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Technical catalogue TK 503/01 E

ZX0.2
Gas-insulated
medium voltage switchgear

Contents
Page

1 Applications

2 Characteristics

3 Your benefit

4 Technical data

4.1

Technical data of the panel

4.2

Technical data of the circuit-breaker

10

4.3

Technical data of the three position disconnector

11

4.4

Technical data of the three position switch disconnector with HV HRC fuses

11

4.5

HV HRC fuses

12

5 Alternative protection and control concepts of panels with circuit-breakers

14

6 Fundamental structure of the panels

15

7 Components

21

7.1

Vacuum circuit-breaker

23

7.2

Three position disconnector

27

7.3

Three position switch disconnector with fuses

28

7.4

Busbar

30

7.5

Outer cone termination system

31

7.5.1 Outer cone connectors type Kabeldon SOC from ABB

32

7.5.2 Further outer cone connector systems

33

7.6

Surge arresters

39

7.7

Main earthing bar

39

78

Capacitive voltage indicator systems

39

7.9

Current and voltage detection devices

41

7.91 Ring core current transformers

41

7.9.2 Dimensioning of current transformers

42

7.9.3 Voltage transformers

43

7.10

Protection and control units

44

7.11

Sulphur hexafluoride

45

7.12

Gas system in the panels

45

7.13

SF6 density sensors

46

7.14

Pressure relief systems

47

7.15

Surfaces

47

2 | Technical catalogue ZX0.2 TK 503 - Revision 01

Page

8 Range of panels

47

Feeder panels

48

8.1

8.1.1 Incoming and outgoing feeder panels with circuit-breaker

48

8.1.2 Feeder panels with three position switch disconnector and fuses

49

8.1.3 Cable termination panels

52

8.2

Busbar sectionaliser and riser panels

54

8.2.1 Couplings within a switchgear block

54

8.2.2 Transfer panel

57

8.2.3 Coupling (connection of two system blocks via cable)

57

9 Busbar earthing

58

9.1

Earthing the busbar by means of an earthing set

58

9.2

Earthing the busbar by means of a sectionaliser and riser or bus coupler

58

10 Building planning

59

10.1

Site requirements

59

10.2 Space required

60

10.3 Minimum aisle widths and emergency exits

62

10.4

Minimum room heights

62

10.5 Concrete floor

63

10.5.1 Floor openings

63

10.5.2 Foundation frames

64

10.6

False floor

65

10.7

Earthing of the switchgear

66

10.7.1 Design of earthing systems with regard to touch voltage and thermal stress

66

10.7.2 EMC-compliant earthing of the switchgear

66

10.7.3 Recommendations on configuration of the switchgear earthing

67

10.8 Panel weights

68

11

Non-standard operating conditions

69

Technical catalogue ZX0.2 TK 503 - Revision 01 | 3

1 Applications
Power supply companies

Marine

Power stations
Transformer substations
Switching substations

Industry

Steel works
Paper manufacture
Cement industry
Textiles industry
Chemicals industry
Foodstuffs industry
Automobile industry
Petrochemicals
Raw materials industry
Pipeline systems
Foundries
Rolling mills
Mining

Platforms
Drilling rigs
Offshore facilities
Supply vessels
Ocean liners
Container vessels
Tankers
Cable laying ships
Ferries

Transport

Airports
Harbours
Railways
Underground railways

Services
Supermarkets
Shopping centres
Hospitals

4 | Technical catalogue ZX0.2 TK 503 - Revision 01

2 Characteristics
Basic characteristics

Terminals

SF6 gas-insulated with hermetically


sealed pressure system
Solid insulated busbar
Rated voltages up to 24 kV
Up to 2500 A and 31.5 kA
Single busbar design
Stainless steel encapsulation, manufactured
from laser cut sheet material
Modular structure
Switchgear with a leakage rate of less
than 0.1 % per annum
Integrated leakage testing of the panels
Indoor installation
Wall mounting installation and free-standing installation
Operator controls separate from low voltage compartment
Operator controls on the panel accessible from the outside
6 00 mm grid dimension of panelswidth

Outer cone terminal system to EN 50180 and EN 50181


Connection facility for surge arresters on the cable
connector and on the busbar

Panel variants
Incoming and outgoing feeder panels as panels with circuit
breaker and three position disconnector
Outgoing feeder panels with three position switch disconnector and fuses
Bussectionaliser panels
Busriser panels
Transfer panels
Switching devices
Vacuum circuit-breakers with series
three position disconnectors
Three position switch disconnectors
with fuses

Current and voltage metering


Current and voltage transformers outside the gas
compartments
Protection and control
Mechanical operation on site
Combined protection and control devices
Discrete protection devices with conventional control
Protection against maloperation
Mechanical switch interlocking with manual mechanisms
between the circuit-breaker and the three position
disconnector
Additional electrical switch interlocks for motor-operated
mechanisms
Various interlocks for manual circuit-breaker operation
Pressure relief
Pressure relief into the switchroom
Installation
No gas work at site

Technical catalogue ZX0.2 TK 503 - Revision 01 | 5

3 Your benefit
Maximum operator safety
All live components are enclosed to prevent accidental
contact.
As the high voltage compartments are independent of
external influences (degree of protection IP65), the probability of a fault during operation is extremely low.
As evidenced by arc fault testing, our switchgear systems
are notable for maximum operator safety.
Minimum overall costs
The compact design of the panels reduces the space
required and therefore the size of the station. The result is
a lower investment requirement.
Freedom from maintenance is achieved by constant conditions in the high voltage compartments in conjunction
with the selection of suitable materials. The injurious influences of dust, vermin, moisture, oxidation and contaminated air in the high voltage compartments are precluded,
as the gas-tight compartments are filled with inert gas.
As a rule, therefore, isolation of the switchgear to perform
maintenance work is not required.
The panels are designed for an expected service life of
over 40 years.
The systematic selection during the development process
of the materials used provides for complete recycling or
reuse of those materials at the end of the service life.

6 | Technical catalogue ZX0.2 TK 503 - Revision 01

The panels only leave our production facilities after documented routine testing. Thanks to the plug-in technology
applied in the areas of the busbars, cables and secondary
systems, extremely short installation times are possible.
No gas work is required as a rule at site. There is thus no
need to evacuate and fill the high voltage compartments,
test them for leakage and measure the dewpoint of the
insulating gas at site.
Maximum availability
The busbar technology permits simple and therefore safe
assembly.
In spite of the extremely low failure probability of the ZX
switchgear systems, replacement of components in the
gas compartments and therefore a rapid return to service
after repairs is possible.
In gas-insulated switchgear, earthing of switchgear sections is performed by a high quality vacuum circuit-breaker.
The circuit-breaker can close onto a short-circuit significantly more frequently and reliably than a positively making
earthing switch.

