ABB UniGear ZVC Manual

— UniGear ZVC Installation, operation and maintenance instruction manual
—
Medium voltage products
UniGear ZVC
Installation, operation and
maintenance instruction manual
• Safety
• Reliability
• Flexibility
• Economy

—
Table of contents
004
005 – 006
007 – 008
009 – 020
021 – 022
023 – 036
037 – 043
044
045 – 051
052 – 053
054
1Safety precautions
2 Description
3Technical data
4 Panel design and equipment
5 Dispatch and storage
6Assembly of switchgear at site
7Operation of the switchgear
8Commissioning
9 Maintenance
10 Troubleshooting
11 Environmental protection

Recommendations
• Only install switchgear and/or switchboards
in closed rooms suitable for electrical
equipment
• Ensure that installation, operation and
maintenance are carried out by specialist
electricians only
• Fullycomply with the legally recognized
standards (IEC or local), the connection
conditions of the local electrical utility and
the applicable safety at work regulations
• Observe the relevant information in the
instruction manual for all actions involving
switchgear and switchboards
• Pay special attention to the hazard notes in
the instruction manual
• Make sure that the specified data are not
exceeded under switchgear or switchboard
operating conditions
• The user’s personnel must act responsibly in
all matters effecting safety at work and correct
handling of theswitchgear
Read and keep theseinstructions
Carefully read and understand this instruction
sheet before installing, operating and maintaining
your UniGear ZVC. For safe operation the
appropriate Chinese or International Standards
should be applied.
Keep the instruction manual accessible to all
personnel involved in installation, operation
and maintenance. This instruction sheet should
be available for reference wherever UniGear
ZVCs are used. Keep this instruction sheet in a
locationwhere you can easily retrieve and refer
to it.
Warning!
• Always follow the instruction manual
and respect the rules of good engineering
practice
• Hazardous voltage can cause electrical
shocks and burns
• Disconnect power and then earth before
proceeding with any work on this
equipment
Notice
The instructions covered in this publication are
intended only for qualified personnel and are
not a substitute for adequate trainingand
experience in safety procedures.
If you have any further questions about this
instruction manual, the members of our field
organization will be pleased to provide the
required information.
—
1 Safety precautions
4UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS

2.1 General
UniGear ZVCis three-phase, air-insulated, type
tested and factory-assembled indoor switchgear
panel designed for the operation, control and
protection of motors and transformers at rated
voltages up to 7.2 kV and rated current up to
400 A. Other applications are possible and
should be referred to the manufacturer. The
panels are designed as withdrawable fused
vacuum contactor modules and are fitted with
a single busbar system.
Details of thetechnical design and configuration
of individual switchboards, such as the technical
data, detailed equipment lists for theindividual
panels and comprehensive circuit documentation,
can be found in the relevant order documents.
2.2 Standards andspecifications
UniGear ZVCswitchgear panels comply with
standards and specifications for type tested
factory-assembled high voltage switchgear to
IEC publications.
Other relevant IECpublications for components
include:
All other corresponding IEC publications, national
or local safety at work regulations and safety
regulations for production materials must be
followed during erection and operation of
UniGear ZVC switchgear. In each case the
order-related data from ABB must be taken
into account.
2.3 Operating conditions
2.3.1 Normal operating conditions
The switchgear is basically suitable for normal
operating conditions for indoor switchgear
and switchboards in accordance with IEC. The
following limit values, among others, apply:
The maximum site altitude is 1000 m above sea
level. For higher site altitude, refer to order
related data.
2.3.2 Special operating conditions
The switchgear is suitable for operation in
climateof Wdatype according to IEC. Special
operating conditions must be discussed with
the manufacturer in advance. For example:
• At site altitudes above 1000 m, the effects of
the reduction in dielectricstrength of the air
on the insulation level must be taken into
account (refer to 2/1)
• Increased ambient temperatures must be
compensated for in the designof the busbars and
branch conductors as well as for the withdrawable
parts, otherwisethe current carrying capacity
will be limited. Heat dissipation in the switchgear
panel can be assisted by fitting additional
ventilation facilities
IEC publication
60470
62271-102
60470 & 60529
62271-200 & 60298
Components covered
Motor starter & contactor
Earthing switch
Degree of protection
Arc fault containment
IP4X external closure
IP2X internal
shutters & partitions
Ambient temperature
Maximum
Maximum 24 h average
Minimum (according to “minus 5 indoor class”)
°C
+40
+35
-5
Ambient humidity
Maximum 24 h average of relative humidity
Maximum 24 h average of water vapour pressure
Maximum monthly average of relative humidity
Maximum monthly average of water vapour pressure
95% RH
2.2 kPa
90% RH
1.8 kPa
—
2 Description
DESCRIPTION 5
Note:
When switchgear is operated in areas with high
humidity and/or major rapid temperature
fluctuations,there isa risk of dew deposits
which must remain an exception in normal
operating conditions for indoor switchgear.
Preventive action (e.g. fitting electric heaters)
must be taken in consultation with the
manufacturer to avoid this condensation
phenomenon and any resulting corrosion or
other adverse effects. The control of theheaters
depends on the relevant project and details
must be taken for the order documents.

