles will require spacers to get a proper aligning.
Figure 2.1.1 Floor layout view, typical
D
CL
CR
Rear cover depth,
Lateral clearance,
Rear clearance,
52 ... 140mm mm
600 (min. 100) mm
600 (min. 100) mm

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The cubicles can be installed on different types of floors.
Anchoring bolts on Concrete flooring:
Holes for the cables should be as small as possible. Avoid having single phase cables separated in different
holes in such a way that magnetic heating occurs in the iron-reinforcement. After the cable termination the
opening shall be sealed against fire and small animals. The aluminium bottom plate in the cubicle can be
used for this purpose. The cubicles should be bolted to the floor similar to Fig 2.1.3
Base irons in the floor slab:
Similar to Fig 2.1.4
Framework flooring for switchgear:
The framework should be made with three longer sections, one in the front, one at the back and one in the
middle along the switchgear. Cross sections are to be fitted to support the sidewalls of the cubicles. The
cubicles should be fastened with bolts through the framework section. Similar to figure 2.1.5
Fig:2.1.2 Version with anchoring
bolts
Fig:2.1.3 Version with base iron
Fig:2.1.4 Version with metal
structure
1: Anchoring bolt
2: Washer-plate appr. 6mm thickness
3-4-6: Screw (hexagon or countersunk)
5: Threaded block
7-8: washer
9: C-profile steel, in concrete
10: Nut
11: Levelled horizontally by spacers
12: Floor level

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2.2 Space requirement
A typical installation in building is shown below. During order-bound design of substation the written
dimensions as well as the min. dimensions should be considered.
Fig: 2.2.1 sectional layout view, typical
CF
HC
*
Front clearance
Ceiling height
1500 mm (min)
3000 mm (min)
see fig 2.1.1
Fig: 2.2.2 rear building view, typical dimensions indicate rectangular holes for arc duct channel
The arc vent duct is a common compartment throughout the switchgear. Every 3rd or 4th cubicle has an exhaust
flap in the rear wall and opens for overpressure. These flaps should be directed to the non-attended part at
minimum 2m height. The flap-channel is fixed and sealed in the wall according to dimensions shown in figure
2.2.2 The flap has to be protected from rain to avoid water drop into the cubicles. The flap has plastic rivets
intended to break at overpressure and should not be fixed with screws. There should be no obstacle for the flap
to open .
During the project-bound design, different layouts for exhaust duct are possible which should be considered
together with the design of substation building.

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2.3 Unpacking and transport
The packing is intended for transport and not for storing purpose. Upon receipt the switchgear must be
unpacked and installed under clean, dry, dust-free, indoor conditions and anti-condensation heaters should
be connected. The cubicles which are without vacuum packing are normally fixed to the pallet. The
palette is suitable for lifting by transpalette or fork-lift from all four sides provided that the width and length
of transpalette is fitting. If the packing includes vacuum bags they might be used for storage indoors or
under shelter for a period of time adapted to the ambient conditions. Packing for storage purpose can be
supplied upon specific request.
! CAUTION! The center of gravidity may vary according to apparatus installed in panels.
CAUTION! Assure that the panel is not damaged,tilted or dropped.
The lifting beam in fig:2.3.3 is not included in the delivery. Consider min 1.5 ton lifting capacity for each
1000mm cubicle.
Fig: 2.3.1
554685-801
Ordering number for the lifting
handles
Fig: 2.3.2
Fig: 2.3.3
For each switchgear transport unit instructive labels
or dwg. is fixed on the wooden crate. Example:
Fig:2.3.4
Study those advices also and check the transport
tools before you attempt lifting and transport.
Fig: 2.3.4
Fig:2.3.5
Fig:2.3.6
At the installation place it will be necessary to remove the wooden transpalette under the panel and adjust the
placement. If a crane is not available than the panel can be lifted by 2 transpalettes or suitable jacking tools
and the panel can slide on 7-8 pcs of roller-tubes.
Pay attention to the hollow part under the cubicle fore-part. (Fig:2.3.6)

