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INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

UniGear ZS1
with a panel width of 500 mm

• Safety
• Reliability
• Flexibility
• Economy
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Table of Contents

Your safety first – at all times! 04

1. Summary 05

2. Technical data 06

3. Panel design and equipment 07

4. Dispatch and storage 18

5. Assembly of the switchgear at site 22

6. Operation of the switchgear 42

7. Commissioning 47

8. Maintenance 48

9. Product quality and environmental protection 52

4 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

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Your safety first – at all times!

That is why our instruction manual begins Warning

with thefollowing recommendations: Always follow the instruction manual and
• Only install switchgear in closed rooms suitable respect the rules of good engineering
for electrical equipment practice!
• Ensure that installation, operation and Hazardous voltage can cause electrical
maintenance are only carried out by qualified shocks and burns.
competent electricians only Disconnect power, then earth and
• Fully comply with the legally recognized shortcircuit before proceeding with any
standards (IEC or local), the connection work on this equipment.
conditions of the local electrical utility and
the applicable safety at work regulations Warning
• Observe the relevant information in the Using of safety clothes like safety gloves
instruction manual for all actions involving according to EN 388 Blade cut resistance
switchgear class 5, long sleeved work jacket or safety
sleeves, safety shoes is recommended
Danger! during all activities done with the
Pay special attention to the hazard notes switchgear.
in the instruction manual marked with this
warning symbol. If you have any further questions about this
• Make sure that the specified data are not instruction manual, the members of our field
exceeded under switchgear operating organization will be pleased to provide the
conditions required information.
• Keep the instruction manual accessible to all
personnel involved in installation, operation We reserve all rights to this publication.
and maintenance Misuse, and including in particular, duplication
• The user’s personnel must act responsibly in and making this manual - or extracts thereof
all matters affecting safety at work and correct available to third parties is prohibited. We do not
handling of the switchgear accept any responsibility for the informations
provided, which are subject to change.
 SUMMARY 5

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1 Summary

1.1 General The normal operational altitude is up to 1,000 m

UniGear ZS1 is a three-phase, metal-enclosed, air above sea level.
insulated switchgear that is factory-assembled,
type tested and suitable for indoor applications up The indoor ambient conditions are free of
for 12 kV. The units are designed to accommodate significant pollution, such as dust, smoke,
withdrawable modules and are fitted with a corrosive and/or flammable gases, vapors or
single busbar system. The withdrawable parts salt, etc.
are equipped with circuit-breakers. Details of the
technical design and configuration of individual 1.3.2 Special operating conditions
switchgear, including detailed equipment lists The switchgear is suitable for operation in the
for the individual panels and comprehensive WDa type of climate according to IEC 60721-2-1.
circuit documentation etc. can be found in the
relevant order documents. k 1,0

1.2 Standards and specifications

UniGear ZS1 switchgear panels comply with the 0,8
standards and specifications for factory-
assembled, metal-enclosed and type-tested high
voltage switchgear, i.e. IEC publications 62271-200 0,6

and 62271-1. In addition, in accordance with IEC

60529, the switchgear panels have the following
0,4
degrees of protection: IP4X for the enclosure and
1000 2000 3000 4000 m 5000 H
IP2X for the partitions.

All other corresponding IEC publications, national Special operating conditions must be discussed
or local safety at work regulations and safety with ABB in advance. For example:
regulations for production materials must be • At site altitudes above 1,000 m, the effects of
followed during the installation and operation of the reduction in dielectric strength of the air on
these systems. Above and beyond this, the order- the insulation level must be taken into account
related data from ABB must be taken into account. (please refer to the diagram in Figure 1)
• Increased ambient temperatures must be
1.3 Operating conditions compensated in the design of the busbars and
1.3.1 Normal operating conditions branch conductors, otherwise the current
The switchgear is basically suitable for normal carrying capacity will be limited
operating conditions for indoor switchgear in
accordance with IEC 62271-200. Among other Note on special climatic operating conditions:
considerations, the following limiting values When switchgear is operated in areas with high
apply. humidity and/or major rapid temperature
fluctuations, there is a risk of dew deposits
Ambient temperature: which must be excluded under normal operating
• Maximum +40 °C conditions for indoor switchgear.
• Maximum 24 h average +35 °C
• Minimum (according to “minus indoor class”) -15 °C Preventive action (e.g. suitable ventilation and
proper air conditioning of the building or housing,
Ambient humidity: use of dehumidifying equipment, etc.) must be
Maximum 24 h average of relative humidity 95% RH taken into consideration with ABB to avoid this
Maximum 24 h average of water vapour pressure 2.2 kPa condensation phenomenon and any resulting
Maximum monthly average of relative humidity 90% RH corrosion or other adverse effects.
Maximum monthly average of water vapour pressure 1.8 kPa
6 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

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2 Technical data

2.1 Electrical data

IEC GB
Rated voltage kV 12 12
Rated insulationvoltage kV 12 12
Rated power frequency withstand voltage kV 1 min 28 42
Rated lightning impulse withstand voltage kV 75 75
Nominal frequency Hz 50/60 50/60
Rated short-time withstand current kA 3 s ...31.5 ...31.5
Peak curent kA 80 80
Internal arc withstand current kA 1 s ...31.5 ...31.5
Main busbars rated current 1) A ...4000 ...4000
Branch connections rated current A 630-1250 630-1250

1) Up to 4000 A if coupled with other UniGear ZS1 units.

2.2 Resistance to internal arc faults 2.3 Dimensions and weights

The fault withstand capacity is 31.5 kA for 1 s.

The switchgear units have been tested

according to IEC 62271-200 standard (Annex A,
accessibility type A, IAC classification FLR) and
also to PEHLA recommendation No.4. In
individual cases, depending on the
configuration of the switchgear panels and/or
the switchroom conditions (e.g. low ceiling
height), additional measures may be necessary
to ensure compliance with criterion 5.

Dimension (mm) Weight (includes withdrawable modules)

Height A 2200/2595 1)
Width
B 500
- Feeder panel
610-850 kg
Depth C 2) 1310/1620
D 2100
Height of the basic part of panel
E 1495

1) Height of the control cabinet is 705/900 mm.

2) Deeper units are available on request.
 PANEL DESIGN AND EQUIPMENT 7

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3 Panel design and equipment

3.1 Basic structure and variants The front of the panel is closed off by pressure
The UniGear ZS1 panel uses insertion technology resistant doors. The cable and circuit-breaker
for the incoming/outgoing feeder panel with a compartments have their own doors. Neighboring
vacuum circuit-breaker. Each UniGear panel panels are separated from one another by the side
consists of three high-voltage compartments - walls of each panel, and an air cushion remains
busbar, circuit-breaker and cable connection - between these walls when the panels are jointed
while a control cabinet houses the secondary together.
equipment. Apart from this, variants are possible
for all operating needs. Limiting, or even avoiding the end effects of an
internal arc fault is dependent on ceiling height,
Figure 2 shows example of possible panel and in individual situations, some special protection
configuration, including electrical equipment. measures are needed.
• The mounting of a pressure relief duct on the
For busbar sectioning, two panels are necessary: a top of the switchgear, with further channels
coupling panel with the withdrawable circuit- leading out of the switchgear room in a form
breaker part and a bus-riser panel (optional with appropriate to the design of the building. The
busbar metering and earthing). shock wave and arc discharge are channeled
off in ducts
Further details about installation and switchgear • A switchgear internal arc causes the air pressure
equipment can be ordered from the manufacturer. inside a compartment to rise. Meanwhile the
doors are closed and sealed, causing the high
3.2 Enclosure and partitioning air pressure to burst through the pressure
A typical panel enclosure is made of 2 mm thick release plate and out through the top of the
high quality galvanized steel sheets. The internal switchgear
partitions consist of 2 mm thick high quality • Steel plates are used to separate the low-and
galvanized steel or stainless steel sheets. The high-voltage compartments
materials used protect the panel against rust • The switchgear end covers are designed not
and oxidation under adverse circumstances. only for aesthetic purposes but their mechanical
The three high-voltage compartments are and electro-caloric properties provide good
equipped with top-mounted and secured protection when an internal fault arc occurs
pressure-relief flaps which are opened (by a
shockwave) to release the pressure and gas
buildup caused by an internal arc fault. The
pressure-relief flaps are secured with steel screws
on one longitudinal side and plastic screws on
the other side. The internal overpressure causes
the plastic screws to rupture.
8 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

1.1

84

5
18
18.1
18.2 7

6
14
14.1
14.2

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Figure 2-1 Example of UniGear ZS1 unit

1 Enclosure 14 Earthing switch operating mechanism

1.1 Pressure relief flap 14.1 Operating shaft for earthing switch
2 Branch conductor 14.2 Slide
3 Busbar 18 Spindle mechanism
5 Isolating bushing 18.1 Spigot on spindle
6 Earthing switch 18.2 Hole in spindle for insertion lever
7 Current transformer 84 Partition
PANEL DESIGN AND EQUIPMENT 9

