UniGear ZS1 Training
UniGear ZS1 Training
UniGear ZS1 Training
© ABB Group
December 15, 2022 | Slide 1
Personal Information
© ABB Group
December 15, 2022 | Slide 2
Contents
Background theory and standards
Introduction
UniGear ZS1 basic description
Service continuity
Internal arc clasiified
Production portfolio overview
- UniGear ZS1 12-17,5kV and 24kV
- Units produced by other ABB factories
© ABB Group
December 15, 2022 | Slide 3
Introduction ...
© ABB Group
December 15, 2022 | Slide 4
ABB portfolio – Medium Voltage Products
www.abb.com
UniGear ZS1
Medium Voltage
Air Insulated Switchgear
© ABB Group
December 15, 2022 | Slide 5
UniGear ZS1 – the basic description
© ABB Group
December 15, 2022 | Slide 6
UniGear ZS1 – the basic description
The switchgear solution
horizontal communication
integrated station via IEC61850-8-1 withdrawable
automation COM600 apparatus
© ABB Group
December 15, 2022 | Slide 7
UniGear ZS1 – the basic description
Design of a typical functional unit
Cable compartment –
interlock-controlled access
(can be combined also with
Circuit breaker compartment – procedure-based access)
interlock-controlled access
(can be combined also with
procedure-based access)
© ABB Group
December 15, 2022 | Slide 8
UniGear ZS1 – the basic description
Application for indoor switchgear solutions
Operating conditions
Indoor installation, normal operating conditions
Authorized person access only switchgear room
Derating factors shall be considered for installations above
1000m asl, or at average temperatures exceeding 40°C
© ABB Group
December 15, 2022 | Slide 9
UniGear ZS1 – the basic description
Safety first
© ABB Group
December 15, 2022 | Slide 10
UniGear ZS1 – the basic description
Designed and type tested as per IEC standards
© ABB Group
December 15, 2022 | Slide 11
Service continuity ...
© ABB Group
December 15, 2022 | Slide 12
UniGear ZS1 – the basic description
Service continuity
© ABB Group
December 15, 2022 | Slide 13
UniGear ZS1 – the basic description
The categories for Loss of service continuity
LSC2B - PM
Segregated switchgear units
(except for the main busbar)
The unit can be disconnected
from the main busbar (LSC-2A)
The unit can be also
disconnected from its cable
compartment (LSC-2B)
© ABB Group
December 15, 2022 | Slide 14
Internal arc classified ...
© ABB Group
December 15, 2022 | Slide 15
UniGear ZS1- safety aspects
Internal arc withstand capability
© ABB Group
December 15, 2022 | Slide 16
UniGear ZS1- safety aspects
Internal arc classification – IEC62271-200
© ABB Group
December 15, 2022 | Slide 17
UniGear ZS1- safety aspects
Arc time duration – influence on the damage level
© ABB Group
December 15, 2022 | Slide 18
UniGear ZS1- safety aspects
Accessibility class IAC AFLR
Pressure relief
flaps
© ABB Group
December 15, 2022 | Slide 19
UniGear ZS1- safety aspects
Gas exhaust protection covers
© ABB Group
December 15, 2022 | Slide 20
UniGear ZS1- safety aspects
Gas exhaust protection covers - channels
© ABB Group
December 15, 2022 | Slide 21
UniGear ZS1- safety aspects
Gas exhaust protection covers – top chimneys
© ABB Group
December 15, 2022 | Slide 22
UniGear ZS1- safety aspects
Detectors for rapid fault clearance – pressure switches
Basic level:
auxiliary switches on the
Option: pressure release flaps
Application of
overpressure sensors Arc detection within 15ms plus
inside the panels direct CB trip (40-60ms)
© ABB Group
December 15, 2022 | Slide 23
UniGear ZS1- safety aspects
Detectors for rapid fault clearance – optic sensors
Advanced level:
arc-protection set REA with
optic sensors and relay unit
© ABB Group
December 15, 2022 | Slide 24
UniGear ZS1- safety aspects
Detectors for rapid fault clearance – UFES
QRU
Advanced level:
arc-protection set UFES with
optic sensors and relay unit
PSE
Extendability by TVOC2
© ABB Group
December 15, 2022 | Slide 25
UniGear ZS1- safety aspects
Internal arc caused by wrong operation sequences
Mechanical interlocks:
© ABB Group
December 15, 2022 | Slide 26
UniGear Family
The production portfolio overview
UniGear
ZS1 ..24kV
Single Busbar
Standard Marine
Double Busbar
Standard Duplex Front to front
Duplex Back to back
Double Level
Standard Marine
550 ..17.5kV
Standard Marine
500R ..12kV
IEC
ENA (for UK)
MCC ..7.2kV
ZVC ..7.2kV
Standard Marine
ZS2 ..36kV
ZS3.2 ..40.5kV
© ABB Group
December 15, 2022 | Slide 27
UniGear
UniGear ZS1 SBB UniGear ZS1 SBB Deep UniGear ZS1 Double Level UniGear MCC
UniGear ZVC UniGear 500R UniGear ZS1 Duplex UniGear ZS1 DBB
Back to Back
© ABB Group
December 15, 2022 | Slide 28
UniGear ZS1
MV AIS 12 - 17,5kV - 24kV
© ABB Group
December 15, 2022 | Slide 29
UniGear ZS1
Basic information
© ABB Group
December 15, 2022 | Slide 30
UniGear ZS1
Technical parameters
© ABB Group
December 15, 2022 | Slide 32