2.1 General
UniGear ZVCis three-phase, air-insulated, type
tested and factory-assembled indoor switchgear
panel designed for the operation, control and
protection of motors and transformers at rated
voltages up to 7.2 kV and rated current up to
400 A. Other applications are possible and
should be referred to the manufacturer. The
panels are designed as withdrawable fused
vacuum contactor modules and are fitted with
a single busbar system.
Details of thetechnical design and configuration
of individual switchboards, such as the technical
data, detailed equipment lists for theindividual
panels and comprehensive circuit documentation,
can be found in the relevant order documents.
2.2 Standards andspecifications
UniGear ZVCswitchgear panels comply with
standards and specifications for type tested
factory-assembled high voltage switchgear to
IEC publications.
Other relevant IECpublications for components
include:
All other corresponding IEC publications, national
or local safety at work regulations and safety
regulations for production materials must be
followed during erection and operation of
UniGear ZVC switchgear. In each case the
order-related data from ABB must be taken
into account.
2.3 Operating conditions
2.3.1 Normal operating conditions
The switchgear is basically suitable for normal
operating conditions for indoor switchgear
and switchboards in accordance with IEC. The
following limit values, among others, apply:
The maximum site altitude is 1000 m above sea
level. For higher site altitude, refer to order
related data.
2.3.2 Special operating conditions
The switchgear is suitable for operation in
climateof Wdatype according to IEC. Special
operating conditions must be discussed with
the manufacturer in advance. For example:
• At site altitudes above 1000 m, the effects of
the reduction in dielectricstrength of the air
on the insulation level must be taken into
account (refer to 2/1)
• Increased ambient temperatures must be
compensated for in the designof the busbars and
branch conductors as well as for the withdrawable
parts, otherwisethe current carrying capacity
will be limited. Heat dissipation in the switchgear
panel can be assisted by fitting additional
ventilation facilities
1000
0, 4
0, 6
0, 8
1, 0
K
2000 3000 4000 5000m H
6UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS
Note:
When switchgear is operated in areas with high
humidity and/or major rapid temperature
fluctuations,there isa risk of dew deposits
which must remain an exception in normal
operating conditions for indoor switchgear.
Preventive action (e.g. fitting electric heaters)
must be taken in consultation with the
manufacturer to avoid this condensation
phenomenon and any resulting corrosion or
other adverse effects. The control of theheaters
depends on the relevant project and details
must be taken for the order documents.
—
2/1 Curve for
determination of the
altitude factor K in
relation to the
altitude H.
—
2/1

Rated voltage
Rated power frequency withstand voltage peak
Rated lightning impulse withstand voltage
Rated frequency
Rated main busbar current
Rated current of tee-off busbar
Rated peak withstand current of main busbar
Rated short time current of main busbar
Earthing switch rated making current peak
Earthing switch rated short time current
Withdrawable fused contactor rated normal current
HV fuse type
CT rated secondary current
1) On request.
3.1 Electrical data
kV
kV
kV
Hz
A
A
kA
kA
kA
kA
A
A
3.6
10
40
50/60
4000
400
125
50/3 s
31.5
12.5/1 s
200/400
Tag type to BS2692-1986 type II 454 mm centres maximum
1
7.2
20 (32) 1)
60
3.2 Resistance to internal arc faults
The internal arc fault withstand capability is up
to 50 kA for 1 swith 125 kAp.
Refer tothe general arrangement drawings of
the order for specific details of the gas duct.
3.3 Dimensions and weights
D
F
C
B
E
A
30
—
3 Technical data
TECHNICAL DATA 7
—
3/1 Front and side
views
—
3/1