4 Technical data
4.1 Technical data of the panel
Table 4.1.1: Technical data of the panel
Rated voltage / maximum operating voltage

Ur

kV

12

24

Rated power frequency withstand voltage

1)

Ud

kV

28

50

Rated lightning impulse withstand voltage

1)

Up

kV

75

fr

Hz

Ir

Rated frequency

2)

Rated normal current of busbars

125
50
...1250, ... 2500

... 630, ...1250 (panel width 600 mm)


Ir

Rated peak withstand current

Ik

kA

...31.5

Rated peak withstand current

Ip

kA

...80

Rated duration of short-circuit

tk

...3

Rated normal current

3)

... 1600, ... 2000, ...2500 (panel width


900 mm and 1200 mm)

Insulating gas system,

4) 5)

Alarm level for insulation

pae

Rated filling level for insulation


Minimum functional level for operation
Rated filling level for switch

9)

9)

kPa

7)

130

8)

kPa

pmm

kPa

140

psw

kPa

150
IP65

Degree of protection of the low voltage compartment and the mechanism bay
Ambient air temperature, maximum
11)

Ambient air temperature, minimum


Site altitude

120

pre

Degree of protection for parts under high voltage

Ambient air temperature, maximum 24 hour averages

6)

12)

IP3X

10)

+40

+35

-5

...1000



3)

4)

5)

6)

Higher levels to international standards on request


Rated current for 60 Hz on request
Panels with switch disconnector and fuses: Dependend on fuses
Insulating gas: SF6 (sulphur hexafluoride)
All pressures stated are absolute pressures at 20 C
100 kPa = 1 bar
7)
Switch disconnector panels: 140 kPa
8)
Switch disconnector panels: 150 kPa
9)
Only relevant for three position switch disconnector panels
10)
Higher degrees of protection on request
11)
Higher ambient air temperature on request
11)
Higher site altitude on request
1)

2)

Technical catalogue ZX0.2 TK 503 - Revision 01 | 7

Internal arc classification


The panels are arc fault tested in accordance with IEC 62271-200.

Table 4.1.2: Internal arc classification of the switchgear in accordance with IEC 62271-200

1)

Classification IAC

Wall mounting installation

I nternal arc

AFL
3 1.5 kA 1 s

Internal arc classification


Free-standing installation

Classification IAC

AFLR

Internal arc

31.5 kA 1 s

Rated short-time current and duration of an arc fault in


the cable termination compartment and in the busbar

0.87 x 31.5 kA

1s

2)

compartment

Key to table 4.1.2:


IAC
AFLR



Internal arc classification


Accessibility from the rear (R - rear)
Accessibility from the sides (L - lateral)
Accessibility from the front (F - front)
Switchgear installed in closed rooms with access
restricted to authorised personnel only

The IAC qualification relies on a system consisting of at least three


panels.
Loss of Service Continuity to IEC 62271-200
The various LSC categories of the standard define the possibility
to keep other compartments and/or panels energised when opening a main circuit compartment.
Gas-filled compartments cannot be opened, as they would then
lose their functionality. This means that there is no criterion for loss
of service continuity of inaccessible compartments.

Table 4.1.3: Loss of Service Continuity of the switchgear in accordance with IEC 62271-200
Cable compartments and surrounding areas of the fuse boxes

LSC2B
Gas compartments are not to be opened under service conditions, and

Gas compartments:

therefore an LSC qualification is not applicable.

Key to table 4.1.3:


LSC2B


1)

2)

Loss of Service Continuity


Other panels and all cable compartments may
remain energised.

IEC 62271-200 corresponds to DIN EN 62271-200 and VDE 0671 Part 200
According to IEC 62271-200, section A.5.2.1 three-phase faults do not generally develop in cable compartments
with plug-in connectors. That means the actual current value is reduced to approximately 0.87 times the specified internal arc
withstand current.

8 | Technical catalogue ZX0.2 TK 503 - Revision 01

Partition class to IEC 62271-200


The partition class to IEC 62271-200 defines the nature of the partition between live parts and an opened, accessible compartment.

Table 4.1.4: Partition class in accordance with IEC 62271-200


Partition class

PM

Key to table 4.1.4:


PM:

partition of metal

Panels of partition class PM provide continuous metallic and


earthed partitions between opened accessible compartments and
live parts of the main circuit.

Technical catalogue ZX0.2 TK 503 - Revision 01 | 9

4.2 Technical data of the circuit-breaker


Table 4.2.1: Technical Data of the circuit-breaker
Ur

kV

Rated power frequency withstand voltage

1)

Ud

kV

28

50

Rated lightning impulse withstand voltage

1)

Up

kV

75

125

fr

Hz

50

Ir

...1250, ...2500

Rated short-circuit breaking current

Isc

kA

...25, ...31.5

Rated short-circuit making current

Ima

kA

...63, ...80

Rated short-time withstand current

Ik

kA

...25, ...31.5

Rated duration of short-circuit

tk

...3

Rated voltage / maximum operating voltage

Rated frequency

2)

Rated normal current

3)

Operating sequence

12

24

O - 0,3 s - CO - 3 min - CO

Closing time

t cl

ms

ca. 60

Rated opening time

t3

ms

60

Rated break time

tb

ms

75

Rated auxiliary voltage

V DC

48, 60, 110, 220

5)

Power consumption of charging motor

200 (500 at start-up)

Power consumption of opening coil

max. 250

Power consumption of closing coil

max. 250

Power consumption of blocking magnet

10

Power consumption of undervoltage release

Permissible numbers of operating cycles of the vacuum interrupters


30000 x Ir
50 x ISC

(Ir = Rated normal current)


(ISC = Rated short-circuit breaking current)

Classes according to IEC 62271-100


Ik 25 kA
Ik > 25 kA
All circuit-breakers
Application: Switching of back-to-back capacitor banks,
Special circuit-breaker




4)

5)

1)

2)

3)

Higher levels to international standards on request


Rated current for 60 Hz on request
Higher operating currents on request
Different operating sequences on request
Different auxiliary voltages on request

10 | Technical catalogue ZX0.2 TK 503 - Revision 01

M2
M1
E2, C2
C2

4)

4.3 Technical data of the three position disconnector


Table 4.3.1: Technical data of the three position disconnector
Rated voltage / maximum rated voltage

Ur

kV

12

24

Rated power frequency withstand voltage across the isolating distance

kV

32

60

Rated lightning impulse withstand voltage across the isolating distance

kV

85

145

Rated normal current

Ik

Rated short-time withstand current

Ik

kA

...31.5

Rated peak withstand current

Ip

kA

...80

Rated duration of short-circuit

tk

Rated auxiliary voltage

Ua

V DC

1)

Power consumption of mechanism motor


Motor running time on opening or closing the disconnector

3)

Motor running time on opening or closing the earthing switch

3)

... 1250, ... 2500

...3
48, 60, 110, 220

2)

210 (maximum), 35 (average)