UniGear ZS1
Standard units SBB – Bus tie and metering
© ABB Group
December 15, 2022 | Slide 34
UniGear ZS1
Deep units SBB – Incomer, Outgoing
© ABB Group
December 15, 2022 | Slide 35
UniGear ZS1
Duplex units - double busbar solution with two CBs
© ABB Group
December 15, 2022 | Slide 36
UniGear ZS1 DBB
Basic information about DBB units
© ABB Group
December 15, 2022 | Slide 37
UniGear ZS1 DBB
Technical parameters
3150 1) 3150 1)
4000 1, 2) 4000 1, 2)
1. The 3150A and 4000A has separate incomers for section A and B (without line
disconnector), the same is for 2500A panel at 24kV
2. With cooling fan
3. Note: against the standard UniGear ZS1 and duplex units, the DBB units are limited in STC
by capabilities of the line disconnectors for 31,5kA (or 25kA at 24kV)
© ABB Group
December 15, 2022 | Slide 38
UniGear ZS1 DBB
Standard units DBB – Incomer, Outgoing
© ABB Group
December 15, 2022 | Slide 39
UniGear ZS1 DBB
Standard units DBB – BTT, BTL and metering
© ABB Group
December 15, 2022 | Slide 40
UniGear ZS1
The main components used in SBB and DBB units
© ABB Group
December 15, 2022 | Slide 41
The main components of UniGear ZS1
Apparatus – circuit breakers 12-17,5 and 24kV
© ABB Group
December 15, 2022 | Slide 42
The main components of UniGear ZS1
Apparatus – vacuum contactors 7,2 and 12kV
© ABB Group
December 15, 2022 | Slide 43
The main components of UniGear ZS1
Measurement – Current transformers
© ABB Group
December 15, 2022 | Slide 47
The main components of UniGear ZS1
Measurement – Electronic transformers (sensors)
© ABB Group
December 15, 2022 | Slide 48
The main components of UniGear ZS1
Measurement – Electronic transformers (sensors)
Transformer Sensor
180 462 154
Customers
benefit
18 308
33 283 3 4 33%
15
234 Cost
Connection Connection saving
Adaptation Adaptation
to REF to REF
© ABB Group
December 15, 2022 | Slide 49
The main components of UniGear ZS1
Protection relays and IEDs
REF630
Suitable for switchgear with
single busbar, double busbar
and duplex systems
REM630
Machine protection terminal
RET630
Transformer protection
Terminals (IEDs) for protection, control, measurement and
supervision
Full implementation of IEC 61850 can be perfectly used for
making of fast switchgear horizontal communication
Interactive mimic diagram
PLC functions for automation and sequence logic functions
© ABB Group
December 15, 2022 | Slide 50
The main components of UniGear ZS1
Protection relays and IEDs
REF615
Suitable for single busbar
switchgear, incoming/out-
going feeders
© ABB Group
December 15, 2022 | Slide 51
The main components of UniGear ZS1
Protection relays and IEDs
REF 610
Suitable for single busbar
switchgear, incoming/out-
going feeders
REM 610
Motor protection relay
REF 542+
Suitable for switchgear with
single busbar, double busbar
and duplex systems;
feeder, transformer and
motor protection
REX 521
Suitable for single busbar
switchgear, incoming/out-
going or motor feeder
© ABB Group
December 15, 2022 | Slide 55
The main components of UniGear ZS1
Protection relays and IEDs
RED 615
Differential protection
for overhead lines and
cable feeders in
distribution networks
© ABB Group
December 15, 2022 | Slide 56
The main components of UniGear ZS1
Protection relays and IEDs
COM 600
Station automation device,
all-in-one communication
gateway and user interface
for utility and industrial
distribution substations
© ABB Group
December 15, 2022 | Slide 57
The main components of UniGear ZS1
Earthing switch – cable and busbar side
© ABB Group
December 15, 2022 | Slide 59
The main components of UniGear ZS1
Cable termination kits
© ABB Group
December 15, 2022 | Slide 60
Switchgear units produced by other ABB factories
UniGear ZVC - slim panel up to 7,2kV
© ABB Group
December 15, 2022 | Slide 63
1. Panels overview and structure
a) Compartments and components
1. LV compartment
2. Gas duct
3. Busbar compartment
4. Cable compartment /
feeder compartment
5. Switching apparatus
(usually circuit breaker)
6. CB compartment /
apparatus compartment
7. Withdrawable VTs
© ABB Group
December 15, 2022 | Slide 64
1. Panels overview and structure
b) Standard Feeder layout
1
2 1
1
3
2 4 4 3
4 2
3
5
6 5
6
5
6
© ABB Group
December 15, 2022 | Slide 65
1. Panels overview and structure
b) Standard Feeder layout
1
2 1
1
3
2 4 4 4
5 2 3
4
5 3
6
6 5
6
© ABB Group
December 15, 2022 | Slide 66
1. Panels overview and structure
c) Bus Voltage Metering and Bus Riser panel layout
1
1
2
© ABB Group
December 15, 2022 | Slide 67
1. Panels overview and structure
c) Bus Coupler panel layout
1
1
1
2
2 3 2
3
4
3 4
4 5
5 5
© ABB Group
December 15, 2022 | Slide 68
2. Low voltage compartment
© ABB Group
December 15, 2022 | Slide 69
2. Low voltage compartment
a) Low voltage compartment exterior and interior
LV compartment exterior:
Key device is usually protection relay
display (HMI)
Additional devices, like voltage
indicators, measurement
visualization, position signalization,
switches and lamps are on the door
as well
The tag (identification) plate of the
panel is on the top, designation
plates are under each device
LV compartment interior:
The LV compartment contains
secondary circuits including MCBs,
terminals, wiring
The protection relay main unit is
usually in top left corner on the
backplane, other auxiliary relays next
to it, MCBs in a row below
Terminals are on the bottom plate,
that can be lifted for access to wiring
© ABB Group
December 15, 2022 | Slide 70
2. Low voltage compartment
b) Terminals in low voltage compartment
© ABB Group
-X8 ... Terminals for EXTERNAL control circuits and signals
December 15, 2022 | Slide 71
2. Low voltage compartment
c) Interconnection wiring
© ABB Group
December 15, 2022 | Slide 72
2. Low voltage compartment
d) Connection of external LV cables
Removable channel
duct cover
© ABB Group
December 15, 2022 | Slide 73
3. Operation of UniGear ZS1 with
circuit breaker
© ABB Group
December 15, 2022 | Slide 74
3. Operation of UniGear ZS1 with circuit breaker
a) Glossary
© ABB Group
December 15, 2022 | Slide 75
3. Operation of UniGear ZS1 with circuit breaker
b) Operating accessories
Hand crank for Ramp for withdrawable
racking in and out cable VT truck
the withdrawable
part inside the
panel
© ABB Group
December 15, 2022 | Slide 77
3. Operation of UniGear ZS1 with circuit breaker
c) CB racking operation
1 - Open the slot
2 - Insert the crank
3 - Turn approx. 20x
clockwise to rack-in or
counterclockwise to rack-out
HD4-Racking.mpg
© ABB Group
December 15, 2022 | Slide 78
3. Operation of UniGear ZS1 with circuit breaker
d) CB mechanical ON/OFF
1 - Turn knob counterclockwise
until stop (only if CB in service
position)
2 - Press desired button (ON or
OFF)
1
© ABB Group
December 15, 2022 | Slide 79
3. Operation of UniGear ZS1 with circuit breaker
e) CB manual spring charging
CB spring is charged
automatically by charging
motor, manual charging is
needed in case of auxiliary
voltage or charging motor failure
© ABB Group
December 15, 2022 | Slide 80
3. Operation of UniGear ZS1 with circuit breaker
f) Withdrawing on service trolley
© ABB Group
December 15, 2022 | Slide 82
3. Operation of UniGear ZS1 with circuit breaker
f) Withdrawing on service trolley
© ABB Group
December 15, 2022 | Slide 83
3. Operation of UniGear ZS1 with circuit breaker
g) Earthing switch operation
1 – Open the
earth switch
operating
slot
2 – Engage the
lever and
turn
clockwise to
switch ON,
conterclockw
ise to switch
OFF
2
1
Earthing-switch.mpg
© ABB Group
December 15, 2022 | Slide 84
3. Operation of UniGear ZS1 with circuit breaker
g) Earthing switch operation
© ABB Group
December 15, 2022 | Slide 85
3. Operation of UniGear ZS1 with circuit breaker
h) VT truck withdrawal
4
1
2
3
© ABB Group
December 15, 2022 | Slide 86
3. Operation of UniGear ZS1 with circuit breaker
i) Shutter lifting truck operation
1 2
3
You can use shutter lifting truck (optional accessories) for access to
spouts after removing the CB from CB compartment:
1 – Place the shutter lifitng truck into the rails for the CB truck in CB
compartment
2 – Push the shutter lifting truck in by means of isolated operation rod and open
the shutters for access to spouts
3 – Rotate the operatio rod to lock the truck and pull the truck out when you are
finished
© ABB Group
December 15, 2022 | Slide 87
4. Interlocks and locks in UniGear
ZS1 with circuit breaker
© ABB Group
December 15, 2022 | Slide 88
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch
Internal circuit breaker mechanical interlocks prevent:
CB racking in or out when CB is closed
CB closing if truck is in the interposition
Mechanical interlocks in the panel prevent:
Disconnecting CB control plug if CB is not in test position
Closing the earthing switch if CB is not in test position
CB racking in if earthing switch is closed
Connecting the control plug of CB with wrong rating
Electrical interlocks (when CB truck blocking coil is applied) prevent:
CB racking in if control plug is disconnected
CB racking in or out if auxiliary voltage is not present
Electrical interlocks (when earthing switch blocking coil is applied)
prevent:
Closing the earthing switch if auxiliary voltage is not present
© ABB Group
December 15, 2022 | Slide 89
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch
Internal circuit breaker mechanical
interlocks prevent:
CB racking in or out when CB is closed
CB closing if truck is in the interposition
© ABB Group
December 15, 2022 | Slide 90
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch
Mechanical interlocks in the panel prevent:
Closing the earthing switch if CB is not in test position
CB racking in if earthing switch is closed
© ABB Group
December 15, 2022 | Slide 91
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch
Mechanical interlocks in the panel prevent:
Disconnecting CB control plug if CB is not in test position
Connecting the control plug of CB with wrong rating
© ABB Group
December 15, 2022 | Slide 92
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch
Electrical interlocks (when CB truck blocking coil is applied) prevent:
CB racking in if control plug is disconnected
CB racking in or out if auxiliary voltage is not present
© ABB Group
December 15, 2022 | Slide 93
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
a) Interlocks for circuit breaker, CB truck and earthing switch
Electrical interlocks (when earthing switch blocking coil is applied)
prevent:
Closing the earthing switch if auxiliary voltage is not present
Earthing switch
blocking magnet
positioning
© ABB Group
December 15, 2022 | Slide 94
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters
Circuit breaker compartment door mechanical interlocks prevent:
CB compartment door opening if CB truck is not in test position
CB truck racking in if CB compartment door are opened
Cable compartment door mechanical interlocks prevent:
Cable compartment door opening if earthing switch is not closed
Earthing switch opening if the cable compartment door are opened
Shutters interlocks (optional) prevent:
Shutter opening by hands
© ABB Group
December 15, 2022 | Slide 95
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters for 24 kV
Circuit breaker compartment door mechanical
interlocks prevent:
CB compartment door opening if CB truck is not in test
position
© ABB Group
December 15, 2022 | Slide 96
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters for 12 kV
Circuit breaker compartment door mechanical interlocks prevent:
CB compartment door opening if CB truck is not in test position
© ABB Group
December 15, 2022 | Slide 97
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters
Circuit breaker compartment door mechanical
interlocks prevent:
CB truck racking in if CB compartment door are
opened
© ABB Group
December 15, 2022 | Slide 98
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters for 24 kV
Cable compartment door mechanical
interlocks prevent:
Cable compartment door opening if
earthing switch is not closed
© ABB Group
December 15, 2022 | Slide 99
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters for 12 kV
Cable compartment door mechanical interlocks prevent:
Cable compartment door opening if earthing switch is not closed
© ABB Group
December 15, 2022 | Slide 100
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters
Cable compartment door mechanical interlocks prevent:
Earthing switch closing if the cable compartment door are opened
© ABB Group
December 15, 2022 | Slide 101
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
b) Interlocks for doors and shutters
Shutters interlocks (optional) prevent:
Shutter opening by hands
© ABB Group
December 15, 2022 | Slide 102
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities
Options
CB racking slot Double bit, padlock, key lock, no
lock
© ABB Group
December 15, 2022 | Slide 103
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities
Options
ES operating slot Padlock, key lock, no lock
© ABB Group
December 15, 2022 | Slide 104
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities
Options
Buttons on the CB Padlock, key lock, no lock
© ABB Group
December 15, 2022 | Slide 105
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities
Options
Buttons on the CB door Padlock, no lock
© ABB Group
December 15, 2022 | Slide 106
4. Interlocks and locks in UniGear ZS1 with circuit
breaker
c) Locking facilities
Options
Shutters Padlock
© ABB Group
December 15, 2022 | Slide 107
UniGear ZS1 installation and
maintenance
© ABB Group
December 15, 2022 | Slide 108
Contents
1. Installation pre-requisites
a) Outline dimensions and MV, LV floor openings in documentation
b) Positioning of switchgear inside the switchroom
c) Foundation frames readiness
2. Installation of the panels
a) Unpacking
b) Tools, equipment, resources and time scale
c) Panels erection & assembly
d) Bus bars assembly
e) Panels LV interconnection
f) Earthing bar installation
g) Top mounted box with earthing switch or VT installation
h) Busbar bridge installation
i) Panel flaps and Ith limitors setup
j) Gas duct installation
k) Fixing the panels to the floor frame
3. Power and control cables installation
a) Control cables installation
b) Preparation for power cable pulling in
c) Power cable entry
4. Maintenance of UniGear ZS1 switchgear
a) Maintenance recommendation
b) Maintenance tasks and intervals