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The HD4 breakers are delivered either
in the panels or in separate packing
according to order planning.
The HD4 breaker has the liftingspots
marked and crane-lifting must consider
these spots.
Please refer to Instruction Manual for
HD4W-36kV circuit breakers.
Doc:ITNIE647016/003
Fig:2.3.7 2.3.8 2.3.9
Circuit Breaker Trolley, Fixed height. (Order no:
1YTW572756-101)
Lift the CB manually or using a suitable hoist,
and place it onto the trolley.
Refer to chapt 4.2 of this manual.
Fig:2.3.10 Fig:2.3.11
2.4 Cubicle’s erection
. ! CAUTION! The encapsulating sheet steel of cubicles may have sharp edges inside and on the roof.
Before erection the highest point of the floor is identified. The erection begins with the left hand cubicle
which is placed in level with the highest point. The cubicles are trestled if necessary in the front, at the back
and the middle along the switchgear. This is made by one or more layers of thin steel plates.
If the cubicle will be mounted against the wall make sure that the bolts for the rear cover are tightened
before fixing the cubicles.
See also 2.5 before the next cubicle is installed. Next cubicle can then be installed and aligned and adjusted
to the first one.
Tighten the cubicles with bolts in the fitting holes close to the front and rear sides. The fixing is made by
M8X25 bolts.
Remaining cubicles should be erected in the same way. When all cubicles are erected the alignment of the
fronts should be checked.
Fig:2.4.1 Fixing points (without arc-vent channel)
Fig:2.4.2 Fixing points (with arc-vent channel)

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2.5 Busbar assembly
! CAUTION! The encapsulating sheet steel of cubicles may have sharp edges inside and on the roof.
Access possibilities for the main busbars installation are shown on the below figure, they are:
-side access during installing the adjacent cubicle
-removable roof plate
-removable rear cover + rear plate of the main busbar compartment
It is advisable that the busbar erection is done in parallel with the cubicles erection when access to the main
busbar compartment is available from side.
The insulated main busbars, and tee-boots are delivered loose in each respective panel,
Fastening parts are delivered ready-fixed on the dropper busbars.
Busbar assembly work require cleanness as the dielectric strength will be decreased by metal dust etc.
Fig:2.5.1 Access for main busbars installation
The insulated busbars must be protected against damaging of the insulation. Damaged insulation must be
renewed. The PVC protective with air cushion will protect the insulated parts from damages also during
transport and installation period. Keep them on the busbars as long as possible until commisioning. Busbar
assembly work require cleanness as the dielectric strength will be decreased by metal dust etc.
Fig:2.5.2
Fig:2.5.3
Make sure the contact surfaces of busbars and connector parts are clean. Use only the strong type of conical
spring-washers (ABB 9ADA334, DIN 6796) for all bolted conductor connections. This will keep the
required pressure for the lifetime of the switchgear eliminate the risk of problems due to overheating.
Torque-meter should be used during erection , tightening torque are as tabulated in chapt:2.8
Note for 1250A main busbar assembly, dropper busbars delivered until mid-2004 had M16 thread in copper,
in this case the engaged length of bolt-thread is critical to be maximum not to damage the copper thread,
also reduced torque (90Nm) with greasing of bolt head should be applied. Greased bolt due to low friction
assure equivalent contact pressure with less tightening torque.

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Below are guide-figures for busbars assembly.
Fig: 2.5.4
Fig: 2.5.5
Fig:2.5.6
Fig: 2.5.7
Fig:2.5.8
Fig:2.5.9
Main busbar 2500A, Circuit: 1600-2000-2500A
2500A Main busbars should be installed while panel erection. Otherwise access necessary both from the
busbar compartment and the CB compartment.