Dimension
Height
Width of a basic panel
Depth
Height of basic panel
Height with standerd gas duct fitted
1) Different arc duct options are available. Check the order documentation for overall height.
Symbol
A
B
C
D
E
F
mm
2200/2400/2595
325
1304/1554 See configuration table below
2100
1535
2680 1)
Description
1304 mm deep panel with busbars ≤4000 A-excluding fused vacuum contactor
1554 mm deep panel with busbars ≤4000 A-excluding fused vacuum contactor
V7/ZVC withdrawable vacuum contactor with HV fuses
Standard gas duct-per panel
End covers-per switchboard
Mass (kg)
400
550
90
40
140
Depth ‘C’ (mm)
Power cable entry
Control cable entry
Gas duct
1304
Bottom entry rear access
Bottom entry front access
Yes/No
Top entry rear access
Top entry front access
No
1554
Top entry rear access
Top entry front access
Yes
Weights table
Depth configuration
Bottom entry front access
Yes/No
8UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS

4.1 Basicstructure
The basis for the UniGear ZVC panel is theoutgoing
feeder panel with fused vacuum contactor of a
horizontal withdrawable design. It is divided into
busbar compartment A, fused vacuum contactor
compartment B, cable compartment C and low
voltage compartment D for the secondary
equipment. Apart from this, there are variants for
other operatingneeds. 4/1 to 4/3 shows examples
of possible configuration of a panel variant for
direct-on-line motor starters including electrical
equipment. Panels can be coupled in combinations
to provide variants for reversing motor starters,
twospeed motor starters, autotransformer motor
starters and reactor motor starters.
Further details about installation and equipping
the switchgear can be obtained from the order
documents.
4.1.1 Busbar compartment (4/12)
The busbars have a flat cross-section made of
copper and are laid in sections from panel to
panel. For higher rated currents (up to 4000 A),
the busbars have a D-shaped cross-section.
According to the current rating,either single or
double configuration is used. They are held by
a resin encapsulated branch conductor. No special
connection clamps are needed. No additional
support is necessary to withstand therated
short circuit current of the busbar system.
Busbars are insulated by means of shrink-on
Raychem sleeves. The bolt connections are without
any covers unless it is a specific requirement of
the customer order document.
4.1.2 Fused contactor compartment (Figures
4/10, 4/12, 4/13and4/14)
The fused contactor compartment contains all
the necessary equipment for removal/insertion
and connection/disconnection operation of the
withdrawable fused contactor. Like the busbar
compartment, it is metallically partitioned on
all sides.
The fused contactor compartment B includes
guiderails for the withdrawable fused contactor.
The withdrawable fused contactor is anchored to
the cubicle with a truck lock operated by a double
bit key. Thetruck is moved between ISOLATED
and SERVICE position by a racking screw.
Self-aligningtulip contacts are located in epoxy
resin spout bushings behind a metal partition
plate.Automatic metal shutters, coveringthe
busbar and cable spout bushing openings, are
also included.
The shutters are opened by means of actuating
rods when the withdrawable fused contactor
moves to the SERVICE position, and are closed
when the withdrawable fused contactor returns
to theISOLATED position. In the ISOLATED position
the withdrawable fused contactor is separated
by metal partitioning from the main current
circuit.
Secondary control wiring contacts are automatically
connected via theplug on the rear of thetruck,
when the truck is installed in the cubicle and
thetruck lock operated.
The switching operations are carried out with
the door closed. The FUSE BLOWN indicator and
ON/OFF mechanical indicator on the contactor
can be observed through an inspection window. A
device for emergency manual opening of a latched
contactor in the SERVICE position is located below
the inspection window.
4.1.3 Withdrawablefused contactor (Figures
4/10, 4/12, 4/13and4/14)
The withdrawable fused contactor consists of a
vacuum contactor, type V7/ZVC, and tag type HRC
HV fuses housed in an epoxy resin monoblock
mounted on a chassis. Contact spouts are
incorporated in the monoblock to establish
connection between thewithdrawable fused
contactor and the tulip contacts in the panel.
The secondary contacts plug is automatically
connected when the contactor is inserted into
the contactor compartment.
The truck is moved manually between theSERVICE
and ISOLATED positions with the front door closed
by a handle engaged in the rackingspindle. SERVICE
and ISOLATED positions are monitored electrically
by means of auxiliary switches.
The earthing connection between the withdrawable
fused contactor and the panel is established by
its rollers and travel rails, which are bolted to
the panel.
Optional Control VT, with primary fuses, is mounted
on the chassis and is connected toterminals
on the load side of the HV fuses.
4.1.4 Cable connection compartment (Figures
4/12and 6/20)
The cablecompartment contains current
transformers, earthing switch, and cable
terminating module. Where specifically ordered,
the compartment can also contain surge arresters,
capacitive insulators and zero sequence current
transformer.
The typeZVCE7 fault-making earthingswitch is
manually operated by handle, with the front door
closed. Its switching position will be indicated
both mechanically and electrically by means of
the auxiliary switch.The physical position of
the moving contacts can beviewed through a
window in the front door.
The compartment is suitable for connectingup
to 1x240 mm2 3-core cable or 2x150 mm23-core
cables on copper tags separated by epoxy resin
phase barriers on the cable terminating module.
Complex combinations of cable type and size,
zero sequence CT, cable clamps/glands,surge
arresters and capacitive insulators must be
decided at thetimeof manufacturer.
4.1.5 Low voltagecompartment (Figures 4/12,
6/19)
The compartment contains control and protection
equipment suitable for both conventional or
microprocessor control technology.
The height of the low voltage compartment is
665/865/1060 mm.
If thesecondary devices are not intended for
door installation, they are mounted on special
metal strips. They enable any subsequent
changes tothe wiring.
In the lower part of the low voltage compartment,
there are rows of terminal strips. There is a bushing
for sliding in the interpanel wires at theside of
the low voltage compartment.
Secondary wiring inside thepanel is inaduct
on theright side of the panel. The left side of
the panel is for the external wiring. The wiring
is protected by a steelcover.
—
4 Panel design and equipment
PANEL DESIGN AND EQUIPMENT 9