c) Inspection
d) Servicing
e) Repair
f) Practical repairs and troubleshooting
© ABB Group
December 15, 2022 | Slide 109
1. Installation pre-requisites
© ABB Group
December 15, 2022 | Slide 110
1. Installation pre-requisites
© ABB Group
December 15, 2022 | Slide 111
1. Installation pre-requisites
a) Outline dimensions and MV, LV floor openings in documentation
© ABB Group
December 15, 2022 | Slide 112
1. Installation pre-requisites
a) Outline dimensions and MV, LV floor openings in documentation
© ABB Group
December 15, 2022 | Slide 113
1. Installation pre-requisites
b) Positioning the switchgear inside the switchroom
© ABB Group
December 15, 2022 | Slide 114
1. Installation pre-requisites
b) Positioning the switchgear inside the switchroom
© ABB Group
December 15, 2022 | Slide 115
1. Installation pre-requisites
c) Foundation frame readiness
© ABB Group
December 15, 2022 | Slide 116
1. Installation pre-requisites
c) Foundation frame readiness
C-profile type
© ABB Group
December 15, 2022 | Slide 117
2. Installation of the panels
© ABB Group
December 15, 2022 | Slide 118
2. Installation of the panels
a) Unpacking
© ABB Group
December 15, 2022 | Slide 119
2. Installation of the panels
b) Tools and equipment
Minimum set of tools:
Spanners M6, M8, M10,
M12
Allen keys M6, M8,
M10, M12
Torque wrench up to
70Nm
Screwdrivers
© ABB Group
December 15, 2022 | Slide 120
2. Installation of the panels
c) Panels erection and assembly
Read and follow the UniGear
type ZS1 – Installation, service
and maintenance manual (UG
ZS1 IOM Man_Rev.H_2013),
chapter 5
Panels erection
One by one – from the first
to the last
Put up Line up
Tighten up
Do not fix panels to the floor
before end of whole
installation!
Finish one task before starting
the second one!
© ABB Group
December 15, 2022 | Slide 121
2. Installation of the panels
c) Panels erection and assembly
© ABB Group
December 15, 2022 | Slide 122
2. Installation of the panels
c) Panels erection and assembly
© ABB Group
December 15, 2022 | Slide 123
2. Installation of the panels
c) Panels erection and assembly
Panels assembly
One by one – from the
first to the last
3 vertical rows of bolts
– middle, front, rear
© ABB Group
December 15, 2022 | Slide 124
2. Installation of the panels
d) Busbar assembly
© ABB Group
December 15, 2022 | Slide 125
2. Installation of the panels
d) Busbar assembly
Bushings 12kV and 17,5kV in busbar comartment
© ABB Group
December 15, 2022 | Slide 126
2. Installation of the panels
d) Busbar assembly
Bushings 12kV and 17,5kV in bus coupler/riser
© ABB Group
December 15, 2022 | Slide 127
2. Installation of the panels
d) Busbar assembly
Bushings 24kV in busbar compartment
© ABB Group
December 15, 2022 | Slide 128
2. Installation of the panels
d) Busbar assembly
Bushings 24kV in bus coupler/riser
© ABB Group
December 15, 2022 | Slide 129
2. Installation of the panels
d) Busbar assembly
Busbar joints
© ABB Group
December 15, 2022 | Slide 130
2. Installation of the panels
d) Busbar assembly
Busbar joints
Clean the contact
surfaces and slightly
grease them with
contact grease
Be careful about correct
positioning of the
conical washers – they
are creating reactive
force (like spring
washers) for the bolts
and nuts not to get
loosened
Dry bolts torque 44Nm
© ABB Group
December 15, 2022 | Slide 131
2. Installation of the panels
d) Busbar assembly
© ABB Group
December 15, 2022 | Slide 132
2. Installation of the panels
d) Busbar assembly
The side caps must be mounted on the busbars prior to
busbar installation
© ABB Group
December 15, 2022 | Slide 133
2. Installation of the panels
d) Busbar assembly
Busbar end cover
Lid holder
Lid cover
Flat
full
washers
delivered in
the
switchgear
accessories
© ABB Group
December 15, 2022 | Slide 134
2. Installation of the panels
e) Panel LV interconnections
© ABB Group
December 15, 2022 | Slide 135
2. Installation of the panels
f) Earthing bar installation
Earthing bar
It creates the least
resistance path for
earth currents
Must be connected
minimum at one point to
substation main
earthing (recommended
two points)
Joints should be
torqued
© ABB Group
December 15, 2022 | Slide 136
2. Installation of the panels
f) Earthing bar installation
Earthing bar – connection to neighbouring panels
© ABB Group
December 15, 2022 | Slide 137
2. Installation of the panels
g) Top mounted box with earthing switch or VT installation
Installation of top mounted
boxes is described in the
manuals
© ABB Group
December 15, 2022 | Slide 138
2. Installation of the panels
h) Busbar bridge installation
Adobe
Acrobat Document
© ABB Group
December 15, 2022 | Slide 139
2. Installation of the panels
h) Busbar bridge installation
Switchgear A Switchgear B
Installation of standard modular Aisle width frame-to
frame
busbar bridges