6-8

6-8

4.4 Technical data of the three position switch disconnector


with HV HRC fuses
Table 4.4.1: Technical data of the three position switch disconnector with HV HRC fuses
Rated voltage

Ur

Rated power frequency withstand voltage across the isolating distance


Rated lightning impulse withstand voltage across the isolating distance
Rated normal current
Rated auxiliary voltage
Motor running time on opening or closing the disconnector

1)

2)

3)

3)

kV

12

24

kV

32

60

kV

85

145

Ir

... 80

...63

Ua

V DC
s

48, 60, 110, 220

2)

When a motor-operated mechanism is used


Different auxiliary voltages on request
At rated auxiliary voltage

Technical catalogue ZX0.2 TK 503 - Revision 01 | 11

4.5 HV HRC fuses


Fuses from Siba (44534 Lnen. Germany) of 442 mm in length
and a maximum diameter of 67 mm are used. Shorter fuses have
to be fitted with a length adapter. The fuses have thermal protection. Tables 4.5.1 and 4.5.2 below show the assignment of transformer ratings to possible HV HRC fuse links. As the fuses are
installed in a fuse box inside the panel, the operating current is
limited to 60 % of the rated current of the fuse.

Table 4.5.1: Selection table for HV HRC fuses, (U r up to 12kV)


Relative impedance

Rated transformer

voltage u K

current

min.

max.

[kVA]

[%]

[A]

[A]

[A]

Operating Voltage

Transformer Rating

[kV]

6 ... 7.2

10 ... 12

Rated current of the HV-fuse

50

4.8

16

16

75

7.2

16

20

100

9.6

20

25

125

12

20

31.5

160

15.4

31.5

40

200

19.2

40

50

250

24.1

40

63

315

30.3

50

63

400

38.5

63

63

400

38.5

63

80 SSK

50

2.9

10

10

75

4.3

10

10

100

5.8

16

16

125

7.2

16

20

160

9.2

20

25

200

11.5

20

31.5

250

14.4

25

40

315

18.2

31.5

50

400

23.1

40

50

400

23.1

40

40

500

28.9

50

63

500

28.9

50

63 SSK

630

36.4

63

80 SSK

630

36.4

63

80 SSK

800

46.2

80 SSK

80 SSK

12 | Technical catalogue ZX0.2 TK 503 - Revision 01

Table 4.5.2: Selection table for HV HRC fuses, (U r up to 24kV)


Relative impedance

Rated transformer

voltage u K

current

[kVA]

[%]

[A]

[A]

[A]

75

3.1

10

10

100

4.2

10

10

Operating Voltage

Transformer Rating

[kV]

13.8

15 ... 17.5

24

Rated current of the HV-fuse


min.

max.

125

5.2

16

16

160

6.7

16

20

200

8.4

20

20

250

10.5

20

25

315

13.2

25

31.5

400

16.7

31.5

40

400

16.7

31.5

31.5

500

20.9

40

50

500

20.9

40

40

630

26.4

50

63

630

26.4

50

50

800

33.5

63 SSK

63 SSK

1000

41.8

80 SSK

80 SSK

75

2.9

10

10

100

3.8

10

10

125

4.8

16

16

160

6.2

16

16

200

7.7

20

20

250

9.6

20

25
31.5

315

12.1

20

400

15.4

31.5

40

400

15.4

31.5

31.5

500

19.2

40

50

500

19.2

40

40

630

24.2

40

63

630

24.2

40

40

800

30.8

50

63 SSK

100

2.9

10

10

125

3.6

10

10

160

4.6

10

16

200

5.8

16

16

250

7.2

16

20

315

9.1

20

25

400

11.5

20

31.5

400

11.5

20

20

500

14.4

25

40

500

14.4

25

25

630

18.2

31.5

50

630

18.2

31.5

31.5

800

23.1

40

40

1000

28.9

50

63 SSK

Technical catalogue ZX0.2 TK 503 - Revision 01 | 13

5 Alternative protection and control concepts of panels


with circuit-breakers

ZX0.2

Protection and control unit


e.g. 615 series
Protection unit
e.g. 610 series

Protection and control unit


e.g. 630 series

Protection and control unit


e.g. 630 series

Three position disconnector manual mechanism

Three position disconnector manual mechanism

Three position disconnector motorised mechanism,


remote control possible

Mechanical interlocks
Three position disconnector,
circuit-breaker

Mechanical interlocks
Three position disconnector,
circuit-breaker

Mechanical and electrical


interlocks
Three position disconnector,
circuit-breaker

14 | Technical catalogue ZX0.2 TK 503 - Revision 01

6 Fundamental structure of the panels


The switchgear system is suitable for both free-standing installation (fig. 6.1) and wall mounting installation (fig. 6.2).

Modular structure
Each cable feeder panel consists of the gas-filled panel module
(A), the solid insulated busbars (B), the cable termination compartment(C), the low voltage compartment(D) and the mechanism
bay (E). There are no gas connections between the two compartments in adjacent panels.

Fig.6.1: Outgoing cable panel 1250A (free-standing installation)

Fig.6.2: Incoming cable panel 1600A with voltage transformers on the


busbar and on the outgoing feeder (wall mounting installation)

2400

2400

1330

1310

Technical catalogue ZX0.2 TK 503 - Revision 01 | 15

Panel module (A)

Panel module with circuit-breaker and three position disconnector (figs. 6.3 and 6.4)

The panel module essentially contains all the live high voltage
parts, i.e. the switching devices, bushings for connection of the
busbar and outer cones for connection of the high voltage cables.
Current and voltage transformers are located outside the panel
modules.
The pressure relief disk for the panel module is located in the rear
wall of the enclosure.

The circuit-breaker operating mechanism, the gas density sensor and the filler valve are located on the circuit-breaker mounting
plate, which is bolted to the front wall of the panel module. The
operating mechanism of the three position disconnector is positioned above the circuit-breaker operating mechanism on the front
wall of the panel module. The live high voltage parts of the switches are located inside the panel module, and the operating mechanisms are easily accessible outside the gas compartment.

The seals of the components are o-ring seals which are not exposed to any UV radiation.
The gas systems of panel modules in a switchgear system consisting of several panels are not connected together.
Three position disconnectors, circuit-breakers with three position
disconnectors and switch disconnectors with HV HRC fuses can
be used.