3.3 Panel compartments part is moved to the test/disconnected position.

3.3.1 Busbar compartment When the withdrawable part is in the test/
The main busbars are either flat or D-shaped and disconnected position inside the panel,
are made of copper. They are laid in sections from partitioning by separation is established in the
panel to panel. main current circuit. Connection of the control
wiring, required for test purposes, is not
According to the current rating, either a single interrupted when in the test/disconnected
or double configuration is used. They are held position. The socket for the control wiring is
in place by branch conductors, and if installed, by mounted inside the circuit-breaker compartment.
busbar bushings. No special connection clamps
are needed. The bolt connections in the busbar In the test/disconnected position, the ON/OFF
system have insulating covers. By means of pushbutton located on the circuit-breaker, and
bushing plates and busbar bushings, partitions the mechanical indicators for ON/OFF and
can be created between panels. These CHARGED/DISCHARGED can be observed through
partitions are necessary for every panel. an inspection window. All switching operations
are carried out with the doors closed. Installation
3.3.2 Circuit-breaker compartment of an additional mechanical switching device to
The circuit-breaker compartment (Fig. 3, 4) manually operate the circuit-breaker in the service
contains all the necessary equipment that position is also possible.
allows the withdrawable part and the panel to
work seamlessly together. Like the busbar
compartment, it is metallically partitioned on
all sides. The isolating contacts and the fixed
isolating contacts are located on a mounting
plate. The metal shutters covering the insertion
openings are also included. The shutters are
automatically opened by the actuating bars of
the withdrawable circuit-breaker part when, by
means of a lever, it is set up in the service position.
The shutters are closed when the withdrawable

10.1

12.1
43.3

12.2

42

14
14.1

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Figure 3-1 Circuit-breaker compartment, open. Figure 4 View into the circuit-breaker compartment
Withdrawal part in the disconnected
position

10.1 Control wiring socket 14.1 Drive shaft

12.1 Top shutter 42 Right travel rail
12.2 Lower shutter 43.3 Duct cover, top right
14 Earthing switch operating mechanism
10 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

3.3.3 Withdrawable parts The withdrawable part and the panel are earthed
1) Withdrawable circuit-breaker parts: together by means of an earthing system in the
The withdrawable part of the UniGear ZS1 panel.
panel forms a complete module consisting of
the vaccum circuit-breaker type VD4 (Fig. 5, Withdrawable parts with the same design are
6), an isolated contact arm with its associated interchangeable. In cases where the dimensions
contact system and a control wiring plug. are identical but the circuit-breaker fittings differ,
the control wiring plug coding (Fig. 16) prevents
The withdrawable assembly and the circuit-breaker incorrect connections between the withdrawable
are coupled via a multi-pole control wiring plug part and the panel. Detailed coding information
connector. The withdrawable assembly establishes is given in the relevant order documents.
the mechanical connection between the panel and
the circuit-breaker. The fixed part of the assembly 2) Other withdrawable parts include:
is connected, on both sides, to the panel by • The metering voltage-transformer truck with
form-coded forking. The moving part with the fuses
circuit-breaker is moved manually between the • The earthing truck without making capacity
service or test/disconnected positions - with (for the main busbar system and power
the front doors closed - by means of a spindle. cables)
Auxiliary switches are used to register both the • The power cable testing truck
selected position and the angular position of the • The isolation truck
spindle. • The metering truck

13.2

13.1

13.4

13.8

13.5

28a

— 13.15 —
Figure 5 VD4 circuit breaker Figure 6 VD4 circuit-breaker pole side

13.1 – Close pushbutton 13.4 – Signaling device for closing springs charged/discharged
13.2 – Open pushbutton 13.15 – Withdrawal part
13.4 – Signaling device for circuit-breaker open/closed 28a – Lever for manually charging the closing springs
13.5 – Operation counter
PANEL DESIGN AND EQUIPMENT 11

3.3.4 Cable connection compartment For more information regarding cable connections,
Depending on individual operating requirements, please refer to chapter 5.10.
the cable compartment can house up to three
current transformers, fixed and withdrawable 3.3.5 Control cabinet
voltage transformers, and an earthing switch. The control cabinet, which covers all control and
Should all three current transformers not be protection aspects, can accommodate both
required, dummies are installed in their place using conventional or microprocessor control technology.
the same installation and connection procedures.
If the secondary devices are not intended for door
The fix-mounted voltage transformers are installation they are mounted on DIN RAILS.
connected on the primary side with flexible, These rails enable any subsequent changes to the
full-insulated cables that are inserted into the wiring. Three rows of DIN RAILS on a swiveling
transformers. DIN RAIL holder are located at the lower part of
the control cabinet, and directly under these is an
The removable voltage transformers are fitted easily accessible auxiliary switch for the control
with HRC fuses. wiring plug.

The ET1 earthing switch can be used with a The secondary wiring inside the panel is housed
manual mechanism. Its switching position is in a duct on the right side of the panel. The
indicated mechanically by an indication on the left-hand side of the panel is for the external
shaft and electrically by means of the auxiliary wiring. The ducts are covered with a steel metal
switch. sheet. Holes at the side of the control cabinet
enable the ring conductors to be slid in.
The surge arrestors can be fix-mounted in the
cable compartment.

Cable connection of units:

• As a standard solution, it is possible to
connect up to three parallel plastic cables with
single-core protection per phase.
In a 1,250 A panel, the cable push-on sealing ends
require a maximum cross section of 300 mm 2
• Customer requests regarding connections to
bars, three-core cables, special cables or sealing
ends of different types must be considered
during the order-planning stage

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Figure 7 Low-voltage compartment, internal view
12 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

3.4 Interlock/protection against incorrect 3.4.2 Interlocking doors

operation • The withdrawable parts cannot be racked in
All interlocking features are realized mechanically if the apparatus compartment door is open
or through an electrical interconnection. (Fig. 8, 9)
• The apparatus compartment door cannot be
3.4.1 Panel internal interlocking opened if the apparatus is in service or in an
To prevent hazardous situations and incorrect undefined position (Fig. 10, 11)
operation, there is a series of interlocks to protect • The earthing switch cannot be operated if the
both personnel and equipment. cable compartment door is open (Fig. 12, 13)
• The withdrawable part can only be moved from • The cable compartment door cannot be opened
the test/disconnected position (and back) if the earthing switch is open (Fig. 14, 15)
when the circuit- breaker and earthing switch
are off. In the intermediate position, the switch 3.4.3 Interlocks between panels
is mechanically interlocked. The interlock is • The busbar earthing switch can only be closed
electrical if the circuit breaker features an when all the withdrawable parts in the relative
electrical release busbar section are in the test/disconnected
• The circuit breaker can only be switched on position (electrical interlock)
when the withdrawable part is in the test or • When the busbar earthing switch is closed, the
service position. In the intermediate position, withdrawable parts in the earthed busbar section
the switch is mechanically interlocked. The cannot be moved from the test/disconnected
interlock is electrical if the circuit-breaker position to the service position
features an electrical release (electromechanical interlock)
• In the service or test positions, the circuit
breaker can only be switched off manually 3.4.4 Locking devices
when no control voltage is applied and it cannot • The shutters can be secured independently of
be closed (electromechanical interlock) each other with a mechanical lock when the
• Connecting and disconnecting the control wiring withdrawable circuit-breaker part has been
plug is only possible when the withdrawable removed
part is in the test/disconnected position • Access to the operating shaft of the earthing
• The earthing switch can only be switched on switch can be restricted using a padlock (or
if the withdrawable part is in the test/ keylock)
disconnected position or outside of the panel • Access to the circuit-breaker racking slot, the
• If the earthing switch is on, the withdrawable circuit-breaker compartment and the cable
part cannot be moved from the test/disconnected compartment can be restricted using a padlock
position to the service position (or keylock)
• Details of possible interlocks, for example in
connection with a locking magnet on the
withdrawable part and/or an earthing switch
drive, can be obtained from the relevant order
document
 PANEL DESIGN AND EQUIPMENT 13

Types of interlocks

Standard safety interlocks (mandatory)

Type Description Condition to be fulfilled

1 A Apparatus racking-in/out Apparatus in OFF position
B Apparatus closing Defined truck position
2 A Apparatus racking-in Apparatus multi-contact plug plugged
B Apparatus multi-contact plug unplugging Truck in test position
3 A Earthing switch closing Truck in test position
B Apparatus racking-in Earthing switch in OFF position
4 A Apparatus compartment door opening Truck in test position
B Apparatus racking-in Apparatus compartment door closed
5 A Feeder compartment door opening Earthing switch in OFF position
B Earthing switch opening Cable compartment door closed

Note: Apparatus is circuit-breaker.

Keys (on request)

6 Apparatus racking-in lock Can only be removed with the truck in the racked-out position.
7 Earthing switch closing lock Can only be removed with the earthing switch open.
8 Earthing switch opening lock Can only be removed with the earthing closed.
9 Insertion of the apparatus raking-in/out crank lever Can always be removed.
10 Insertion of the earthing switch operating lever Can always be removed.

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.

Locking magnets (on request)

16 Apparatus racking-in/out Magnet energized.
17 Earthing switch ON/OFF Magnet energized.

Accessory devices
20 Shutters fail-safe The device locks the shutters in the closed position when the
21 apparatus is removed from the compartment. The operator
22 cannot open the shut ters manually. The shutters can only be
operated by the apparatus truck.
Apparatus-switchgear unit compatibility matrix 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.
Circuit-breaker mechanical operating mechanism 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 pushbuttons,
keeping the door closed. The controls can be operated with the
circuit-breakers in the operation and racked-out position.
14 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

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Figure 8 Circuit- breaker compartment door enabling device

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Figure 9 Circuit- breaker truck enabling slot

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Figure 10 Circuit- breaker compartment door locking device
PANEL DESIGN AND EQUIPMENT 15

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Figure 11 Circuit-breaker compartment door locking device

Note: It’s not suitable for floor rolling version.