The bridge is constructed
for aisle width that was
specified before the
manufacturing and is
measured frame to frame
© ABB Group
December 15, 2022 | Slide 140
2. Installation of the panels
h) Busbar bridge installation
© ABB Group
December 15, 2022 | Slide 142
2. Installation of the panels
i) Panel flaps and Ith limitors setup
A B C
Flaps purpose:
Limit the duration of arcing
to a maximum of 100 ms,
minimizing damages
reduced downtime.
Fault area selective control
A – cable compartment
B – busbar compartment
C – CB compartment
Internal arc duration has
influence on the level of
damage, generally:
>500ms – severe damage
<100ms – small damage
<35ms – subtle damage
© ABB Group
December 15, 2022 | Slide 143
2. Installation of the panels
i) Panel flaps and Ith limitors setup
© ABB Group
December 15, 2022 | Slide 144
2. Installation of the panels
i) Panel flaps and Ith limitors setup
Detection pin
matching the hole in
the pressure relief
© ABB Group
December 15, 2022 | Slide 145
flap
2. Installation of the panels
j) Gas duct installation
Gas duct purpose:
Creates an enclosed
compartment above the
switchgear flaps and leads
the gases from internal arc
out of the building or
spread the gas energy to
wide area by top chimneys
Assembly:
Gas dusts are delivered as
loose items (separate for
each panel), start
assembly from one side of
the switchgear and finish
on the other side
© ABB Group
December 15, 2022 | Slide 146
2. Installation of the panels
j) Gas duct installation
Top chimneys
© ABB Group
December 15, 2022 | Slide 147
2. Installation of the panels
j) Gas duct installation
Standard gas duct 12kV / 17,5kV for 40kA with top chimneys
© ABB Group
December 15, 2022 | Slide 148
2. Installation of the panels
j) Gas duct installation
Standard gas duct 12kV / 17,5kV for 40kA without top chimneys
© ABB Group
December 15, 2022 | Slide 149
2. Installation of the panels
j) Gas duct installation
Standard gas duct 12kV / 17,5kV for 50kA with and without top chimneys
© ABB Group
December 15, 2022 | Slide 150
2. Installation of the panels
k) Fixing the panels to the floor frame
C-profile foundation
frame installation
material
Fixing from the top is
possible with set of fixing
material, that can be
delivered on request
In non seismic zone it‘s
enough to fix leftmost
and rightmost panel and
every 5th panel in the
row in between
In seismic zones it‘s
mandatory to fix all and
every panel
© ABB Group
December 15, 2022 | Slide 151
2. Installation of the panels
k) Fixing the panels to the floor frame
© ABB Group
December 15, 2022 | Slide 152
3. Power and control cables
installation
© ABB Group
December 15, 2022 | Slide 153
3. Power and control cables installation
a) Control cables installation
© ABB Group
December 15, 2022 | Slide 154
3. Power and control cables installation
a) Control cables installation
© ABB Group
December 15, 2022 | Slide 155
3. Power and control cables installation
b) Preparation for power cable pulling in
Loosen the four bolts holding the partition from inside and
pull the partition out of the panel
© ABB Group
December 15, 2022 | Slide 156
3. Power and control cables installation
b) Preparation for power cable pulling in
Bolts on the right hand side hold part of the earth switch interlock,
be careful when removing and replacing the partition
© ABB Group
December 15, 2022 | Slide 157
3. Power and control cables installation
b) Preparation for power cable pulling in
© ABB Group
December 15, 2022 | Slide 158
3. Power and control cables installation
c) Power cable entry
© ABB Group
December 15, 2022 | Slide 159
3. Power and control cables installation
c) Power cable entry
Alternatively, the system of
non drilled stainless steel
plates can be delivered and
it‘s up to installation
company to properly drill
and gland the cable entry
point
© ABB Group
December 15, 2022 | Slide 160
3. Power and control cables installation
c) Power cable entry
© ABB Group
December 15, 2022 | Slide 161
3. Power and control cables installation
c) Power cable entry
Do not cut the botom
plates, the sharp edges
may damage your cable,
always use at least
grommets to seal the cable
entry
© ABB Group
December 15, 2022 | Slide 162
4. Maintenance of UniGear ZS1
switchgear
© ABB Group
December 15, 2022 | Slide 163
4. Maintenance of UniGear ZS1 switchgear
a) Maintenance recommendations
Read and follow the UniGear
type ZS1 – Installation, service
and maintenance manual (UG
ZS1 IOM Man_Rev.H_2013),
chapter 8
Maintenance comprises
following closely related
activities:
Inspection: Determination
of the actual condition
Servicing: Measures to
preserve the specified
condition
Repair: Measures to
restore the specified
condition
© ABB Group
December 15, 2022 | Slide 164
4. Maintenance of UniGear ZS1 switchgear