4.1 Basicstructure
The basis for the UniGear ZVC panel is theoutgoing
feeder panel with fused vacuum contactor of a
horizontal withdrawable design. It is divided into
busbar compartment A, fused vacuum contactor
compartment B, cable compartment C and low
voltage compartment D for the secondary
equipment. Apart from this, there are variants for
other operatingneeds. 4/1 to 4/3 shows examples
of possible configuration of a panel variant for
direct-on-line motor starters including electrical
equipment. Panels can be coupled in combinations
to provide variants for reversing motor starters,
twospeed motor starters, autotransformer motor
starters and reactor motor starters.
Further details about installation and equipping
the switchgear can be obtained from the order
documents.
4.1.1 Busbar compartment (4/12)
The busbars have a flat cross-section made of
copper and are laid in sections from panel to
panel. For higher rated currents (up to 4000 A),
the busbars have a D-shaped cross-section.
According to the current rating,either single or
double configuration is used. They are held by
a resin encapsulated branch conductor. No special
connection clamps are needed. No additional
support is necessary to withstand therated
short circuit current of the busbar system.
Busbars are insulated by means of shrink-on
Raychem sleeves. The bolt connections are without
any covers unless it is a specific requirement of
the customer order document.
4.1.2 Fused contactor compartment (Figures
4/10, 4/12, 4/13and4/14)
The fused contactor compartment contains all
the necessary equipment for removal/insertion
and connection/disconnection operation of the
withdrawable fused contactor. Like the busbar
compartment, it is metallically partitioned on
all sides.
The fused contactor compartment B includes
guiderails for the withdrawable fused contactor.
The withdrawable fused contactor is anchored to
the cubicle with a truck lock operated by a double
bit key. Thetruck is moved between ISOLATED
and SERVICE position by a racking screw.
Self-aligningtulip contacts are located in epoxy
resin spout bushings behind a metal partition
plate.Automatic metal shutters, coveringthe
busbar and cable spout bushing openings, are
also included.
The shutters are opened by means of actuating
rods when the withdrawable fused contactor
moves to the SERVICE position, and are closed
when the withdrawable fused contactor returns
to theISOLATED position. In the ISOLATED position
the withdrawable fused contactor is separated
by metal partitioning from the main current
circuit.
Secondary control wiring contacts are automatically
connected via theplug on the rear of thetruck,
when the truck is installed in the cubicle and
thetruck lock operated.
The switching operations are carried out with
the door closed. The FUSE BLOWN indicator and
ON/OFF mechanical indicator on the contactor
can be observed through an inspection window. A
device for emergency manual opening of a latched
contactor in the SERVICE position is located below
the inspection window.
4.1.3 Withdrawablefused contactor (Figures
4/10, 4/12, 4/13and4/14)
The withdrawable fused contactor consists of a
vacuum contactor, type V7/ZVC, and tag type HRC
HV fuses housed in an epoxy resin monoblock
mounted on a chassis. Contact spouts are
incorporated in the monoblock to establish
connection between thewithdrawable fused
contactor and the tulip contacts in the panel.
The secondary contacts plug is automatically
connected when the contactor is inserted into
the contactor compartment.
The truck is moved manually between theSERVICE
and ISOLATED positions with the front door closed
by a handle engaged in the rackingspindle. SERVICE
and ISOLATED positions are monitored electrically
by means of auxiliary switches.
The earthing connection between the withdrawable
fused contactor and the panel is established by
its rollers and travel rails, which are bolted to
the panel.
Optional Control VT, with primary fuses, is mounted
on the chassis and is connected toterminals
on the load side of the HV fuses.
4.1.4 Cable connection compartment (Figures
4/12and 6/20)
The cablecompartment contains current
transformers, earthing switch, and cable
terminating module. Where specifically ordered,
the compartment can also contain surge arresters,
capacitive insulators and zero sequence current
transformer.
The typeZVCE7 fault-making earthingswitch is
manually operated by handle, with the front door
closed. Its switching position will be indicated
both mechanically and electrically by means of
the auxiliary switch.The physical position of
the moving contacts can beviewed through a
window in the front door.
The compartment is suitable for connectingup
to 1x240 mm2 3-core cable or 2x150 mm23-core
cables on copper tags separated by epoxy resin
phase barriers on the cable terminating module.
Complex combinations of cable type and size,
zero sequence CT, cable clamps/glands,surge
arresters and capacitive insulators must be
decided at thetimeof manufacturer.
4.1.5 Low voltagecompartment (Figures 4/12,
6/19)
The compartment contains control and protection
equipment suitable for both conventional or
microprocessor control technology.
The height of the low voltage compartment is
665/865/1060 mm.
If thesecondary devices are not intended for
door installation, they are mounted on special
metal strips. They enable any subsequent
changes tothe wiring.
In the lower part of the low voltage compartment,
there are rows of terminal strips. There is a bushing
for sliding in the interpanel wires at theside of
the low voltage compartment.
Secondary wiring inside thepanel is inaduct
on theright side of the panel. The left side of
the panel is for the external wiring. The wiring
is protected by a steelcover.
10 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS
—
4/1 Feeder unit -
direct-on-line
motor starter.
Front access.
—
4/2 Feeder unit -
direct-on-line
motor starter with
surge arresters and
voltage indicator
bushings. Front
access.
—
4/1
—
4/2