Fig. 6.3: Panel module with circuit-breaker, 1250 A, panel width 600mm

Fig. 6.4: Panel module with circuit-breaker, 2000 A, panel width 1200mm

1.12

1.12

1.0

1.0

2.3
2.4
1.10
1.11
1.1

2.3

2.4
1.10
1.11
1.1

1.2

1.13

1.2

1.3

1.7

1.3

1.9

1.13

1.9

3.5

3.5
1.8

1.0
1.1
1.2
1.3
1.7

1.8
1.9
1.10
1.11

Panel module (enclosure)


Circuit-breaker pole
Circuit-breaker mechanism
Outer cone
Isolating system for voltage
transformer
Voltage transformer
Current transformer
Gas density sensor
Gas filling valve

16 | Technical catalogue ZX0.2 TK 503 - Revision 01

1.12
1.13
2.3
2.4

3.5

Cast resin bushing to busbar


Pressure relief disk
Three position disconnector
Three position disconnector
operating mechanism
Main earthing bar
Insulating gas SF6

Panel module with three position switch disconnector and


fuses (fig. 6.5)
The live parts of the switch are inside the panel module and the
operating mechanism is located in an easily accessible position
outside the gas compartment. The optional fuses can be replaced
without any gas work

Fig. 6.5: Panel module with switch disconnector and fuses

1.0
1.10
1.11

1.15

1.16

1.17
1.3
1.18
1.13

1.0
1.3
1.10
1.11
1.13
1.15

Panel module (enclosure)


Outer cone
Gas density sensor
Gas filling valve
Pressure relief disk
Three position switch disconnector

1.16

1.17
1.18

Three position switch disconnector


operating mechanism
Fuse box
Earthing switch
Insulating gas SF6

Technical catalogue ZX0.2 TK 503 - Revision 01 | 17

The busbar (B)


The solid insulated busbar is located on the roof plates of the panel modules. The insulating silicone parts of the busbar (end adapters, cross adapters and conductor insulation) have a metallised,
earthed coating on the outside. The busbar is thus shockproof in
normal operation. The busbar can be fitted with voltage and current transformers.

Fig. 6.6: Busbar with optional current and voltage transformers on a four-panel ZX0.2 switchgear system (viewed from the rear), shown without cover
plates on the busbar.

1.8

1.12
2.1
1.0
1.9

1.0
1.8
1.9
1.12
2.1

Panel module (enclosure)


Voltage transformer
Current transformer
Cast resin bushing to busbar
Busbar

18 | Technical catalogue ZX0.2 TK 503 - Revision 01

The cable termination compartment (C)


The cable termination compartment (figs. 6.7 and 6.8) represents
a supporting frame for the panel, manufactured from aluminium
sections and galvanised steel sheets. The cable termination compartments of adjacent panels are segregated from each other by
sheet steel walls.

The cover of the cable termination compartment may optionally be


interlocked so that the cable termination compartment is only accessible when the cables are earthed.
In the unlikely event of an internal arc fault in the cable termination
compartment, the pressure is discharged to the rear.

The cable termination compartment contains the main earthing bar


(3.5), the high voltage cables (3.2) with cable connectors (3.1) and
cable fasteners (3.3), optional surge arresters, current transformers and optional voltage transformers (1.8) and the mechanism for
the isolating device for voltage transformers (3.8).

Partitioning of the cable termination compartment from the cable


basement is effected by split floor plates in the area of the cables.
The cable termination compartment is safe to touch when appropriate cable connectors are used.

Fig. 6.7: Cable termination compartment (C) , example configuration with


one cable per phase

Fig. 6.8: Cable termination compartment (C) , example configuration with


fixed mounted voltage transformers and two cables per phase

3.0

1.9

3.1

3.5

1.9

3.0

3.5

3.8
3.1

1.8

3.3
3.7

3.2
3.7

3.2

3.3
3.6

1.8
1.9
3.0
3.1
3.2
3.3
3.5
3.6
3.7
3.8

3.6

Voltage transformers, in this case fixed mounted


Current transformers
Cable termination compartment (C)
Cable connector
High voltage cable
Cable fastener
Main earthing bar
Floor plate
Cover
Mechanism for the voltage transformer
isolating device (optional)

Technical catalogue ZX0.2 TK 503 - Revision 01 | 19

The low voltage compartment (D) and the mechanism bay


(E)
the cover of the mechanism bay.
The low voltage compartment and the mechanism bay are two
independent metal enclosures. The low voltage compartment has
a door (door stop alternatively right- or left-hand side), and the
mechanism bay a screw-fastened cover.
The low voltage compartment accommodates the protection devices and further secondary equipment with wiring. The mechanism bay houses the operating mechanism for the circuit-breaker
(1.2), the operating mechanism for the three position disconnector
(2.5) or operating mechanism for the three position switch disconnector, and the sensors for gas density monitoring (1.10) and the
filler valve (1.11) of the gas compartment.

The controls and indicators of the operating mechanisms are accessible from the outside.
The entry for external secondary cables (6.5) is located in the roof
plate of the low voltage compartment. Optionally, the entries for
secondary cables can be provided in the floor plate of the cable
termination compartment. In that case, the secondary cables are
led in through the floor plate of the cable termination compartment
at the left and laid through the cable termination compartment
and through the mechanism bay towards the low voltage compartment in a cable duct at the side.

The sockets for the capacitive indicator system (1.5) are located in

Fig. 6.9: Low voltage compartment and mechanism bay

6.5
6.0
6.6

2.5
1.10
1.11
6.10
1.2
1.5

20 | Technical catalogue ZX0.2 TK 503 - Revision 01

1.2
1.5

1.10
1.11
2.5

6.0
6.6
6.5
6.10

Circuit-breaker operating mechanism


Measuring sockets for capacitive voltage
indicator system
Gas density sensor
Gas filling valve
Three position disconnector operating
mechanism
Low voltage compartment
Low voltage compartment door
Secondary cable entry
Mechanism bay

7 Components
Fig. 7.1: Circuit-breaker panel, 1250 A, example configuration

6.5
6.0
6.6
2.1
1.12
2.3

1.3
1.13

1.0
2.4
6.10
1.10, 1.11
1.1
1.2
1.5
1.9
3.1
3.5

3.2
3.0

3.3
3.6

Fig. 7.2: Circuit-breaker panel, 1600 A, example configuration

1.8a

1.12
2.3
1.18

1.7
1.3
1.13

6.5
6.0
6.6
2.1
1.0
2.4
6.10
1.10, 1.11
1.1
1.2
1.5
1.9
3.1
3.8
3.5

1.8b
3.0

3.2
3.3
3.6

Technical catalogue ZX0.2 TK 503 - Revision 01 | 21

Fig. 7.3: Panel with switch disconnector and fuses, example configuration

6.5
6.0
6.6
2.1
1.0

1.12
2.3

6.10
1.10, 1.11
1.16

1.15

1.17
1.5
1.3

3.1
3.5

1.13

3.2
3.0

1.0
1.1
1.2
1.3
1.5

1.7
1.8a

1.8b
1.9
1.10
1.11
1.12
1.13
1.15
1.16
1.17
1.18

Panel module
Circuit-breaker pole
Circuit-breaker operating mechanism
Outer cone
Measuring sockets for capacitive voltage indicator
system
Isolating system for voltage transformer
Voltage transformer for busbar measurement
(optional)
Voltage transformer for feeder measurement (optional)
Current transformer
Gas density sensor
Filling valve
Cast resin bushing to busbar
Pressure relief disk
Three position switch disconnector
Three position switch disconnector mechanism
Fuse box
Heat sink