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Fig:2.5.10
2500A Busbar connections with helicoil springs. Adjacent springs are in opposite direction.
The connection helicoil springs are contact-greased against oxidation.At the end of installation rotate a few
times the busbars for best connection surface.
The tee connectors on the droppers are pre-assembled during production and normally need not to be dis-
assembled. Below is for information.
*
Fig:2.5.11 **
Fig:2.5.12
***
Fig:2.5.13
* 1600-2000-2500A Busbar tee connector with brass expansion part un-tightened.
** Turn clock-wise the threaded tee connector minimum 3 of 7 full turns . This will give 12mm adjusting
margin for the aligned axis of the main busbars.
*** Tightening by the M10 bolt .For dis-assembly untighten the bolt by 10-15mm and hit by hammer to drop
and release the expansion brass part
Fig:2.5.14
Tee boot of transparent
polycarbonate
Fig:2.5.15
Tee boot on 2500A main busbar
L3 right extremity
Fig:2.5.16
Fasten with plastic strap after final
assembly
THE TEE BOOTS apply for all main busbar-dropper connections, check the correct size for tee boots and
place them on the main busbar before fixing the main busbar onto the dropper.
After finishing busbars assembly and checking for tightening torque and cleanliness, slide to close the
insulating tee-boots. Just push the two halfs together and secure with plastic strap around the dropper end.
The main busbar ending shall have a half shaped tee boot with closed-end.

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Fig:2.5.17
Sectionalizer-Busriser lower main bars assembly, 1250A
Fig:2.5.18
Sectionalizer-Busriser lower main bars assembly, 1600-2000-2500A
Fig:2.5.19 Fig:2.5.20
Fig:2.5.21
View from front of lower main bars 1600-2000-2500A. Sectionalizer (left) Busriser (middle) Detail of
fixing by 2 pcs M12 bolts (right)

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2.6 Through Earth Bar
! CAUTION! The encapsulating sheet steel of cubicles may have sharp edges, be careful !
All cubicles have a copper bar for the earth system. The main earth bar is placed at bottom of cubicle
under the earthing switches. Those bars should be bolted together and the station earth system shall be
connected to through earth bar. Conical washers to ABB standard 9ADA334 must also be used
throughout the earth bar connections.
The bare earth bar and the cubicle steelplates must not “just touch” either must be fixed with an air gap or
bolted as connection. Copper bars used for earth connection to the AluZinc plate must be greased “type
E” to avoid galvanic corrosion.
The earth main bars have standard length.
Fig 2.6.1 Through earth bar,assembly.

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2.7 Cables termination
The cables must have been earthed before access to cables compartment. Removal of the horizontal bottom
plate in the breaker compartment and/or removal of the rear-cover allows access to cables compartment.
Please consider that some commissioning tests (part 3) are done with the power cables disconnected.
Fig:2.7.1
Fig 2.7.2
Fig:2.7.3
Fig: 2.7.1 2.7.1 2.7.3 2.7.3 2.7.2
Cable comp. width,mm 1000 1000 1200 1200 2000
Cu conn. bars, Cu 2x40x10 2x80x10 4x40x10 4x80x10 4x80x10
Typical Cable lugs
DIN46235, sqmm/ph 2x1x400 2x1x630 4x1x400 4x1x630 4x1x630

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1) Mark and prepare holes on the aluminium bottom plates
2) Pull the cable into the cable compartment and make a termination according to the suppliers instructions.
3) put a transparent hose onto the earthwire and connect it to the earth-bar.
4) Bring the cable to a final position and fix it with clamp such that connection points are not forced.
5) Tighten connections considering the table below.
6) For the fig 2.7.3 1200mm wide cables compartment install the insulated plates (4pcs) between phases
with screws of insulating material
Due to limited dimensions of switchgear cables compartment, number and size of cables must be complied
and minimum length of bolt etc. must be used not to decrease clearances between phases and earth.
Refer to order bound instructional drawings for cases other than above.
2.8 Final Tightening Tolerance: -0% ... +20% M6 M8 M10 M12 M16
General assembly with steel bolts and nuts of min 8.8 property
class, mechanical and electrical connections
9 22 45 75 185
Main busbars assembly, conductors supported by epoxy
components with steel or brass nut-threads with conical
spring-steel washer DIN6796, thread and bolt head contact
surface * LUBRICATED with grease or oil (ref:DIN 43673) *4.5 *10 *20 *40 *80
2.9 Control Cables
The control cables will be terminated in the low voltage compartment. When they enter from the basement
they can run inside the front part of the end panels. The control cables will then follow the cable duct on top
of the low voltage compartments to the intended cubicle. There is a slot for cable entrance where the cables
can be fixed. Earth connections shall be done at the copperbar that is located close to the fixing point.
Fig:2.9.1 Fig:2.9.2
Fig:2.9.3 Fig:2.9.4
Fig:2.9.5
*
300x50mm
**
600x30mm
**** dia.
60mm
***
300x50mm
* Main horizontal channel at top of low voltage compartments
** Vertical channel between low voltage comp and main horizontal channel
*** Main vertical channel inside end-covers at left&right extremity panels
**** Vertical holes for aux cables rising through the floor (option)