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Figure 12 Cable compartment door enabling device

Pin ON Pin OFF

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Figure 13 Cable compartment door enabling slot and earthing switch enabling pin
16 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

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Figure 14 Cable compartment door locking device

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Figure 15 Cable compartment door locking device
PANEL DESIGN AND EQUIPMENT 17

3.5 Circuit-breaker plug connector coding Coding:

The control wiring plug connector coding allows (…) The corresponding coding designation for
the withdrawable parts for switching devices the control wiring plug is given in brackets.
to be assigned to particular panels. This ensures
that withdrawable parts with different rated The coding pins can be fitted in the control wiring
currents or different control wiring circuits can socket and/or in the control wiring plug.
only be used in the panels they are intended for.
– Basic design
Coding pins are fitted in the control wiring sockets The number of sockets is optional but the basic
10.1 or control wiring plugs 10.2, and engage with assignment is 1, 8, 10, 20, 21, 31, 33 and 40.
the corresponding bores of the relevant plug 10.2
or socket when the two parts are connected. Sockets and pins can be mixed as required in the
control wiring socket and control wiring plug.
The plug connector coding is order-related, and
is noted in the relevant wiring documentation. 3.6 I th Limitors
It is 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.
10.5 10.4 10.1

11.5

It may be necessary to move the auxiliary switches into their service

position when the lifting eyebolts have been removed.

11.5 Ith limiter

The centre of the switch knob of the auxiliary switch must be

adjusted to the centre of the pressure relief flap hole.

11.5

49.2
10.4
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Figure 16 Control wiring plug connector coding

10.1 – Control wiring socket

10.4 – Centering striking tabs
10.5 – Bore for actuating pin of the control wiring
plug for controlling the auxiliary switch 49.2 Pressure relief flap

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Figure 17 Auxiliary Ith limiter switch
18 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

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4 Dispatch and storage

4.1 Condition on delivery Transport panels upright. Take the high centre of
At the time of dispatch, the UniGear panels are gravity into account. Only ever carry out loading
factory-assembled, the withdrawable parts are operations when it has been ensured that all
in the test position and the doors are closed. precautionary measures to protect personnel and
materials have been taken and use the following:
The factory-assembled panels are checked at the • Crane
works for completeness in terms of the order and • Fork-lift truck and/or
simultaneously subjected to routine testing • Manual trolley jack
(normally without AC voltage testing of the
busbars) to IEC publication 62271-200, and are Loading by crane:
therefore tested for correct structure and function. • Fit lifting ropes of appropriate load capacity
with spring catches (eyebolt diameter: 30 mm)
The busbars are not assembled. The busbar • Keep an angle of at least 60° from the horizontal
material, fasteners and accessories are packed for the ropes leading to the crane hook
separately. • Hang the unit using ALL four eyebolts

4.2 Packing For detailed information on switchgear handling,

Available manners of packing: please refer to chapter 4.6.
• Polythene foil - storage time 1/2 year in clean
and dry environment 4.4 Delivery
• OSB boards - storage time 1/2 year in outdoor The responsibilities of the consignee when the
environment according to IEC switchgear arrives at site include, but are not
• Wood boxes - storage time 1 year in outdoor limited to, the following:
environment according to IEC • Checking the consignment for completeness
and lack of any damage (e.g. also for moisture
According to the kind of transport and country and its detrimental effects). In case of doubt,
of destination, the panels remain unpacked or the packing must be opened and then properly
packed in seaworthy crates. A drying agent is resealed, putting in new drying agent bags,
provided to protect them against moisture. when intermediate storage is necessary
• Panels with basic packing or without packing • If any quantities are short, or defects or transport
• Panels with seaworthy or similar packing damage are noted, these must be:
(including packing for containerised shipments): - Documented on the respective shipping
- Sealed in polyethylene sheeting document
- Transport drying agent bags included - Notified to the relevant carrier or forwarding
agent immediately in accordance with the
4.3 Transport relative liability regulations
The transport units normally comprise two
panels and, in exceptional cases, small groups of Note:
panels. The panels are each fitted with four lifting Always take photographs to document any major
eyebolts. damage.

30 ≥60° 1.5
1.5

1.5 lifting eyebolt

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Figure 18 Handling by crane
DISPATCH AND STORAGE 19

4.5 Intermediate storage 4.6 Handling

Optimum intermediate storage, where this is 4.6.1 Switchgear
necessary, without any negative consequences The switchgear sections are usually fixed to
depends on compliance with a number of minimum wooden pallets. Handling should be carried out
conditions for the panels and assembly materials. by means of bridge or mobile cranes. Otherwise,
use rollers or fork lift trucks.
1. Panels with basic packing or without packing:
• A dry well-ventilated store room with a climate Weights and dimensions of each section are listed
in accordance with IEC 62271-1 in the shipping documents and in the plant
• The room temperature must not fall below -5 °C drawings.
• There must not be any other negative
environmental influences 4.6.1.1 Handling with bridge crane or mobile
• Store the panels upright crane and unpacking
• Do not stack panels Handling the switchgear in the wood packing.
• Panels with basic packing
• Open the packing, at least partially The switchgear must be lifted by means of a crane
• Panels without packing: and circular slings 1 (Fig. 19). The slings must be
- Loosely cover with protective sheeting inserted according to the lifting symbols marked
- Ensure that there is sufficient air circulation on the crate.
• Check regularly for any condensation until
installation is started Weight and lifting opening angle must be taken
into account when choosing the circular slings.
2. Panels with seaworthy or similar packing with
internal protective sheeting: Unpacking
• Store the transport units • Remove the nails and crate lid and sides
• Protected from the weather • Open the compartment door and loosen the
• In a dry place bolts fixing the switchgear to the pallet
• Safe from any damage • Lift the cubicles by means of the crane
• Check the packing for damage following the instructions below
• Check the drying agent (also see section 4.2): • Remove the pallet
- On arrival of the consignment • Position the unloading shims
- Subsequently at regular intervals • Put the switchgear on the loading shims by
• When the maximum storage period, starting using the crane
from the date of packing, has been exceeded:
- The protective function of the packing can Switchgear handling
no longer be guaranteed
- Take suitable action if intermediate storage Warning
is to continue • Only use a suitable balanced lifting system

Warning
Do not walk on the roof of the panels
(rupture points in pressure relief devices!).
The pressure relief devices and/or Ith
Limiters could be damaged.

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Figure 19 Handling the switchgear in the wooden crate
20 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

After unpacking, lift the unit groups by means 4.6.2 Apparatus

of a crane (Fig. 18). Use the eyebolts (1.5) and The apparatus can be handled by cranes, fork
the ropes fitted with safety. After installation lift trucks or using the truck provided by ABB.
of the panels, remove the eyebolts used for For each piece of apparatus follow the
lifting. instructions below.

4.6.1.2 Handling by means of rollers 4.6.2.1 Handling by crane

Circuit-breakers
Warning Hook the lifting bolts to the relevant supports.
• Only use rollers on a level floor While handling, pay the utmost attention not
• Move the switchgear section avoiding to put any stress on the insulating parts or on
any possible tilting the circuit-breaker terminals.

Lift the switchgear section by means of a bridge Before putting into service, remove all the
or mobile crane or using jacks (Fig. 18); remove lifting eyebolts.
the wooden pallet loosening the screws fixing it
to the switchgear section base. Put a sturdy metal 4.6.2.2 Handling by fork-lift trucks
sheet between the rollers and the unit base and Handling by fork-lift trucks can be carried out
place the switchgear on the sliding rollers. only after the apparatus has been positioned
on a sturdy support.
4.6.1.3 Handling by means of transpallet or
fork lift trucks While handling, pay the utmost attention not
to put any stress on the insulating parts or on
Warning the circuit-breaker terminals.
• Only use transpallets or fork lift trucks
on a level floor Warning
• Move the switchgear section avoiding Do not insert the truck forks straight
any tilting underneath the apparatus but put the
apparatus on a sturdy support.
To guarantee stability, the switchgear must not
be lifted too high. Check the levelness of the forks.

Sliding rollers
Metal sheet

— — —
Figure 20 Handling by means of rollers Figure 21 Lifting switchgear packed in Figure 22 Switchgear handling
a wooden crate
 DISPATCH AND STORAGE 21

4.6.2.3 Handling by service truck Further warnings:

For handling and inserting the apparatus into When moving the switchgear on cylinders
the switchgear, use the service truck (Fig. 25). always put the cylinders collinear (in parallel)
with the front side of the switchgear!
Warning
• Do not use the service truck for any
purpose other than handling ABB’s
apparatus
• Fix the circuit-breaker to the truck before
moving it

In order to handle the circuit-breaker with the

relevant truck, follow the instructions below: Always keep the switchgear in the vertical position!
• Hook the lifting bolts to the circuit-breaker
supports and align it above the truck (1)
• Press the handles (2) towards the circuit-breaker
centre (*) to insert the horizontal check pins
• Put the circuit-breaker on the truck
• Push the circuit-breaker towards the circuit-
breaker compartment and insert the truck into
the guides until the handles (2) are released (**)
outwards and the horizontal locking pins go Do not try to open the cable or the circuit-breaker
into the slots (4), locking the circuit-breaker compartment doors, close the earthing switch or
withdraw the circuit breaker if an auxiliary voltage
is not connected to the switchgear!