22 | Technical catalogue ZX0.2 TK 503 - Revision 01

3.3
3.6

2.1
2.3
2.4
3.0
3.1
3.2
3.3
3.5
3.6
3.8

6.0
6.5
6.6
6.10

Busbar
Three position disconnector
Three position disconnector mechanism
Cable compartment
Cable connector
High voltage cable
Cable fastener
Main earthing bar
Floor plate
Mechanism for the voltage transformer
isolating device (optional)
Low voltage compartment
Secondary cable entry
Low voltage compartment door
Mechanism bay

Insulating Gas SF6

7.1 Vacuum circuit-breaker


The fixed mounted vacuum circuit-breakers are three phase
switching devices and fundamentally consist of the operating
mechanism and the three pole parts. The pole parts contain the
switching elements proper, the vacuum interrupters.
The pole parts are installed on a common mounting plate. The
operating mechanism is on the opposite side from the mounting
plate. In this way, the pole parts, mounting plate and operating
mechanism form a single assembly. The mounting plate for this
assembly is screwed to the front wall of the circuit-breaker compartment in a gas-tight manner at the works.

For earthing, the three position disconnector prepares the connection to earth while in the de-energised condition. Earthing
proper is performed by the circuit-breaker. A circuit-breaker functioning as an earthing switch is of higher quality than any other
earthing switch.
The circuit-breaker operating mechanism is located in the mechanism bay of the panel. The indicators and controls for the circuitbreaker are located in the operator control area of the panel (fig.
7.1.1) and are accessible from the outside.

The pole parts are located in the circuit-breaker compartment


which is filled with SF6, and are therefore protected from external
influences. The operating mechanism is located in the mechanism
bay and is therefore easily accessible.
Functions of the vacuum circuit-breaker
-
-
-

Switching operating current on and off


Short-circuit breaking operations
Earthing function in conjunction with the three position
disconnector

Fig. 7.1.1: Operator control area, controls and indicators for the circuit-breaker

1
2
4
6
(3)

1
2
3

4

5


6

Mechanical ON pushbutton circuit-breaker


Mechanical OFF pushbutton circuit-breaker
Receptacle for manual charging of the
stored-energy spring (behind the cover)
Mechanical indicator for Circuit-breaker
ON Circuit-breaker OFF
Mechanical indicator Stored-energy
spring charged Stored-energy spring dis-
charged
Operating cycle counter

Technical catalogue ZX0.2 TK 503 - Revision 01 | 23

Secondary equipment for the circuit-breaker operating


mechanism
The secondary equipment options for the circuit-breaker operating
mechanism can be found in table 7.1.1.

VDE designation

IEC designation

Table 7.1.1: Secondary equipment options for the circuit-breaker operating mechanism

Equipment

Standard

-MS

(-M0)

Charging motor for spring mechanism

-BS2

(-S1)

Auxiliary switch Spring charged

-MO1

(-Y2)

Shunt release OFF

-MC1

(-Y3)

Shunt release ON

-BB1

(-S3)

Auxiliary switch CB ON/OFF

-BB2

(-S4)

Auxiliary switch CB ON/OFF

-BB3

(-S5)

Auxiliary switch CB ON/OFF

-KN

(-K0)

-RL1

(-Y1)

Blocking magnet CB ON

-BL1

(-S2)

Auxiliary switch for blocking magnet

-BB4

(-S7)

Auxiliary switch for fault signal (impulse time 35 ms)

-MU

(-Y4)

2)

Undervoltage release

-MO3

(-Y7)

2)

Indirect overcurrent release

-MO2

(-Y9)

2nd shunt release OFF

1)

2)

Anti-pumping device

Option

With control by RE_


Combination of -MU with -MO3 is not possible

24 | Technical catalogue ZX0.2 TK 503 - Revision 01

Locking of the mechanical pushbuttons

Fig. 7.1.2: Securing to prevent operation of the OFF button


and securing to prevent cancellation of earthing

The following methods of locking the mechanical pushbuttons for the circuitbreaker are available.
Securing to prevent operation of the OFF button (fig. 7.1.2)
The standard version of the OFF button is fitted with a swivel flap.
The padlocked flap prevents operation of the OFF button.
Interlocking of the OFF button in the earthed condition (fig. 7.1.2)
(securing to prevent cancellation of earthing)
In addition to the lock to prevent operation of the OFF button, the
mechanical OFF button for the circuit-breaker can only be locked
in this version when the earthing switch and the circuit-breaker are
closed (feeder earthing).
Locking to prevent inadvertent operation of the OFF and/or ON buttons (fig. 7.1.3)

The devices permit locking of the ON and/or OFF buttons with
padlocks.

Fig. 7.1.3: Securing by lock switch (locking of both buttons shown here)

Locking by lock switch (fig. 7.1.4)


The ON and/or OFF buttons can be designed as lock switches.
In this option, the ON button can only be operated with a key. The
button does not engage when pressed.
The OFF button can be operated without a key. The switch remains
in the OFF position, as the button engages when pressed. Electrical
closing of the circuit-breaker is not then possible. The pressed OFF
button can be released locally with the key.

Fig. 7.1.4: Locking by lock switch: locking of the OFF


button

Technical catalogue ZX0.2 TK 503 - Revision 01 | 25

7.2 Three position disconnector


The three position disconnectors are combined disconnectors and
earthing switches. The three switch positions, connecting, disconnecting and earthing, are clearly defined by the mechanical
structure of the switch. Simultaneous connection and earthing is
therefore impossible.

The mechanical controls and indicators for the operating mechanism are located in the cover of the mechanism bay and are accessible from the outside.

Knife-switch three position disconnectors are used. The switching


components of the three position disconnector are located in the
SF6-filled panel module, while the operating mechanism block is
easily accessible in the low voltage compartment.

For manual operation of the switch with a lever (1), the relevant
opening for the lever (5 and 3, for the disconnector or earthing switch) is to be uncovered by turning the selector lever. The
switch position is indicated mechanically (2 and 4). In order to
avoid maloperation, manual mechanisms are interlocked mechanically with the relevant circuit-breaker within the panel.

The three position disconnectors can be manually or motor-operated operated. Emergency manual operation is always possible.

Manual operating mechanism

Motorised operating mechanism


Motorised mechanisms are preferably to be operated using the
control unit. Manual operation as with a manual mechanism is
also possible. The motorised mechanism is mechanically and
electrically interlocked with the circuit-breaker.

Fig. 7.2.1: Operator control area, mechanical controls and indicators for the three position disconnector

4
5
2
1
3

1
2
3
4
5

26 | Technical catalogue ZX0.2 TK 503 - Revision 01

Selector lever
Switch position indicator earthing switch
Opening for operation of the earthing switch
Switch position indicator disconnector
Opening for operation of the disconnector

Mechanism variants and secondary equipment


The secondary equipment options for the three position disconnector
mechanism variants can be found in table 7.2.2.