4.2 Enclosure and partitioning (4/12)
The enclosure and internal partitions of the panels
are of 2 mm thick high quality aluminium-zinc
coated steel sheets. The three high voltage
compartments (busbar compartment A,fused
contactor compartment B and cable connection
compartment C) are equipped with top-mounted
and secured pressure relief flaps. These open in
the case of overpressure due to an internal arc
fault.
The front of thepanel is closed off byapressure
resistant door which isopened with the double
bit key to anangle of 120˚.The door is fitted
with a manual closing system secured byscrews.
Cable and fused contactor compartments share a
common door. The door is equipped with pressure
resistant inspection windows for viewing the
fused contactor and cable connection/earthing
compartments. Neighbouringpanelsare
partitioned from one another by theside walls
of each panel and, as a result of the design, an
air cushion remains between these walls when
thepanels are joined together.
door screws
(4 in total)
double bit key
The enclosure is completed:
a Above, by top-mounted pressure-relief flaps
which, according to the rated branch conductor
current, are made of sheet steel or expanded
metal, and
b Below, by means of floor mounted sheet steel
cable entry gland plate. The pressure-relief flaps
are secured with steel screws on the front
longitudinal side and on the other longitudinal
side with plastic screws. In the case of internal
overpressure, the plastic screws are the point
of rupture.
Arc fault current limitation in thebusbar and
fused contactor compartments can be achieved
by instantaneous incoming breaker release,
initiated by Ith limiter auxiliary switches (4/16)
operated by thepressure wave acting on the
pressure relief flaps.
Arc fault current limitation in thefused contactor
and cable compartments is inherent in rupture
of the current limiting HV fuse.
PANEL DESIGN AND EQUIPMENT 11
—
4/3 Feeder unit-
direct-on-line
motor starter with
standard arc duct
and top rearentry.
—
4/4 Operation of
the door screw
—
4/3
—
4/4