Do not step on the pressure relief flaps!

4 4

— — —
Figure 23 Handling by fork-lift trucks Figure 24 Vmax circuit-breaker Figure 25 Service truck
22 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

—
5 Assembly of the switchgear on site

In order to obtain an optimum installation sequence Dimension chart of structural data (Also see figures 5/1 to 5/11)
and ensure high quality standards, on-site Rated voltage kV 12
installation of the switchgear should only be Panel width FT mm 500
carried out by specially trained and skilled Aisle width 1) G mm 1300
personnel, or at least by personnel supervised Switchgear room door width mm 700/1200
and monitored by responsible persons. Switchgear room door height 2) mm 2400
Opening in ceiling if transported
5.1 General through roof:
On commencement of installation on site, the
Width mm 1000
switch room must be completely finished. This
Length mm 1500
means it must be provided with lighting and an
Ceiling load 3) kg/m2 1200
electricity supply. In addition, it must be lockable,
dry and with facilities for ventilation. All the 1) Pay attention to the appropriate national standards.
2) Applies to low-voltage compartments of standard height.
necessary preparations, such as wall openings, 3) Approximate numbers depending on the type of panels.
ducts, etc., for routing the power and control
cables up to the switchgear must already be
5.2.1 Method of installation A – Installation of
complete. The ceiling height must be sufficient
the base irons
for the opening travel of the pressure relief plates
Due to different switchgear dimensions, one or
(Higher than 3 m).
more parts make up the base irons. Their
installation is usually carried out by site personnel
The ceiling must be high enough for the assembly
and should, if possible, be performed under the
of a pressure relief duct (Higher than 3 m).
supervision of an ABB specialist.

Compliance with the conditions for indoor

Method of installation - Installation of the base
switchgear according to IEC 62271-1, including
irons:
the conditions for the indoor temperature class
• When base irons are composed of several parts,
must be ensured.
connect them with a bolt in the required order
and position them horizontally
5.2 Foundations
• Lay the irons in the specified position on the
It is recommended that the switchgear is installed
concrete floor as shown in the relevant foundation
on the base irons of a “C” profile shape set into
drawing
the concrete floor of switch room.
• Mark out holes for drilling. These holes are
for the anchoring bolts that will fix the base
Further structural data guidelines enable a rough
irons in the floor
calculation of the space required to be made and
• Put the plugs in the holes and use the bolts
the planning of the room design for a switchgear
to attach the base irons to the floor. Do not
project.
tighten the bolts until the base irons have been
correctly leveled
When the final construction documents are
• Carefully level the base irons both longitudinally
compiled for the execution of a building, the
and transversally over the entire length and
binding data supplied by ABB for a particular
correct the height by using strips with a suitable
case must always be taken into account!
thickness and a levelling instrument. Usually
the top edge of floor frame should be 2 mm
above the finished floor surface (Fig. 26, 29)

Tolerances for laying the floor frame are:

• Evenness tolerance: ±1 mm within a measuring
length of 1 m
• Straightness tolerance: 1 mm per 1 m, but not
ASSEMBLY OF THE SWITCHGEAR ON SITE 23

more than 2 mm over the entire length of the • Insert the plugs in the holes and put the individual
frame panels on the traced perimeters of the units
• After levelling the base irons, the bolts can be to create the switchgear
tightened. The adjusted position of the base • Level the units and then bolt them together
irons on the concrete floor must not be changed in the front and rear part
during this operation • Fix the units with bolts with special washers
(the coupling material is supplied on request)
Check again and, if need be, correct any deviations. • In the case of a metal floor - to make the holes,
• Weld the individual parts of the base irons use a drill with a suitable bit for the type of
inside the “C” profile together at the seams fixing to be made (through or threaded hole)
so that a conductive connection is achieved
• When the floor top covering is applied, carefully 5.2.3 Method C – installation on a raised false floor
backfill the floor frame, leaving no gaps In this case, fastening of the units is carried out
• The base irons must not be subjected to any by welding outside panels to the steel floor frame
harmful impacts or pressures, particularly during in the places where the frame is larger than the
the installation phase base of the switchgear, i.e. on the outside lateral
walls of the unit row. This method of installation
If these conditions are not respected, problems is not recommended if seismic resistance is
during switchgear assembly and possibly with required.
movement of the withdrawable parts, as well as • Clean the installation area
with the opening and closing of the doors cannot • After installation of the frame, take any necessary
be ruled out. measures for perfect earthing of the frame with
galvanized steel strips with min. dimensions
5.2.2 Method B – installation on the levelled 30x4 mm. Two earthing connections are
concrete floor recommended for a panel row longer than
Installation directly on the levelled concrete floor approx. 5 panels
makes much higher demands on the floor levelling, • Place the units on the frame according to the
which must, in this case, fulfil the same tolerances relevant foundation drawings, taking the
as the base irons during method A installation. minimum wall and obstacle clearances into
account
Fastening is carried out by anchoring bolts in the • Level the units and then bolt them together
concrete floor. in the front and rear part
• Clean the switchgear installation area carefully • Carry out attachment by welding the outside
• On the slab, visibly trace the perimeter of all panels to the steel floor frame in the place
the units making up the switchgear according where the frame juts out from the switchgear
to the relevant draw-ing, taking the minimum bottom, i.e. on the outside lateral walls of the
wall and obstacle clearances into account unit row. This method of installation is not
• Level the floor both longitudinally and recommended if seismic resistance is required
transversally, evenness tolerance is ±1 mm over • In the case of a metal floor - to make the holes,
a measuring length of 1 m use a drill with a suitable bit for the type of
• Drill the floor at the intended fixing points, fixing to be made (through or threaded hole)
referring to the slab drilling drawings. To make
the holes, use a hammer drill with a bit according
to the steel plugs used
24 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

A B
700 1)

B
2)
A

20 20 20 20 20

x) x) x) x)
10 10 10 10 10

1)
80 80
1)

FT FT nx FT FT
1)
G

TB
TH

A-A
B-B View B
700 1)
30

B
60

60
80

80

6
42
2,5

—
Figure 26 Guideline structural data for a raised false floor

10 Door
Panel depth (A) B C
11 Rear cover
X): Max. dimensions 1310 mm 1205 mm 735 mm
1): Min. dimensions
2): Dimension must be verified in
1620 mm 1205 mm/1515 mm 785 mm
documentation of the relevant order
G: Width of operating aisle (See table on page 20)
TB: Door width=FT+200 mm (See table on page 20)
TH: Door height=FH+200 mm (See table on page 20)
FT: Panel width (See table on page 20)
FH: Panel height (See table on page 20)
ASSEMBLY OF THE SWITCHGEAR ON SITE 25

100 300 100

35

100

81
67 366 67

350

Power cables entry

843
1235
1310

6-mounting holes
(36x20)
785

11
56

Control cables entry

271
185

311
80
40

40

500

—
Figure 27 Base iron fixing system

700

—
Figure 28 Structural data for foundation frame on concrete floor
26 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

90

90
d 16

d 16

— —
Figure 29 a) Anchoring bolts on concrete floor Figure 29 b) Base irons on concrete floor

M 12
M 12

— —
Figure 29 c) Through hole on metal structure Figure 29 d) Threaded hole on metal structure
ASSEMBLY OF THE SWITCHGEAR ON SITE 27

5.3 Assembly of the switchgear panels Any tightening torques that deviate from those
Use screws of tensile class 8.8. The maximum in the general tables (e.g. for contact systems or
recommended tightening torques based on type device terminals) must be taken into account as
of connection are given in the following tables. stated in the detailed technical documentation.

The tightening torques for copper bars or It is recommended that the threads and head
busbars connections together. contact surfaces of bolts should be lightly oiled
or greased so as to achieve the precise rated
Maximum recommended tightening torque 1) Nm
tightening torque.
Lubricant 2)
Thread 3) Without (η=0,14) Oil or grease (η=0,10)
The individual installation stages are as follows:
M5 4) - - • Remove the withdrawable parts from the
M6 4) - 8 switchgear panels and store them with suitable
M8 - 20 protection
M10 - 40 • Dismantle the lifting eyebolts
M12 - 69 • Transport the switchgear panels to the prepared
M16 - 170 installation point, following the sequence shown
on the switchgear plan
The tightening torques for copper bar • Remove the vertical partitions in front of the
connections combined with epoxy insulators. busbar compartments by releasing the fixing
screws
Maximum recommended tightening torque 1) Nm
• Release the fixing screws and draw out the
Lubricant 2)
horizontal partition below the withdrawable
Thread 3) Without (η=0,14) Oil or grease (η=0,10)
part travel rails
M8 15 -
• Release and remove the floor cover
M10 32 -
• Remove the covers from the vertical control
M12 45 -
wiring ducts, positioned on the right- hand
M16 110 -
left-hand sides of the panel front
M20 220 -

Fit and screw down the lids.