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2.10 End covers
Fig:2.10.1 Ref: ABB dwg:1YTW572721-100
Towards the end of installation assemble the end covers at the right and left extremities .
2.11 Cleaning
After the installation of the main circuit before closing the enclosure covers and doors the cubicles have to
be checked and if necessary carefully cleaned. Busbars insulation, epoxy insulation and bushings should
be wiped dry and vacuum-cleaned.
3 PUTTING INTO SERVICE
All operations for putting into service must be carried out either by ABB personnel or other skilled
personnel authorized by the user organization.
! CAUTION! Untill putting into service by authorized and skilled personnel the switchgear must not
be energized. The earthswitches must be closed all the time until the regular energising.
Related personnel for putting into service should consider the below referred instructions:
Installation and service instructions, HD4 CHAPTER-8
ABB doc. no: ITNIE647016-003
Installation and maintenance instructions, UniSafe CHAPTER-11
ABB doc. no: ITNIE647647-001

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4 OPERATING INSTRUCTION
The operators access area is in front of the switchgear. Only authorized operating personnel may access
the switchgear.
! CAUTION! Only the Circuit breaker compartment door and Low Voltage compartment door can be
necessary to open by operator.
Do not attempt to open any other covers or shutters or screens before reading part 5 Maintenance
instruction.
4.1 Earthing Switch
! CAUTION! Earthing switch must not be attempted for operation when it is possible that a
personnel may be in the cubicle.
OPEN
AÇIK
CLOSED
KAPALI
Fig:4.1.1
Left-top: Earth Switch Manover position indicator as should be seen on front
Left-bottom: Earth switch position indicator as should be seen from lower window
7: Key lock*for ESw at open position
8: Key lock* for ESw at closed (earthed) position
9: Key lock* to prevent CB racking-in
10+11: Handle-cover to open entrance for operating lever
12+13: Esw operating lever (Art.No: 143429-802)
*Key-locks are optional. Lock by rotating the key 180º clockwise. It is possible to remove the key only at
locked position.
Fig:4.1.2 Esw type ST US 36
Fig:4.1.3 Esw type EB W 36

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Closing the earthing switch:
Check that the circuit breaker is in test or withdrawn position.
Open the lever entrance(11) by turning 90º the handle(10) anti-clockwise. This will not be possible if:
-the CB is in service position
-keylocked (7) for Esw at open position.. Do not force.
Insert operating lever.(12+13)
Assure that the circuit to be earthed has no voltage.
Turn the lever (12+13) clockwise 180º to close the earthing switch. This will not be possible if:
-electrical interlocking of ES position is on. Do not force.
Remove the operating lever, the lever entrance (11) is open.
See the closed (Earthed) position of Esw on indicator from the lower inspection window.
Key-lock if necessary the Esw in closed position (8)
Opening the earthing switch
Check that the circuit breaker is in test or withdrawn position.
The crank entrance (11) is open.
Insert the operating lever (13). This is not possible if the Esw is keylocked(8) at closed position.
Turn the lever anti-clockwise 180º to open the earthing switch. This is not possible if electrical
interlocking coil is on. Do not force.
Withdraw the operating lever.
Close the crank entrance by turning handle(10) 90º clockwise. (Note: The crank entrance must be
closed before the circuit breaker can be racked into service position)
See the open ( 0 ) position indicator from the lower inspection window.
Key-lock if necessary the Esw in open position (7)
Key-lock if necessary the CB against racking into service position (9)
Fig:4.1.4 Fig:4.1.5
Fig:4.1.6
Front view with operating
handle inserted
View from front the position
indicator and auxiliary contacts
View from inside the cubicle,
electro magnetic interlock for
earthing switch