The necessary safety measures to counteract
the effects of an internal arc fault must be
ensured in relation tothe ceiling height. In
individual cases, this may require additional
operator protection measures on theswitchgear
panels. These measures include:
1 Mounting a pressure relief duct (4/5 and 4/6)
on thetop of the switchgear, with further
channels leading out of theswitchgear room
in aform appropriate for the design of the
building. The shockwave and arc discharge
are channeled off in the duct.
2Depending on the value of thesystem fault
current and the constraints of the switchroom
design the arc products are vented through
a top chimney of the arc duct and into the
switchroom.Atypical arrangement is shown
in 4/7.
The rear wall of busbar compartment A, mounting
plate with shutters and horizontal partition and
form part of the internal partitioning.
The low voltage compartment for thesecondary
equipment is completely protected from the high
voltage area thanks to its steel-sheet casing.
On thetwo ends of theswitchboard, end covers
ensure good appearance and are mechanically
and thermally arc fault proof should such an
event occur.
Doors and rear walls aswell as the end cover are
thoroughly cleaned and treated against corrosion.
Then doors and end cover receive high quality
powder coating of paint. Rear wall can be
painted by agreement. The finishing coat is in
the standard RAL 7035colour (light grey - other
colours on request). Stoving completes the
painting procedure and provides protection from
impact and corrosion.
12 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS
—
4/5 Typical standard
arc duct arrangement
—
4/6 Typical compact
arc duct arrangement
—
4/5
—
4/6

Removable horizontal partition
End cover
PANEL DESIGN AND EQUIPMENT 13
—
4/7 Typical top
chimney arc duct
arrangement
—
4/8 Switchboard
with bolted end
cover
—
4/9 View into
contactor
compartment with
door open
—
4/7
—
4/9
—
4/8

Tulip contacts
Actuating rods
Top shutter (Busbar)
Lower shutter (Cable)
Secondary contacts plug
Provision for padlock
14 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS
—
4/10 View inside
contactor
compartment
—
4/11 Lower shutter
may be secured with
padlock to prevent
unauthorized
operation
—
4/10
—
4/11

4.3 Interlock/ protection against incorrect
operation
4.3.1 Panelinternal interlocking (4/12)
To prevent hazardous situations and erroneous
operation, there is a series of interlocks to protect
both personneland equipment.
• The withdrawable part can only be moved
from the test/disconnected position (and
back) when the contactor and earthing switch
are off (i.e. the switch must be off beforehand).
In the intermediate position, thecontactor is
mechanically and electrically interlocked and
the earthing switch is mechanically interlocked
• The contactor can onlybe switched on when
the withdrawable part is in the ISOLATED or
SERVICEposition. In the intermediateposition,
the contactor is mechanically and electrically
interlocked
• The contactor cannot be switched on if an HV
fusehas ruptured
• In panels with digital control technology,
prevention of malfunction of the apparatus
can also be achieved by means of the panel
software
A
B
C
D
Busbar compartment
Vacuum contactor compartment
Cable compartment
Low voltage compartment Enclosure
Pressure relief flap
Pressure relief flap
Branch conductor
Busbar
Earthing switch
Current transformers
Voltage transformer
Removable partition
Control wiring
plug connector
Mounting plate
Top shutter
Lower shutter
Withdrawable part
Earthing switch
operating
mechanism
Gland plate
Main earthing bar
Ventilation grid
Emergency
opening
pushbutton
Cable tags
A
B
C
D
• In the SERVICE or ISOLATED positions, the
mechanically latched contactor can only be
switched off manually when no control voltage
is applied
• The earthing switch can only be switched on if
the withdrawable part is in the ISOLATED
position or outside of the panel (mechanical
interlock)
• If theearthing switch ison, the withdrawable
part cannot be moved from the ISOLATED
position to the SERVICEposition (mechanical
interlock)
• Details of other possible interlocks, e.g. in
connection with a locking magnet on the
withdrawable part and/or earthing switch
drive, can beobtained from the relevant
order documents
• The voltage transformer secondary winding,
when fitted, is isolated when the withdrawable
fused contactor is moved from the SERVICE
position
PANEL DESIGN AND EQUIPMENT 15
—
4/12 Example of
UniGear ZVC feeder
unit
—
4/12