The tightening torques for copper bar • Correctly position and vertically align the
connections combined with ABB CTs. switchgear panels along the floor frame - the
panel edges must not deviate by more than 2
Maximum recommended tightening torque 1) Nm
mm from the vertical, especially at the front -
Lubricant 2)
and bolt the panels together. It is advisable to
Thread 3) Without (η=0,14) Oil or grease (η=0,10)
start from the centre when assembling
M12 70 - switchgears with more than ten panels
• When the switchgear has been properly
The tightening torques for copper bar or cable assembled, fix the panels to the concrete floor
connections combined with ABB VTs. using plugs, or weld or adequately bolt them
to the foundation frame
Maximum recommended tightening torque 1) Nm
Lubricant 2)
Thread 3) Without (η=0,14) Oil or grease (η=0,10)
M10 20 -

1) The recommended maximum tightening torques are based on a

coefficient of friction for the thread of 0.14 (without lubrication) or
0.10 (with lubrication).
2) Thread and head contact surface lubricated.
3) The tightening torques are recommended for screws ISO 4014-4018
and ISO 4762 (tensile class 8.8). In case of usage of other types of
screws contact please ABB for clarification.
4) Applicable only for fixing of subsidiary covers or terminal connections.
28 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

5.4 Procedure for setting-up the doors

Closing of doors could be problematic in some
cases. To avoid problems with doors closing
the following shall be fulfilled and followed:

If switchgear is installed properly the doors

shall be in the position in which the upper edge
of door will be parallel with the gap between
the circuit breaker compartment and the low
voltage control cabinet.

—
Figure 30 Correct position of cable compartment doors

Doors gasket shall be installed in correct

direction (3 tooth on inner side and 1 tooth of
the gasket on outer side).

—
Figure 31 Doors gasket
ASSEMBLY OF THE SWITCHGEAR ON SITE 29

Sliding part of the doors locking mechanism If guiding screws in open position of handle
shall not be bended (could happen because of don’t reach end position, it’s necessary to
wrong and rough closing operation). loose a bit screws.

—
Figure 33 Guiding screws

—
Figure 32 Sliding part of doors locking mechanism

If guiding screws after loosing still don’t reach Doors shall be closed by both hands.
end position, then it’a necessary to replace the
handle.

— —
Figure 34 Guiding screw Figure 35 Doors closing
30 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

5.5 Installation of the bushing (if have) Before fixing the panels side by side (according
Bushings are made of epoxy resin castings and to the general drawings) bushings 29.x must be
are arranged as a single casting for all three fixed (for switchgear with busbar partitioning
phases (Fig. 36). only).

Bushing of 12 kV panels

29.5

30

31

32

L1

28

L2

—
2 Figure 37 a) 12 kV panels - fixing bushings

29
L3 29.5 nr. 1 Bushing
30 nr. 8 8x25 screws
31 nr. 8 M8 washer
32 nr. 3 Rubber partition (busbar support)

Lower bus-tie system

• Insert bushing 29.6 for the lower rear bus-tie
into bushing plate 28.2 from the right side in
contrast to the procedure for the other two
bushings

36
35
29.1 29.6

28.2

— —
Figure 36 Bushing plate and busbar bushing arrangement Figure 37 b) 12 kV panels - fixing bushings

2 Branch bar
28 Bushing support 28.2 nr. 1 Bushing plate
29 Bushing 29.6 nr. 3 Bushing
29.1 Busbar support for single conductor 35 nr. 12 8x25 screws
36 nr. 12 M8 washer
ASSEMBLY OF THE SWITCHGEAR ON SITE 31

5.6 Fixing of the panels The junction points where the panels should be
Before fixing the panels side by side be fix are as follows:
sure that the bushings are fixed according • Nr.6 in the front side (A-B-C-D-E-F)
to chapter 5.5. • Nr.4 in the middle part (L-M-N-O)
• Nr.5 in the rear side (G-H-I-J-K)
Fit and screw down the side covers.
• Align the switchgear panels on the floor frame The nuts are already fixed on the right side of the
for correct positioning and vertical alignment panel (except in the middle part); on the left side
(deviations of the panel edges from the vertical there is the an empty space where the screws are
must not exceed 2 mm, especially at the front) to be fixed.
and bolt the panels together (Fig. 38). It is
advisable to start from the centre when The screws needed are:
assembling switchgear with more than 10 panels • 10x30 screws (complete with M10 washer)

K
E
O
J

N
C
26
H

M
B

G
L

A
26 Cover plate

— —
Figure 38 View of the fixing points Figure 39 End panel of a switchboard with bolted-on cover plate
32 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

5.7 Installation of the busbars • Install the busbars panel by panel. Screw on
Access to the busbars is possible either from the individual busbar elements one above the
above after the pressure relief plate has been other (depending on the system layout) and
removed, or from the front of the circuit-breaker in line with the branch conductor. Use the
compartment. To get at the busbars from the hexagonal socket head screws provided. See
circuit-breaker compartment, first withdraw the the table in section 5.3 for the correct tightening
circuit breaker and then remove the horizontal torque. Use two dished washers for each screw
partition. Once this has been completed, the
following steps should be taken: Note:
• Install the bushings The busbars are connected using so-called
• Clean the insulation on the busbar sections “stabilized connections”. This means the quality
with a soft, dry cloth and check for insulation of the copper busbar connections does not change
damage. Remove any grease or adhesive dirt irrespective of operating time and therefore
• Busbar connections regular inspection of the tightness of the busbar
• The silver plated surfaces of the connections connections is unnecessary. However, this is on
must be cleaned with a metal-free non-woven condition that switchgear assembly is carried out
cleaning cloth, and thinly and evenly coated exactly as described above and that all connections
with Syn-Setral-EK 339 grease are tightened with the prescribed torque according
• The non-silver plated surfaces of the connections to the table in section 5.3.
are either brushed with a wire brush, to preserve
the grease film, or cleaned with a metal-free We recommend that the tightness of the busbar
non-woven cleaning cloth and evenly greased connections are inspected during repairs only.
with a thin coat of Syn-Setral-EK 339
• Prepare the shield covers and install them to
the busbar and T-off bar joint, to cover the
screws

29 Busbar bushing
58 Shield cover

—
Figure 40 Installation of the busbars and the installation at the busbar ends
ASSEMBLY OF THE SWITCHGEAR ON SITE 33

Busbars for 12 kV units bushings are single and are arranged in the
Busbars are made of copper and have a flat lower part of the unit. Bushings are held in
cross-section for rated current up to 1250 A. bushing plates.
For 1600 and 2000 A, the busbars have a single
D-shaped cross-section. For 2500, 3150 and For 12 kV, the busbars are fitted without insulating
4000 A, the busbars have a double D-shaped covers up to 1250 A.
cross-section. Branch conductors always have a
flat cross-section. 1600, 2000, 2500, 3150 and 4000 A D-shaped
busbars are fitted with insulating covers.
12 kV bushings are arranged as a single casting
for all three phases. For bus-tie units the

40

42

43

40 nr. 4 10x35 screws

42 nr. 8 M10 washers
43 nr. 4 M10 nuts

—
Figure 41 12 kV panels – T-off 630-1250 A, busbars 1250 A

41

42

42

41 nr. 4 10x60 screws

42 nr. 8 M10 washers
43 nr. 4 M10 nuts

—
Figure 42 12 kV panels – T-off 630-1250 A, busbars 1600 A-2000 A
34 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

4 nr. 4 10x60 screws

42 nr. 8 M10 washers
43 nr. 4 M10 nuts
44 nr. 1 spacer (15 mm)

—
Figure 43 12 kV panels – T-off 630-1250 A, busbars 2500 A-3150 A-4000 A
ASSEMBLY OF THE SWITCHGEAR ON SITE 35

Busbar compartment access After circuit-breaker has been withdrawn from the
Access to the busbar compartment is possible panel, it is possible to remove the horizontal
either from the top of the panel after dismounting partition.
the pressure relief plate after the dismounting of
the gas duct, or from the front of the circuit-breaker After that, the partition can be dismantled and
compartment. taken out of the panel, which makes access to
busbars from the circuit-breaker compartment
See figure 45 taken from cable compartment. easier.
On each side there are two screws which must
be unscrewed (detail on fig. 46).

—
Figure 45 View from cable compartment

—
Figure 46 Two screws on each side

—
Figure 47 Front view on window among cable and
circuit - breaker compartment

—
Figure 48 Circuit- breaker compartment
36 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

5.8 Installation of the top-mounted boxes 5.8.1 Anti-ferroresonant resistor for voltage
For ease of transportation top mounted boxes transformers open delta connection
are delivered separate from the panel in When using a ferroresonance resistor for VTs
pre-assembled sections. open delta connection is necesary to adjust the
position of this resistor during site installation.

The ferroresonance resistor is placed on the

top of switchgear on the CB relief flap for the
transportation (Fig. 52).

When moving the resistor from relief flap to LV

compartment (LVC) please follow pictogram
(Fig. 53) on the top of LVC.

The resistor has to be fixed by means of screws

on the top of the LVC (Fig. 54).

Assemble resistor prior to instalation of

preassure relief gas duct. Pay attention to the
resistor’s wires whilst installing gas duct.

— — —
Figure 49 Transport position of Figure 50 Pictogram on the top of LVC Figure 51 Correct position of
antiferro-resonant resistor antiferro-resonant resistor
ASSEMBLY OF THE SWITCHGEAR ON SITE 37

5.9 Pressure relief ducts 5.9.1 Gas duct with outlet

• The pressure relief duct is supplied dismantled Once the panels are bolted up, and busbars are
in single components. The rear and front wall installed, it is possible to start fixing the gas duct
correspond, as far as length is concerned, with on the top of the switchgear. Every panel has
the appropriate panel width three fixing points in the front part (Fig. 56) and
• The screw fixing material is contained in the three fixing points on the rear part (Fig. 57).
“pressure relief duct” set of bags. Rivet nuts
are already provided in the metal sheets
• Detailed instructions for gas exhaust duct
assembly are described in document 1VLG100135
and in assembly manual 1VLM000034

Note:
The rear pressure relief flap must be mounted
according to figure 55.