b) Maintenance tasks and intervals
© ABB Group
December 15, 2022 | Slide 165
4. Maintenance of UniGear ZS1 switchgear
c) Inspection
Inspection means
primarily a visual check
for grime, corrosion and
moisture:
Corrosion on the
primary circuits
© ABB Group
December 15, 2022 | Slide 166
4. Maintenance of UniGear ZS1 switchgear
c) Inspection
Inspection means
primarily a visual check
for grime, corrosion and
moisture:
Effects of high
temperature on the
main circuits
Traces of partial
discharge on the
insulating material parts
© ABB Group
December 15, 2022 | Slide 167
4. Maintenance of UniGear ZS1 switchgear
c) Inspection
Inspection means
primarily a visual check
for grime, corrosion and
moisture:
Traces of leakage
current on the insulating
material parts
© ABB Group
December 15, 2022 | Slide 168
4. Maintenance of UniGear ZS1 switchgear
c) Inspection
Inspection must contain functional tests for correct
mechanical and electrical operation of main functional
goups:
Switching devices (circuit breakers, contactors and
earthing switches) including actuating and auxiliary
devices
Instrument transformers including their secondary circuits
up to the measuring and protection devices – by primary
injection
Primary circuit joints conductivity – especialy busbar joints
conductivity test
Interlocks between CB, truck and ES, door interlocks
Functionality of control and protection circuits – by
secondary injection and function testing
Switchgear insulation – by insulation resistance
measurement
© ABB Group
December 15, 2022 | Slide 169
4. Maintenance of UniGear ZS1 switchgear
d) Servicing
Servicing covers following tasks
(scope is based on the input gathered
during inspection):
Cleaning of the surfaces, insulators,
contact system
Greasing of joints and contact
systems, operating mechanisms of
switching devices
Reassembly and retightening of
primary circuit joints (busbars, cable
connections)
Mechanical troubleshooting of
switching devices and their
operating and auxiliary mechanisms,
interlocks, shutter mechanism
Troubleshooting of the
measurement and protection system
including instrument transformers
Functional troubleshooting of control
and protection circuits
© ABB Group
December 15, 2022 | Slide 170
4. Maintenance of UniGear ZS1 switchgear
d) Servicing
Access to busbar compartment for maintenance:
Access is best from the back side after removing the back
cover and the rear separation plate
Access is possible from the top after removing the busbar
compartmenr pressure flap, if no gas duct is installed
Access is possible from the front side after removing cable
and CB compartment partitioning plate and front separation
plate of the busbar compartment
Cable and CB
Separation compartment
plate for partitioning
rear and
access separation
plate for front
access
© ABB Group
December 15, 2022 | Slide 171
4. Maintenance of UniGear ZS1 switchgear
e) Repair
Repair is action to restore specified (usually normal
functionality, operation) condition
Depending on the type and extent of the failure, the
basic repairs with in-catalogue spare parts for
switchgears outside of warranty period can be done by
third party, the rest of repair should be done by
certified ABB personnel
© ABB Group
December 15, 2022 | Slide 172
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Releasing the locking magnet RL2 on breaker truck
Remove front plate of circuit breaker, check for access
through a slot to the locking magnet in the truck
Disengage locking magnet RL2 by pulling the magnet
armature
While doing so, turn crank about one half turn (either
direction of rotation is permissible
© ABB Group
December 15, 2022 | Slide 173
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of circuit breaker trolleys auxiliary switches
BT2
BT1
© ABB Group
December 15, 2022 | Slide 174
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of circuit breaker truck auxiliary switches
Rack the CB out to test position
For adjustment of the auxiliary switches you need to access
the CB truck from bottom side:
On a de-energized panel, remove the separation plate
between CB and cable compartment and get access to CB
truck from the bottom
© ABB Group
December 15, 2022 | Slide 175
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of circuit breaker truck auxiliary switches
If you the panel is energized, you can withdraw the breaker
and tilt it to one side on a firm horizontal surface in the same
height with service trolley platform
Remove plastic sheet covering both swithes BT1 and BT2 (1
screw off)
© ABB Group
December 15, 2022 | Slide 176
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of circuit breaker truck auxiliary switches
Unscrew two allen-key screws. Push the aux group BT2
according to the arrow indication and lock the screws.