16 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS
Type
1
2
3
4
Keys (on request)
5
6
7
Padlocks
8
9
10
Locking magnets (on request at time of ordering)
11
12
Description
Racking truck IN
Contactor closing
Closing earthing switch
Racking truck IN
Opening panel door
Racking truck IN
Opening panel door
Earthing switch OFF
Truck racking IN lock
Earthing switch closing lock
Earthing switch opening lock
Insertion of truck
Insertion of earthing switch
Shutter open or closed
Truck racking IN/OUT
Earthing switch ON/OFF
Conditions be fulfilled
Contactor OFF, earthing switch OFF, door closed
Truck in SERVICE or ISOLATED
Truck in ISOLATED position
Earthing switch OFF
Truck in ISOLATED position, earthing switch ON
Panel door closed, earthing switch OFF
Earthing switch ON
Panel door closed
Key removed with truck in ISOLATED position
Key removed with earthing switch open
Key removed with earthing switch closed
A
B
A
B
A
B
A
B
4.3.2 Doorsinterlocking
The panels are equipped with thefollowing
interlocks:
• The fused contactor cannot be racked-in if
the contactor compartment door is open
• The contactor compartment door cannot be
opened if the fused contactor is in SERVICE
or in an undefined position
• The contactor/cable compartment door
cannot be opened if the earthingswitch is
open
• The contactor/cable compartment door cannot
be closed if theearthing switch is open
4.3.3 Locking devices (Figures 4/10,4/11, 4/12)
• The shutters can be secured independent of
each other with padlocks when thewithdrawable
fused contactor has been removed
• Access to the operating-shaft of the earthing
switch can be restricted with a padlock
4.4 Types of interlocks
• Access to the fused contactor racking spindle
can be restricted with a padlock
• Access to the fused contactor compartment
and the cable compartment can be restricted
with a padlock
4.3.4 Racking blocking electromagnet
The locking magnet is only active in the ISOLATED
position and SERVICEposition. In intermediate
positions it has no effect.
Withdrawable fused contactors with order-related
blocking magnet Y0 may not be moved in case of
control power failure, or when there is no control
power. Do not forcibly move locked withdrawable
fused contactors! Releasing the locking magnet
Y0 when the module isin the SERVICE position
(refer to 10.4.3).

PANEL DESIGN AND EQUIPMENT 17
—
4/13 V7/ZVC
operating elements
—
4/13
4.5 Interchangeability and coding
Fused contactor are interchangeable.In cases
where the order documents require the fused
contactor and panels tobe coded for contactor
rating or HV fuse rating code pins are fitted to
the transport chassis and the fused contactor
compartment floor to prevent amodule from
insertingfully in to a compartment if the
combination is not permitted. If any coding
applies, it will be recorded on the routine test
report.
4.6 Contactor truck V7/ZVC
V7/ZVC truck consists of an epoxy resin moulding
containing fuse holders that accept parallel HV
fuses, vacuum interrupters, the moving apparatus,
the electromagnet, the multi-voltage control
feeder and auxiliary accessories.
HV fuses
Truck guide
Contact spout
Control voltage transformer
Truck lockRacking spindle
Contactor ON/OFF indicator
Fuse-blown indicator
Truck position indicator
Operation counter Emergency opening pushbutton
The load &lineside connectors for the
withdrawable portion are moulded into the
epoxy resin.
Closing of main contacts is carried out by means
of the control electromagnet.
Opening is carried out by means of a special
opposing spring.
Construction is compact and sturdy and ensures
very long electrical and mechanical life.