Details regarding connection to the wall and a

discharge grating for pressure relief outside the
switchroom will be agreed on with the customer.

50

50 Pressure relief duct

— —
Figure 52 Schematic diagram of the pressure relief duct. Figure 53 Fixing points on the front

— —
Figure 54 Fixing points on the rear Figure 55 Assembly of pressure relieve flaps with or without gas duct
38 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

5.9.2 Gas duct with top chimneys

In order to mount the gas duct with top chimneys
please follow the appropriate instructions.

The difference between the two solutions is that

in this case there are no side exits, but the gas
generated from an internal the arc exits from the
duct through the top chimneys located on the top
part of the gas duct on each panel.

On the top of the gas duct there are two openings

(Fig. 59); for each opening the perforated
metal plate must be fixed with 6 spacers (Fig.
60).

— —
Figure 56 Openings on top of the gas duct Figure 57 Net and spacers of top chimneys

At this point it is possible to fix the top cover with 12xM8 screws.
—
Figure 58 Top cover of top chimneys
ASSEMBLY OF THE SWITCHGEAR ON SITE 39

5.10 Cable connection Connection of cables in typical panels:

5.10.1 Power cables
Power cables connection Rated Rated Max. Max. Range Range

• The cables are routed from below through voltage current number of cross of of

the floor covering, which is divided at the cable (kV) (A) parallel section cable reducer
entry point. The cables go through rubber cables per of cables clamp ring
reducer rings, which can be adapted to the phase (mm2) (mm) (mm)
required cable diameter in a range from 35 to 12 ...1250 2 (1)(2)
300 35-54 27-62
54 mm (Fig. 62) (1) In the case where removable voltage transformers are on the
• Cable sealing ends are mounted onto the truck or surge arresters are used, the number of parallel cables
is reduced by one per phase.
cable cores according to the manufacturer’s (2) For an IF panel with cable bottom entry and depth of 1,650 mm,
instructions. It is possible to use cable up to 2 parallel cables per phase can be used.

sealing ends from different manufactures

(e.g. Pirelli, Raychem etc.), but it is necessary Important notice
to keep the length of the cable ends, including Typically, connections in the panel are made using
cable sealing ends, which is given by the single-core plastic insulated cables. Special or
distance of cable connecting bars from the unusual cable connection cases (e.g. three-core
panel floor covering. These bars have different cables, cables with paper or special insulation
versions, the difference being the number of etc.) must be agreed between the customer and
parallel cables and the values of the rated manufacturer.
and short-circuit currents
• The bars are equipped with holes to Mounting procedure for power cables:
accommodate M16 screws. If M12 screws are • The power cables must be first inserted, then
used for the cable connections, special cut to length and stripped
washers for these screws are also supplied. In • The reducer rings must be adapted to the cable
all cases, the earthing of the cable screens is diameter before being fitted onto the cable
carried out on the strip-holding cable clamps. • Cable sealing ends must be prepared and
The cable strip is connected to the earth mounted on cable cores according to
potential manufacturer’s instructions
• The removable arrangement of voltage • The cable eyes must be connected to the
transformers can also be placed in the cable prepared connection bars with strain relief
compartment. These can be fitted with • The cables must be correctly earthed
high-voltage fuses similar to those used in • Individual parts of the floor covering must be
the measuring panel. Three fixed-mounted mounted
surge arresters can also be installed. However, • The reducer rings must be moved down so that
in both cases the number of parallel cables nuts in the rings fit into the corresponding
must be reduced - see table below recesses in the floor coverings. In this way the
cable passages are sealed
• Cables must be fastened in the prepared cable
clamps (the maximum tightening torque
applicable to the clamp screws is 9 Nm)

—
Figure 59 a) Cable compartment
40 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

—
Figure 59 b) Dimension of power cable connection

In (A) Width (mm) Ith (kA) A B C Max. number of cables in one phase
...1250 500 ...31.5 1086 1310 691 2 (300 mm2)
ASSEMBLY OF THE SWITCHGEAR ON SITE 41

5.10.2 Control cables 5.12 Laying the ring circuits

The control cables are conveyed into the panel The ring circuits are supplied - as a rolled-up
through the control wiring duct on the left-hand bundle - in the control cabinet or in the accessories.
side of the panel. Mounting procedure: They are marked and fitted with ferrules or
• Insert the cables into the control wiring duct connectors at both ends.
on the left-hand side. The duct is covered by
covers Openings are provided in the side walls of the
• Fasten the control cables at the top end of the control cabinet so that these lines can be looped
duct, stripthe insulation and convey the cable through from panel to panel.
control cores into the low-voltage compartment
after the terminal strip frame has been swung up 5.13 Final erection work
• Connect the control cables to the terminal strip • Check painted areas of the switchgear for
according to the circuit diagram possible damage and touch up where required
• Control wiring connections to adjacent panels • Check bolt connections, in particular all those
are made using a bushing made during the on-site erection of the busbars
and earthing system. Tighten if required
5.11 Earthing the switchgear • Thoroughly clean the switchgear
• Connect the main earthing bar to the connections • Remove all foreign bodies from the panels
provided in every panel • Correctly replace all coverings, etc. removed
• The floor frame or the erected raised false floor during erection and connection
needs to be protected using the correct wiring • In the enclosure, any remaining openings must
connection be closed if they are no longer needed
• Connect the earthing conductor - coming from • Check the isolating contacts and interlocking
the earth electrode preferably via a removable mechanisms for smooth motion, and grease
bolted connection for testing purpose - to the again with isoflex topas NB 52 where necessary
main earthing bar of the switchgear • The withdrawable circuit-breaker parts must
be inserted and the control wirings connected
• The panels doors must be properly closed

—
Figure 60 An open terminal frame
42 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

—
6 Operation of the switchgear

Note on safety at work • Turn the crank clockwise (approx. 20 turns)

All relative work and operating procedures must until the stop is reached and the withdrawable
be carefully carried out by trained specialists part is in the service position (Fig. 66)
familiar with the installation, taking into account • Observe the position indicator
all the relative safety regulations according to the • Remove the hand crank
IEC and other relevant professional bodies, as well
as any local and work regulations and instructions. The spring loaded pin head will lie completely on
the rear side of the panel door when the hand
Warning: crank is moved from the square spigot of spindle
Do not walk on the top surfaces of the mechanism. This ensures that the rear part of the
switchgear panels as they contain rupture pin head has been shifted onto the hexagonal
points for pressure relief which could be cap of the spindle and prevents unintentional
damaged! wrenching of the spindle during panel service.
Wrenching may lead to the circuit-breaker blocking.

6.1 Switching operations Note:

Carry out switching operations with the The withdrawable part must not be stopped in
front doors closed! any intermediate position as it is moved between
the service and test/disconnected positions!
6.1.1 Withdrawable circuit-breaker part
Manual insertion from the test/disconnected Manual withdrawal from the service position to
position to the service position: the test/disconnected position:
• Connect the control wiring plug (Fig. 64) • Ensure that the apparatus is in the OFF position
• Close the front door • Reverse the procedure described above for
• Ensure that the apparatus is in the OFF position insertion into the service position
• Fit the hand crank onto the square spigot of
the spindle mechanism after the hole has been
opened for it by turning the slide. The slide is
turned using a knob (Fig. 65)

145

121.1

— —
Figure 61 The control wiring plug connector is blocked to Figure 62 Before inserting the hand crank, it is
prevent disconnection with the withdrawable part necessary to open the hole for it. To do this,
in the service position turn the slide by means of the key
OPERATION OF THE SWITCHGEAR 43

Important note: Withdrawal from the test/disconnected position

The insertion and withdrawal of onto the service truck:
circuit-breakers (and other withdrawable • Open the door of the circuit-breaker
parts) must be gradual to avoid any shocks compartment
that could deform the mechanical interlock. • Release the control wiring plug and place it in
If any operations are prevented, do not the storage position on the withdrawable part
force the interlocks and check that the • Position the service truck, with the adjustable
operating sequence is correct. The force bench-top guide pins, at the correct height
normally applicable to the insertion/ facing the panel front and allow the catch to
withdrawing lever is 260 N. In any case, engage (Fig. 67)
the maximum applicable force must never • Move the sliding handles inwards against the
exceed 400 N. Please refer to the springs to release the withdrawable part. Draw
circuit-breaker technical documentation the withdrawable part out onto the service
for installation operations. truck and secure it in the catches on the truck
(Fig. 68)
Caution • Press the release lever - positioned at the front
Insertion and withdrawal must always be carried underneath the bench top - and release the
out with the apparatus open! service truck from the switchgear panel
• Insertion from the service truck into the test/
In the event of an auxiliary voltage drop, do not disconnected position
use force to move the withdrawable parts with • Carry out the procedure described above for
locking magnets Y0 or RL2. After a voltage drop withdrawal in reverse order
has occurred, the magnets are locked along the
entire travel range between the service and test
positions. To remove the interlock, consult the
circuit-breaker technical documentation.