Be careful that there is 0,5 mm of gap between the shaft and
the aux frame.
0,5mm
© ABB Group
December 15, 2022 | Slide 177
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of circuit breaker truck auxiliary switches
To adjust the aux. group BT1 (service position) is necessary
simulate the CB in service position
Push the service position forcing slider with a screwdriver and
unscrew the allen-key screws for BT1, push the aux group
BT1 according to the arrow indication and lock the screws.
Again maintain 0,5mm safety distance between the fixed and
moving part.
© ABB Group
December 15, 2022 | Slide 178
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of circuit breaker truck auxiliary switches
After adjusting BT1 group, don‘t forget to put the slider into
original position and apply the plastic cover
© ABB Group
December 15, 2022 | Slide 179
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of earthing switch auxiliary switches
Slider
© ABB Group
December 15, 2022 | Slide 180
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of earthing switch auxiliary switches
Auxiliary limit switch (BE2) for earthing switch ON must
be operated immediately after the dead centre position of
the toggle spring mechanism is reached in the closing
process and the automatic rapid closing process has
started
If adjustment of BE2 is required
Loosen the cam plate
Set the cam plate into correct position
© ABB Group
December 15, 2022 | Slide 181
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Adjusting of earthing switch auxiliary switches
Auxiliary limit switch BE3 for earthing switch OFF must
a) be operated on earthing switches with manual
mechanisms during the opening movement of the
slide before half of the hexagonal shaft has become
visible, or 1 mm before the tab of the slide makes
contact with the armature of the de-energised locking
magnet
b) be operated on earthing switches with motor
operators immediately after the toggle spring
mechanism has passed the dead centre position
during rotation to the OFF position
If adjustment of BE3 is required
Loosen 2 screws fastening switch BE3 to cubicle
Set the BE3 to requested position
© ABB Group
December 15, 2022 | Slide 182
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
© ABB Group
December 15, 2022 | Slide 183
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Safety notes for VD4 circuit breaker repair
Before you start any work on CB auxiliaries, make sure
the CB auxiliary wiring is disconnected from the power
source and the mechanical energy stored in the CB
main and auxiliary springs is discharged – i.e. CB is
opened and main spring is discharged.
© ABB Group
December 15, 2022 | Slide 184
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Replacement of closing (MC), opening (MO) and
undervoltage (MU) coil
The coil baseplate on right hand side is locked in place
by one bolt only. Remove the bolt and take out the
baseplate with coils by releasing handle.
© ABB Group
December 15, 2022 | Slide 185
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Replacement of closing (MC), opening (MO) and
undervoltage (MU) coil
Each coil is holding on two bolts and has one electrical
connection with the baseplate itself.
When returning the baseplate in it‘s position, match the
two holes on the baseplate with the guiding pins in
breaker, which allows proper alignment
© ABB Group
December 15, 2022 | Slide 186
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Replacement of blocking coil (RL1)
The coil baseplate on right upper side above the
closing pushbutton is mounted in place by two bolts.
Disconnect the control wiring plug, remove the bolts,
and take out the baseplate with coil. Replace the coil
and mount the holder back in place.
© ABB Group
December 15, 2022 | Slide 187
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Replacement of spring charged signalling contact
(BS2)
The contact is located on right bottom side below the
coils. The baseplate with coils must be removed to
access the contact. Disconnect the contact electrical
connections, two bolts are holding the contact in
position.
© ABB Group
December 15, 2022 | Slide 188
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Replacement of charging motor
The motor is located left to the operating mechanism.
After disconnecint the electrical connections and
removing one locking screw, the motor can be sliped
from the shaft sideways and replaced.
© ABB Group
December 15, 2022 | Slide 189
4. Maintenance of UniGear ZS1 switchgear
e) Practical repairs and troubleshooting
Replacement of charging motor
To align the motor with the shaft, first set the motor
socket to match the position as shown on the picture
and then slip the motor on the shaft. Holding the
charging lever can help you to get more space for the
alignment.
© ABB Group
December 15, 2022 | Slide 190
© ABB Group
December 15, 2022 | Slide 191