4.6.1 Versionsavailable
• Electrically held
• Mechanically latched
4.6.2 Standard equipment
• Operatingmechanism
• Fuse blown indicator with 1 N/O auxiliary
contacts
• Mechanical operation counter
• 3 N/O+3 N/C contactor auxiliary contacts
• 24 pin automatic connection plug
• Contactor ISOLATED and SERVICE indicator
• Contactor ON-OFF (I-O)indicator
• Emergency trip provision (only for mechanically
latched)
4.6.3 Optionalequipment
• Control voltage transformer
• Mechanical latch coil
• Trip circuit supervision provision
• Racking blocking coil
• Fuse blown indicator with 1 N/O or 1 N/C
auxiliary contacts
4.7 Panel variants
4.7.1 Motor starter (direct on line)
Motor starter (DOL) ZVC Ratings
Circuit full load
current
Rated frequency
Rated voltage
Width
Depth 1
Height 2
A
Hz
kV
mm
mm
mm
400
50/60
7.2
325
1304
2200
1 Bottom power cable entry version. Top cable power entry version
1554 mm with gas duct.
2 Larger LV compartment with correspondingtotal panel height
2400 and 2596 mm available.
Refer toshipping sections in the general
arrangement drawing.
Note thelocation of the power cable entry in the
contract drawings.
Pay special attention to clauses 6.4 to join
panels and 6.5 to install busbars.
4.7.2 Slip ring induction starter
ROTOR
STATOR
Note:
external secondary resistor
Slip ring induction ZVC-SRI Ratings
Circuit full load
current
Rated frequency
Rated voltage
Width
Depth 1
Height 2
A
Hz
kV
mm
mm
mm
400
50/60
7.2
325
1304
2200
1 Bottom power cable entry version. Top cable power entry version
1554 mm with gas duct.
2 Larger LV compartment with correspondingtotal panel height
2400 and 2596 mm available.
Slip ring induction starter type ZVC-SRI
Slip ringor wound rotor motor is an induction
machine where the rotor comprises a set of
coils that are terminated in slip rings to which
external resistors can be connected. Thestator
is thesame as is used with a standard squirrel
cage motor.
Refer toshipping sections in the general
arrangement drawing. Note thelocation of the
power cable entry in the contract drawings.
Pay special attention to clauses 6.4 to join
panels and 6.5 to install busbars.
18 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS

Cable to bus ZVC-CTB Ratings
Circuit full load current
Rated frequency
Rated voltage
Width
Depth 1
Height 2
A
Hz
kV
mm
mm
mm
400
50/60
7.2
325
1304
2200
1 Bottom power cable entry version. Top cable power entry version
1554 mm with gas duct.
2 Larger LV compartment with correspondingtotal panel height
2400 and 2596 mm available.
Refer toshipping sections in the general
arrangement drawing.
Note thelocation of the power cable entry in the
contract drawings.
Pay special attention to clauses 6.4 to join
panels and 6.5 to install busbars.
Transformer feeder ZVC Ratings
Circuit full load
current
Rated frequency
Rated voltage
Width
Depth1
Height2
A
Hz
kV
mm
mm
mm
400
50/60
7.2
325
1304
2200
1 Bottom power cable entry version. Top cable power entry version
1554 mm with gas duct.
2 Larger LV compartment with correspondingtotal panel height
2400 and 2596 mm available.
Refer toshipping sections in the general
arrangement drawing.
Note thelocation of the power cable entry in the
contract drawings.
Pay special attention to clauses 6.4 to join
panels and 6.5 to install busbars.
Double feeder ZVC-DF Ratings
Circuit full load current
Rated frequency
Rated voltage
Rated frequency
withstand
Rated tmpuse withstand
Short time current-3 sec
Width
Depth 1
Height 2
A
Hz
kV
kV
kVpx
kA
mm
mm
mm
400
50/60
7.2
32
50
50
325
1304
2200
1 Bottom power cable entry version. Top cable power entry version
1554 mm with gas duct.
2 Larger LV compartment with correspondingtotal panel height
2400 and 2596 mm available.
Refer toshipping sections in the general
arrangement drawing.
Note thelocation of the power cable entry in the
contract drawings.
Pay special attention to clauses 6.4 to join
panels and 6.5 to install busbars.
4.7.3 Transformer feeder
4.7.4 Conveyor belt double motor feeder
4.7.5 Cable to bus
PANEL DESIGN AND EQUIPMENT 19

4.8 Ith Limiter designs
It is an additional safety feature on the top of
each unit. The microswitch generates an
immediate fault signal when the overpressure
flap is opened. Reaction time is less then 15 ms.
The signal from the microswitch can be sent
directly to trigger the circuit-breaker OFF.
Lth limiterSocket screw
Busbar compartment
microswitch bracket
Pressure relief flap,
made of steel sheet
Rupture bolt (plastic)
Truck compartment
microswitch bracket
4.9 Resistance to internal arc faults
The switchgear has been successfully tested in
accordance with IEC. Severalarc control
measures to meet the AFLR rating are adopted
to suit the design of the switchroom. The
specific variation and installation parameters
are given in thegeneral arrangement drawings
of the contract. Refer to clause 6.6.
20 UNIGEAR ZVC MEDIUM VOLTAGE PRODUCTS
—
4/16 Auxiliary Ith
limiter switch
—
4/16