13

121

124.2
13.11

124.3

124

— — —
Figure 63 Movement of the withdrawable part Figure 64 Positioning the service truck Figure 65 Service truck engaged with the
between the test/ disconnected with the guide pins on the switchgear panel. Withdrawable
position and the service position: adjustable - height bench top part released for removal with the
clockwise up to the stop for service at the correct height for approach handles slid inwards
position and anticlockwise for the to the switchgear panel and
test/disconnected position engaging the catch

121 Hand crank 124.2 Guide pin 13 Withdrawable part

124.3 Catch pin 13.11 Sliding handle
124 Service truck
44 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

6.1.2 Cicuit-breaker - type VD4 • Operate the local or remote electrical control
Charging the stored energy spring system: - observe the switch position indicator
• Automatic charging is carried out on a • The switching operation counter (Fig. 70) for
circuit-breaker with charging motors. If the the circuit-breaker automatically increases by
charging motor fails, the charging procedure one unit with each operating cycle
can be carried out or completed manually • An additional control mechanism fitted in the
• On breakers with manual charging systems, door of the circuit-breaker compartment enables
take the lever and pump 8 or 9 times until the mechanical operation of the circuit-breaker with
charged condition is indicated (Fig. 70) the door closed and with the withdrawable part
• When the charged condition is reached, the in either position (Fig. 71)
charging mechanism is automatically • Press the relative mechanical pushbutton, having
disengaged. Any further strokes of the lever will first turned the knob anti-clockwise to the stop
have no effect position in the event that the withdrawable part
• Opening and closing the circuit-breaker was in the service position
• Opening and closing operations with the • Observe the switch position indicator
withdrawable part in the service position should
only be performed with the door closed

13.2 13.1

13

45.2
13.11
13.4

45.1
90°
124.4 13.8

124.1 128a
13.5

124 13.11

— — —
Figure 66 Withdrawable part standing on Figure 67 Manual operation of the Figure 68 Handling of the mechanical
service truck and secured in the withdrawable part with V-max circuit - breaker operation in the
catches circuit-breaker switchgear panel door with the
withdrawable part in the service
position

13 Withdrawable part 13.1 Mechanical ON push-button 45.1 Mechanical pushbutton

13.11 Sliding handle 13.2 Mechanical OFF push-button 45.2 Knob
13.12 Catch (connected to sliding 13.4 Mechanical switch-position
handle 13.11) indicator
124 Service truck 13.5 Mechanical operating-cycle counter
124.1 Height adjuster 13.8 Charging condition indicator
124.4 Release lever for catch pin 13.11 Sliding handle connected to
the catch on the withdrawable
assembly
128a Charging lever
OPERATION OF THE SWITCHGEAR 45

6.1.3 Withdrawable metering part Caution: If the operation is prevented, do

Handling of the withdrawable metering or the not force the interlock and check that the
voltage-transformer part in the metering panel operation sequence is correct.
is described in section 6.2.1. Withdrawable
voltage-transformer parts in incoming and • Fit the operating lever (Fig. 73) onto the
outgoing feeder panels are put into the cable hexagonal shaft, which is now released for
compartment using a ramp. They reach the service operation.
position immediately and engage with the panel
earthing. The voltage transformers used correspond Note: Put the operating lever in a pointed
to the type used in the voltage-transformer panel, upwards or downwards position so that
thereby allowing HRC fuses to be implemented. there is sufficient room for it to move.

6.1.4 Earthing switch - ET1 • To close the earthing switch, turn the lever
The earthing switch has a snap closing mechanism clockwise through approx. 180 °until the stop
which is independent of the rotation of the drive position is reached. Turning the lever in an
shaft. An earthing switch allocated to a circuit- anticlockwise until the stop position is reached
breaker is only enabled for switching when the opens the earthing switch
withdrawable part is in the test/disconnected • Observe the mechanical/electrical switch
position or removed from the switchgear panel. position indicator
Earthing switches should be turned on only when • Remove the operating lever. The slide remains
the doors are closed. open if the earthing switch is in the closed
position
Manual opening and closing:
• Press the slide of the operating lever recess Make sure the operating lever fully reaches the
socket downwards (Fig. 72) to open. If the stop position in the opening process to ensure
switch is closed, the slide will already be in that the earthing switch is in its defined limit
this position position. The manual operating mechanism can
also be fitted with a locking magnet.

14.1

122

14.2

— —
Figure 69 Preparing to operate the earthing switch - press Figure 70 Preparing to operate the earthing switch - operating lever
the slide downwards in upright position ready to switch to on/off position

14.1 Hexagonal shaft for earthing switch operating 122 Operating lever
mechanism
14.2 Slide
46 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

6.2 Test procedures 6.2.2 Current and voltage tests

6.2.1 Testing the off-circuit condition The testing and earthing module is available
In switchgear panels which are not equipped for carrying out current and voltage tests. It is
with capacitive voltage indication, checking also suitable for supplying primary current to
the off-circuit condition is carried out with a HV any current transformers which may be fitted
tester on the isolating contacts in the isolating during measurements in the protection circuit
tulips, after the corresponding upper shutter or and, for example, for application of a test voltage
lower shutter has been opened. during insulating tests.
• Isolate and secure the working area in
If the panels are equipped with capacitive voltage accordance with the IEC safety regulations
indication, checking the off-circuit condition can • For primary current supply, fix the connecting
be carried out by means of this device. In this case, cable of the test transformer to the contact pins
proceed according to the manufacturer’s • For AC voltage tests, ball is required on the
instructions or the indicators (Optionally, contact pin. The bore in the ball is used for
switchgear can be equipped with various types connection of the voltage supply
of indicators coming from various manufacturers). • For current tests, for example of small connected
generators, the short-circuit bridge must be
In case of any doubt about correct operation of fixed onto the contact pins
capacitive voltage indication, the off-circuit
condition must be checked using a HV tester. Note:
With voltage tests at power frequency withstand
Checking the off-circuit condition must always be voltage and/or impulse voltage, carry out the
carried out in compliance with the relevant safety following procedure:
regulations and local operating conditions! • Disconnect any voltage transformers and
capacitive dividers and cover them with an
insulating plate

10.1

12.1
43.3

12.2

42

10.1 Control wiring socket

12.1 Top shutter
12.2 Lower shutter
14 14 Earthing switch operating mechanism
14.1 Drive shaft
14.1 42
43.3
Right travel rail
Duct cover, top right

—
Figure 71 View into the circuit-breaker compartment
 COMMISSIONING 47

—
7 Commissioning

7.1 Preparatory work • For any other matters regarding operation of

To prepare for commissioning, the following work the withdrawable circuit-breaker part and testing
must be carried out prior to the connection of facilities for the withdrawable part, please see
the high voltage power supply: section 8.5
• Check the general condition of the switchgear • Instruct local operators regarding the basic
for any damage or defects details in the regular handling of the switchgear
• Visually inspect the switching devices, • Check readiness for operation and the switching
withdrawable parts, isolating contacts, status of electrical systems upstream and
insulating parts, etc downstream of the switchgear
• Check the connection between the main • Depending on the allocation of responsibilities,
earthing bar and the installation earthing it may also be necessary to check the following
conductor equipment in areas adjacent to the switchgear:
• Check the paintwork for damage and, where - Power cables
necessary, touch up as described in section 8.5 - Auxiliary cables
• Remove all residues of materials, foreign bodies - Auxiliary power source
and tools from the switchgear - Remote control system
• Clean the switchgear, rubbing down the - Complete earthing system
insulating parts with a soft, dry, clean, non-fraying - Switchroom equipment
cloth. Remove any greasy or sticky dirt as - Switchroom conditions
described in section 8.4
• Correctly remount all covers etc. removed during 7.2 Start-up
the assembly and testing procedures • Comply with all relevant safety regulations
• Remove the transport caps on the vacuum • Ensure that the circuit breakers in the system
circuit-breakers if they are still fitted are in the OFF position
• Perform AC voltage testing of the main circuits • Remove any existing earthing and short-circuiting
according to IEC 600271-200 where necessary. connections in the critical switching area
Pay special attention to the voltage transformers • Energize the feeder cables
and cables, etc. during this procedure • Connect the switchgear step by step, observing
• Switch the auxiliary and control voltage on the signals and indicators
• Carry out testing operations on switching • Check that the relative conductors are in phase
devices manually or by electrical control, and and, where necessary, when there are several
simultaneously observe the relative position incoming feeder cables and switchgear sections
indicators • Carry out all measurements and check the
• Check the mechanical and electrical interlocks functions which depend on the connection of
for effectiveness without using force a high-voltage power supply
• Set the protective devices in the switchgear • Watch out for irregularities of any kind
to the required values and check their function
with test equipment
48 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

—
8 Maintenance

8.1 Maintenance strategies Note:

Preventive maintenance When carrying out all maintenance work, the
is maintenance carried out at predetermined regulations in the country of installation must
intervals or according to prescribed criteria, aimed be strictly adhered to. Maintenance work should
at reducing the failure risk or performance only be undertaken by trained personnel familiar
degradation of the equipment. This method is with the characteristics of the individual
based on scheduled activities performed on the switchgear. All work should be carried out in
out-of-service equipment including: visual checks, accordance with all relevant IEC safety regulations
apparatus cleaning, mechanical components and with those of other technical authorities and
with other overriding instructions. It is
lubrication, worn parts replacement and routine
recommended that ABB service personnel perform
tests execution.
the servicing and repair work detailed below.