Table 7.2.2: Secondary equipment options for the three position disconnector operating mechanism variants in a feeder panel

VDE designation

IEC designation

Three position disconnector operating mechanism

Equipment

Manual mechanism

Standard

-MI

(-M1)

-BI1

(-S15)

-BI2

(-S16)

-BE1

(-S57)

-BE2

(-S58)

-BI1

(-S11)

Option

Motor-operated mechanism

Standard

Drive motor
Microswitch to detect switch position

Disconnector OFF
Microswitch to detect switch position

Disconnector ON
Microswitch to detect switch position

Earthing switch OFF


Microswitch to detect switch position

Earthing switch ON

Auxiliary switch Disconnector OFF

-BI2

(-S12)

Auxiliary switch Disconnector ON

-BE1

(-S51)

Auxiliary switch Earthing switch OFF

Auxiliary switch Earthing switch ON

-BE2

(-S52)

-BL1

(-S151)

-BL2

(-S152)

Microswitch on the selector lever

Option

-RL4

(-Y1)

Blocking magnet disconnector

-RL3

(-Y5)

Blocking magnet earthing switch

1) When shunt release ON MC1 is used in the circuit-breaker operating mechanism

Technical catalogue ZX0.2 TK 503 - Revision 01 | 27

7.3 Three position switch disconnector with fuse


The three position switch disconnectors with fuses are a combination of a switch disconnector , a positively making earthing switch,
an HV HRC fuse and an additional positively making cable earthing switch .

earthing switch is effected positively when the earthing switch in


the three position switch disconnector is operated.
The operating mechanism block is located in the low voltage
compartment and is therefore easily accessible. The mechanism for the switch is designed as a snap action spring mechanism, and the switching velocity is therefore independent of the
speed at which the mechanism is operated.

Knife-type three position switch disconnectors are used. The


switching elements (1) of the three position switch disconnectors are located in the SF6-filled panel module. The disconnector
contact of the three position switch disconnector is fitted with a
quenching plate system. This consists of cooling plates which
split the arc into short partial arcs connected in series. The reestablishment of the contact gap after extinction of the arc at the
current zero is supported by the cooling of the arc.

The switch disconnector is always manually operated.


The mechanical ON button of the operating mechanism can
optionally be secured with a padlock.

The HV HRC fuses are located in the fuse box below the switch
disconnector, in air at atmospheric pressure. A fuse flap (1.19)
located in front of the insulated handles on the HV HRC fuse is
blocked when the outgoing feeder is not earthed. Blown fuses
can therefore only be replaced when the feeder is earthed.
The additional cable earthing switch ensures that blown HV HRC
fuses are also earthed on the cable side. Operation of the cable

The controls and indicators of the operating mechanism are


shown in fig. 7.3.1.
Options for secondary equipment on the mechanism can be
found in table 7.3.1.

Fig. 7.3.1: Controls and indicators of a panel with switch disconnector and fuses

6
1
2

5
3
5
7
4

1
2
3

4
5

6
7

28 | Technical catalogue ZX0.2 TK 503 - Revision 01

Mechanical OFF pushbutton switch disconnector


Mechanical ON pushbutton switch disconnector
Opening for manual charging of the switch-disconnectors
stored-energy spring
Opening for operation of the earthing switch
Mechanical indicator for Circuit-breaker ON
Circuit-breaker OFF
fuse blown indicator
Mechanical indicator Stored-energy
spring charged Stored-energy spring discharged

VDE designation

IEC designation

Table 7.3.1: Secondary equipment options for the three position switch disconnector operating mechanism with fuse

Equipment

Standard

Option

-BI1

(-Q0S3)

Auxiliary switch switch disconnector ON/OFF

-BI2

(-Q0S4)

Auxiliary switch switch disconnector ON/OFF

-BI3

(-Q0S13)

Auxiliary switch switch disconnector ON/OFF

-BI4

(-Q0S14)

Auxiliary switch switch disconnector ON/OFF

-BE1

(-Q8S1)

Auxiliary switch earthing switch ON/OFF

-BE2

(-Q8S2)

Auxiliary switch earthing switch ON/OFF

-BE3

(-Q8S11)

Auxiliary switch earthing switch ON/OFF

-BE4

(-Q8S12)

Auxiliary switch earthing switch ON/OFF

-BI5

(-Q0S1)

-BI6

(-Q0S2)

Auxiliary switch earthing switch ON/OFF

-MO1

(-Q0Y2)

Shunt release OFF

-FF1

(-F1S1)

Auxiliary Switch HV HRC fuse blown

-RLI15

(-Q0S151)

Auxiliary switch selector slide position disconnector

-RLE15

(-Q8S151)

Auxiliary switch selector slide position earthing switch

Technical catalogue ZX0.2 TK 503 - Revision 01 | 29

7.4 Busbar
The busbars are located outside the gas compartment.
The insulation of the busbar is of silicone. The surfaces of the busbar components are metallised and are connected to earth potential after assembly. The busbars are thus shockproof in normal
operation.
The conductive connections between the busbars and from the
busbars to the relevant cast resin bushing in the panel module are
made by the cross and end adapters.

Fig. 7.4.1: Busbar with cross and end adapters

30 | Technical catalogue ZX0.2 TK 503 - Revision 01

Bushing-type current transformers can be mounted between two


panels in the busbar run. Voltage transformers can be installed
above the cross and end adapters for detection of the busbar
voltage (see also fig. 6.7).

7.5 Outer cone termination system


Outer cone device termination components to EN 50180 and EN
50181, fitted gas-tight in the wall between the panel module and
the cable termination compartment, facilitate connection of cables
and surge arresters (figs. 7.5.1 to 7.5.3). The termination height
of 700 mm provides for good accessibility when installing cables.
When the shutter on the cable termination compartment has been
removed, the cables are accessible from the front of the system.
In panels of 1200 mm width, the two outer cones per phase are
to be fitted with the same number of plug connectors.

Fig. 7.5.1: View into the cable termination area with outer cones in air,
without cable connectors (during assembly at the works, without the cable
termination compartment)

Fig. 7.5.3: View into the cable termination compartment in


air with shockproof cable connectors (ABB type SOC 630...)
and cables

Furthermore, at operating voltages of up to 12 kV, operating currents of up to 630 A and short-time withstand currents of up to
25 kA, connection of plastic-insulated cables (35mm2 - 400 mm2)
and paper-insulated cables (50mm2- 400mm2) is possible using
an insulated cable termination (type RCAB 12 kV) from manufacturer Tyco. This cable termination (fig. 7.5.4) is not shockproof.
When this termination system is used, the cover on the cable termination compartment should be lockable.
Apart from this, always use shockproof termination systems where
possible.