Risk-based maintenance
The inspection and servicing intervals for some
is maintenance carried out by integrating analysis,
of the equipment/components (e.g. parts subjects
measurement and periodic test activities to
to wear) are determined by fixed criteria, such as
standard preventive maintenance. switching frequency, length of service and number
of short-circuit breaking operations. For other
The gathered information is viewed in the context parts of the switchgear, the length of the intervals
of the environmental, operation and process may depend, for example, on the different modes
condition of the equipment in the system. The of operation in individual cases, the degree of
aim is to perform the asset condition and risk loading and environmental influences (including
assessment and define the appropriate pollution and aggressive air).
maintenance tasks.
The operating instructions for the Vmax circuit
Please refer to next chapters for details of breaker must also be followed, and if necessary,
preventive and risk-based maintenance programs. further details (such as special operating conditions
agreed on with the manufacturer) described in
Safery warning the technical documentation specific to the
Always follow 7 safety steps: switchgear installation should also be taken into
• Clearly identify the work location consideration.
• Disconnect and secure against
reconnection Intervals for inspection, servicing and repairs
The time intervals for any maintenance work
• Protect against any other live parts
depend on the operating conditions of the
• Take special precautions when close to
switchgear, and in particular on the mode of
bare conductors
operation, the number of rated and short-circuit
• Check the installation is dead
current switching operations, ambient temperature,
• Carry out earthing and short circuiting
pollution etc. We recommend carrying out
• Issue a permit work
maintenance work at the following intervals:

8.2 Preventive maintenance Activity According Time interval According to

Maintenance serves to preserve trouble-free performed to section in years number

operation and achieve the longest possible working of switching
life of the switchgear. It comprises the following operations
activities. Inspection 8.3 3 1) 2500
Servicing 8.4 3 2) 2500 3)
Inspection: Determining the actual condition. Repair 8.5 As required As required

1) In more demanding service conditions, we recommend reducing this

Servicing: Measures to preserve a specified condition. interval suitably – also see sections 1 and 2.
2) According to the results of the inspection.
3) See the instruction manuals of the circuit-breakers.
Repair: Measures to restore the specified condition. *) Earthing switch.
MAINTENANCE 49

8.3 Inspection 8.5 Repair

• Where necessary, the working area must be 8.5.1 Repair on switchgear assemblies
isolated and secured against reconnection in 8.5.1.1 Repair of surface damage
accordance with the safety regulations specified • Carry out repair work immediately after a
by IEC and any appropriate national standards defect has been discovered
before inspection • Completely remove all rust from damaged
• Correct switchgear functionalities should be paintwork areas on steel sheet and other
monitored by regular inspections steel parts by mechanical means, e.g. with a
• Under normal operating conditions, inspection wire brush
should be carried out once every four years • Lightly grind the surrounding paint coat and
by specially trained professional electricians carefully degrease the entire area. Then
• Under abnormal operating conditions (including immediately apply an anti-rust primer and, after
adverse climatic conditions) and/or special an appropriate hardening time, apply the top
environmental stresses (heavy pollution and coat. Only use suitable and compatible paint
an aggressive atmosphere among others), the products
frequency of inspection may have to be increased • Apply the top coat in standard RAL7035 colour,
• Inspection is primarily to carry out a visual check or the relevant special colour
for grime, corrosion and moisture: • Carefully remove any white rust on aluminium/
- Effects of high temperature on the main zinc surfaces with a wire brush or cleaning pad,
circuits e.g. Scotch-Brite, and clean loosely adhering
- Traces of partial discharge on the insulating particles with a dry, non-fraying cloth. Next
material parts treat the cleaned parts with zinc spray or zinc
- Traces of leakage current on the insulating powder paint and, finally, treat with aluminium
material parts spray for colour matching
- Surfaces of the contact systems • Carefully remove any white rust from passivated
• However, inspection must also include correct operating parts and rust formation on
mechanical/electrical operation of the following phosphatised parts with a wire brush or
parts: switching devices, actuating, interlocking, metal-free cleaning pad, e.g. Scotch-Brite, and
protection and signalling devices clean with a dry cloth. Then grease evenly (with
mechanical grease for moving parts)
Caution
With regard to the switching devices, Remove the contact system and thoroughly clean.
their separate Instruction manual should
be followed. Note:
The set installation position of the contact arms
8.4 Servicing must not be changed by undue use of force.
When, during an inspection, the need to carry Replace the contact pins when the surface has
out cleaning operations is noted, proceed as been damaged. Replaced pins should be
follows: retightened using socket head bolts.
• Clean the surfaces:
- Remove any dry dust deposits which are not 8.5.1.2 Repair on earthing switch signaling
very adherent using a soft dry cloth contact
- Remove any more adhering dirt with ethanol The auxiliary switches of the interchangeable
F 25 M groups are adjusted at the factory.
• Clean the insulating surfaces and the conductive
components with ethanol F 25 M When final installation of the earthing switch and
• After cleaning, rinse with clean water and dry operator takes place on site, it may be necessary to
carefully carry out further precise adjustment of the auxiliary
• Should any partial discharges occur as a switch. In this case, the following should be taken
consequence of the condensation phenomenon, into account:
a temporary remedy which is often effective • There must be a run-on of 0.5 mm in the fully
is application of a thin layer of silicone over operated position before the plunger reaches
the surface involved. For a permanent remedy the stop position (for safety reasons)
to this type of unusual problem, contact the • The auxiliary limit switch for earthing switch
ABB service department ON must be operated immediately after the
toggle spring mechanism is precisely centered
in the closing process and the automatic rapid
closing process has started
50 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

• The auxiliary limit switch (Fig. 72) for earthing In this way, the service activity is no longer driven
switch OFF must be operated on earthing by predefined timeframes, observations and past
switches with manual mecha nisms during experiences, but takes into account the actual
the opening movement of the slide (Fig. 72), condition of the equipment, the required reliability
and before half of the hexagonal shaft has level and the expetation for life time extension.
become visible, or 1 mm before the tab of the
slide makes contact with the armature of the This assessment is performed by trained
de-energized locking magnet technicians as part of risk-based maintenance
programs or is carried out automatically by on-line
8.5.2 Repairs on withdrawable parts monitoring systems for condition-based
When functional tests are carried out on maintenance solutions.
withdrawable parts, compliance with the
conditions listed below should also be checked. Please refer to brochure 1VCP000427 - maintenance
by ABB for more details on risk-based
The following operating instructions must also maintenance.
be followed, together with this instruction
manual in the individual cases concerned. 8.7 Spare parts, auxiliary materials and
lubricants Spare parts
• Vacuum circuit-breaker: type VD4 A spare parts list is available on request for
procurement of spare parts. It basically includes
Thread Rated tightening torque ungreased moving parts and parts subject to wear. When
M10 50 Nm parts are required, the serial number of the
relevant switchgear or switching device should
8.6 Risk-based maintenance always be quoted.
ABB supports UniGear users with optimized and
cost effective strategies to ensure that the correct Auxiliary materials, lubricants
actions are implemented at the right time. Asset Lubricant
managers are fully supported in moving from • Isoflex topas NB 52
conventional approaches (‘‘corrective maintenance’’
and ‘‘preventive maintenance’’) to advanced Halogen-free cleansers (optional)
strategies (‘‘risk-based maintenance’’ and • Ethanol F 25 M (for general cleaning)
‘‘condition-based maintenance’’).
Touch-up paint (optional)
• Standard colour RAL7035

14.1
14.2

14.3

11.3

11.4

11.3 Auxiliary switch – earthing switch OFF

11.4 Auxiliary switch – earthing switch ON
14.1 Drive shaft (earthing switch)
14.2 Slide
14.3 Cam plate, adjustable
—
Figure 72 Manual earthing switch mechanism with auxiliary switches (side cover has been removed)
MAINTENANCE 51

8.8 Operating accessories

145
147

121 Hand crank (to move the withdrawable part inside the
panel)
122 Operating lever (for earthing switch)
145 Double bit key (for the central catch and screw type
door catch)
147 Hand crank (for the central catch or screw type door
catch)

122 121

—
Figure 73 Operating accessories
52 UniGear ZS1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

—
9 Product quality and environmental
protection

The UniGear type panels are produced in The duty of company is to facilitate subsequent
compliance with the requirements of international recycling or disposal at the end of product life.
standards for the quality management system
and environmental management system. In these During disposal of the product, it is always
fields, the excellent level is proved by quality necessary to act in accordance with local legal
certificates according to ISO 9001 and by the requirements in force.
EMS according to ISO 14001.
We the following methods of disposal:
End of life of product Disposal can either be carried out thermally in an
The ABB company is committed to complying with incineration plant or by storing on a waste site.
the relevant legal and other requirements for
environment protection according to the ISO
14001 standard.

Raw material Recommended method of disposal

Metal material (Fe, Cu, Al, Ag, Zn, W, others) Separation and recycling
Thermoplasts Recycling or disposal
Epoxy resin Separation of metal material and the disposal of rest
Rubber Disposal
Oil as dielectric (transformer oil) Draining from equipment and further recycling or disposal
Packing material – wood Recycling or disposal
Packing material – foil Recycling or disposal
—
Note
—
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—
ABB Xiamen Switchgear Co., Ltd.
No.885, FangShanXiEr Road, Xiang'an District,
Xiamen, Fujian, 361101
Tel: 0592 602 6033
Fax: 0592 603 0505

ABB China Customer Service Hot Line:

TEL: 800-820-9696 / 400-820-9696
mail: cn-ep-hotline@abb.com

www.abb.com

1YHA000317_EN_REV C 08-2021
XM-VS

© Copyright 2021 ABB. All rights reserved.

Specifications subject to change without notice.