Fig. 7.5.2: Outer cones in a panel with three position disconnector and
fuses

Fig. 7.5.4: Cable termination RCAB 12 kV from Tyco, 630 A, 25 kA

Technical catalogue ZX0.2 TK 503 - Revision 01 | 31

7.5.1 Outer cone connectors type Kabeldon SOC from ABB


In the form of the Kabeldon SOC product, ABB offers outercone
connectors for polymeric cables of all current cable cross-sections
and cable diameters.

All connector sleeves are routinely tested with regards to partial


discharge and AC, to ensure that supplied accessories are of
highest quality.

The connectors are made of rubber and they are cold mountable.
The outer conductive layer of the conductor ensures a touch proof
system is approximate 2 mm thick and vulcanized together in one
process with the insulation and inner deflector. This method gives
a robust product with highest mechanical withstand.

The kits are supplied with adaptor, cable lug and connector hood
with pre-installed earth conductor. Extra material such as earthing
kits, crutch seals for 3-core cables and screen potential material for cable armouring is also within the ABB range of products.
Kindly contact ABB Sales Representative for more information.

Fig. 7.5.1.1: Connector ABB type Kabeldon SOC for cable cross section
from 25 to 300 mm2

Fig. 7.5.1.2: Connector ABB type Kabeldon SOC for cable cross section
from 400 to 630 mm2

Table 7.5.1.1: Technical data of the connector ABB Kabeldon type SOC
Voltage level

Designation

Diameter over insulation

Conductor cross section

[mm]

[mm2]

[kV]
12 - 24

SOC 630-1

15 - 26,8

50 -120

12 - 24

SOC 630-2

21,4 -34,9

150 -300

12 - 24

SOC 630-3

31,5 - 42

400

12 - 24

SOC 630-4

31,5 - 42

500

12 - 24

SOC 630-5

40 - 46

630

32 | Technical catalogue ZX0.2 TK 503 - Revision 01

7.5.2 Further outer cone connector systems


A selection of various shockproof connector systems which can
be installed depending on the space available is presented in
tables 7.5.2.1 and 7.5.2.6. When making your selection, please
observe the current and short-circuit ratings of the cables and

connector systems. Please consult the manufacturers latest catalogues for the precise ordering data and information on any couplings required.

Table 7.5.2.1: Selection of cable connectors, panels with three position switch disconnector and fuses, 12 kV

12

16 - 150

25 - 95

25 - 120

25 - 150

Tyco

Sdkabel GmbH

nkt cables GmbH

EUROMOLD

[mm2]

Cable connector manufacturer / connector type

ABB Kabeldon

Cable cross-section

[kV]

One cable

Maximum operating
voltage

Cables fitted

158LR
SOC 250
EASW 10/250

RSES-52..
SEW12

Technical catalogue ZX0.2 TK 503 - Revision 01 | 33

Table 7.5.2.2: Selection of cable connectors, panel width 600 mm, 12 kV

CB12-630

400TB/G

430TBM-P2

430TBM-P3

25 - 300

CB12-630

RSTI-58xx

CC12-630

RSTI-CC-58xx

CB12-630

RSTI-58xx

2 x CC12-630

2 x RSTI-CC-58xx

430TB

CB12-630

RSTI-58xx

300SA

CSA12-.

RSTI-CC-58SA

400PB
430TBM-P2

300SA

RSTI-58xx

400TB/G

50 - 120

Tyco

430TB

Sdkabel GmbH

nkt cables GmbH

EUROMOLD

ABB Kabeldon

Cable connector manufacturer / connector type

One cable +
surge arrester
Two cables +
surge arrester
Three cables +
surge arrester

Three cables

[mm2]

Two cables

Cable cross-section

[kV]

One cable

Maximum operating
voltage

Cables fitted

CB12-630

RSTI-58xx

CC12-630

RSTI-CC-58xx

CSA12-...

RSTI-CC-58SA

CB12-630

RSTI-58xx

2 x CC12-630

2 x RSTI-CC-58xx

CSA12-...

RSTI-CC-58SA

SOC 630-1

SET12
SET12

SEHDK13.1
SET12

50- 300

MUT13
SET12

SEHDK13.1
MUT13

12

150 - 300

SOC 630-2
SEHDT13

300 - 500
400

SEHDT13

MUT13

SOC 630-3

CB36-630(1250)
CB36-630(1250)

CC36-630(1250)
CB36-630(1250)

400

2 x CC36-630(1250)
CB36-630(1250)

500

CSA12-..

600

CB36-630(1250)

CC36-630(1250)
CSA12-..
CB36-630(1250)

2 x CC36-630(1250)
CSA12-..

440TB/G

400 - 630

440TB/G-P2
440TB/G

400PB

400 - 800

500

SOC 630-4

630

SOC 630-5

34 | Technical catalogue ZX0.2 TK 503 - Revision 01

RSTI-x95x

[kV]

Tyco

Sdkabel GmbH

nkt cables GmbH

EUROMOLD

ABB Kabeldon

Cable connector manufacturer / connector type

Four cables +
surge arrester
Six cables +
surge arrester

Six cables

Four cables

Cables fitted

Two cables

Cable cross-section

Maximum operating
voltage

Table 7.5.2.3: Selection of cable connectors, panel width 1200 mm, 12 kV

[mm2]

4 x 400TB/G

2 x 430TBM-P2

2 x 430TBM-P3

25 - 300

2 x 430TBM-P2

300SA

2 x CB12-630

2 x RSTI-58xx

2 x CC12-630

2 x RSTI-CC-58xx

2 x CB12-630

2 x RSTI-58xx

4 x CC12-630

4 x RSTI-CC-58xx

2 x CB12-630

2 x RSTI-58xx

2 x CC12-630

2 x RSTI-CC-58xx

CSA12-...

RSTI-CC-58SA

2 x CB12-630

2 x RSTI-58xx

4 x CC12-630

4 x RSTI-CC-58xx
RSTI-CC-58SA

CSA12-...
300 - 500

400

12

4 x SEHDT13
SOC 630-3
2 x CB36-630(1250)

2 x CC36-630(1250)
2 x CB36-630(1250)

400
500
600

4 x CC36-630(1250)
2 x CB36-630(1250)

2 x CC36-630(1250)
CSA 12-...
2 x CB36-630(1250)

4 x CC36-630(1250)
CSA 12-...

400 - 630
400 - 800

2 x 440TB/G-P2

2 x RSTI-x95x

500

SOC 630-4

630

SOC 630-5

Table 7.5.2.4: Selection of cable connectors, panels with three position switch disconnector and fuses, 24 kV

[kV]

24

Tyco

Sdkabel GmbH

nkt cables GmbH

EUROMOLD

Cable connector manufacturer / connector type

ABB Kabeldon
(recommended)

One cable

Cable cross-section

Maximum operating
voltage

Cables fitted

[mm2]
16 - 120

16 - 150

25 - 95

25-120

RSES-52xx
K158LR
SOC 250

SEW24
CE24-250

Technical catalogue ZX0.2 TK 503 - Revision 01 | 35

Table 7.5.2.5: Selection of cable connectors, panel width 600 mm, 24 kV

[kV]

Tyco

Sdkabel GmbH

nkt cables GmbH

EUROMOLD

ABB Kabeldon

Cable connector manufacturer / connector type

One cable +
surge arrester
Two cables +
surge arrester
Three cables +
surge arrester

Three cables

Two cables

One cable

Cable cross-section

Maximum operating
voltage

Cables fitted

[mm2]

CB24-630

25 - 300

K400TB/G

K430TBM-P2

RSTI-CC-58xx

CB12-630

RSTI-58xx

2 x CC12-630

2 x RSTI-CC-58xx

CB24-630

RSTI-58xx

CSA24-.

RSTI-CC-58SA

CB12-630

RSTI-58xx

CC12-630

RSTI-CC-58xx

CSA24-...

RSTI-CC-58SA

CB12-630

RSTI-58xx

2 x CC12-630

2 x RSTI-CC-58xx

CSA24-...

RSTI-CC-58SA

K430TBM-P3
K430TB

35 - 300

K300SA
K400TB/G

K400PB
K430TBM-P2

RSTI-58xx

CC24-630

K430TB

50 - 120

K300SA

SOC 630-1

24

RSTI-58xx

CB24-630

SET24
SET24

SEHDK23.1
SET24

50- 300

MUT23
SET24

EHDK23.1
MUT23

150 - 300

SOC 630-2
SEHDT23

300 - 500
400

SEHDT23

MUT23

SOC 630-3

CB36-630(1250)
CB36-630(1250)

CC36-630(1250)
CB36-630(1250)

400
500

2 x CC36-630(1250)
CB36-630(1250)

CSA24-..

600

CB36-630(1250)

CC36-630(1250)
CSA24-..
CB36-630(1250)

2 x CC36-630(1250)
CSA24-..

36 | Technical catalogue ZX0.2 TK 503 - Revision 01

Table 7.5.2.5: Selection of cable connectors, panel width 600 mm, 24 kV

[kV]

Tyco

Sdkabel GmbH

nkt cables GmbH

EUROMOLD

Cable connector manufacturer / connector type

ABB Kabeldon

One cable +
surge arrester
Two cables +
surge arrester
Three cables +
surge arrester

Three cables

Two cables

One cable

Cable cross-section

Maximum operating
voltage

Cables fitted

[mm2]

K440TB/G

400 - 630

K440TB/G-P2
K440TB/G

K400PB

400 - 800

500

SOC 630-4

630

SOC 630-5

RSTI-x95x

Technical catalogue ZX0.2 TK 503 - Revision 01 | 37

[kV]

Tyco

Sdkabel GmbH

[mm2]

25 - 300

400

2 x RSTI-58xx
4 x RSTI-CC-58xx

2 x CB24-630

2 x RSTI-58xx

2 x CC24-630

2 x RSTI-CC-58xx

CSA24-...

RSTI-CC-58SA

2 x CB24-630

2 x RSTI-58xx

4 x CC24-630

4 x RSTI-CC-58xx

CSA24-...

RSTI-CC-58SA

2 x K430TBM-P2
K300SA
4 x SEHDT13
SOC 630-3
2 x CB36-630(1250)

2 x CC36-630(1250)
2 x CB36-630(1250)

400
500
600

2 x CB24-630
4 x CC24-630

2 x K430TBM-P3

2 x RSTI-58xx
2 x RSTI-CC-58xx

2 x K430TBM-P2

300 - 500

2 x CB24-630
2 x CC24-630

4 x K400TB/G

25 - 300

24

nkt cables GmbH

EUROMOLD

ABB Kabeldon

Cable connector manufacturer / connector type

Four cables +
surge arrester
Six cables +
surge arrester

Six cables

Four cables

Cables fitted

Two cables

Cable cross-section

Maximum operating
voltage

Table 7.5.2.6: Selection of cable connectors, panel width 1200 mm, 24 kV

4 x CC36-630(1250)
2 x CB36-630(1250)

2 x CC36-630(1250)
CSA24-...
2 x CB36-630(1250)

4 x CC36-630(1250)
CSA24-...

400 - 630
400 - 800

2 x 440TB/G-P2

2 x RSTI-x95x

500

SOC 630-4

630

SOC 630-5

38 | Technical catalogue ZX0.2 TK 503 - Revision 01

7.6 Surge arresters

LRM-system (Fig. 7.8.1)


Additional indicator unit (Fig. 7.8.2) required
Repeat testing necessary

Surge arresters are fitted directly with cable connectors. Fitting of


several cables plus a surge arrester per phase is possible (see tables 7.5.2.1 to 7.5.2.6). The terminals of the surge arresters must
be suitable for the type of cable connector used. Further information on surge arresters can be obtained from the relevant cable
connector manufacturer.
In addition, surge arresters can be directly connected to the busbar. We will be pleased to provide information on these surge arresters on request.

7.7 Main earthing bar

KVDS-system (Fig. 7.8.3)

LC-Display
Three phase
No additional indicator unit required
Maintenance-free with integrated self-test:
No symbol visible:
De-energised
Half lightning arrow displayed: Voltage applied
Full lightning arrow displayed: Voltage applied and selftest passed

Fig. 7.8.1: Three phase LRM-system

The main earthing bar of the switchgear system runs through the
cable termination compartments of the panels. The earthing bars
in the individual panels are connected together during installation
at site.
The cross-section of the main earthing bar is 300 mm2
(ECuF30 30mmx10 mm).

7.8 Capacitive voltage


indicator systems
Fig. 7.8.2: Indicator unit for LRM-systems

Various capacitive, low impedance voltage indicator systems are


available for checking of the off-circuit condition of a feeder. The
high voltage side capacitor is integrated in the outer cone device
termination components. The capacitive voltage indicator system
is located in the low voltage compartment door.
Capacitive pick-offs can be installed on cross or end adapters in
the solid insulated busbars to detect the off-circuit condition of the
busbars. The capacitive voltage indicator system can be integrated in the cover of the operator control area of incoming or outgoing feeder panels and in sectionaliser and riser panels.

Fig. 7.8.3: KVDS-system

All systems used are voltage dectection systems (VDS) according


to IEC 61243-5.
All the systems used permit phase comparison with the aid of an
additional, compatible phase comparator.

Technical catalogue ZX0.2 TK 503 - Revision 01 | 39

CAVIN-system (Fig. 7.8.4)

Fig. 7.8.4: CAVIN-system

As the KVDS-system, but:


Two integrated relay contacts
for signals/interlocks
LED display of relay status:
No Error: Relay 1 closed (All three
conductors have the same voltage
state and auxiliary voltage is available.)
Error: Relay 1 open (The three conductors are carrying
different voltages, or the auxiliary voltage has failed.)
HV OFF: Relay 2 closed (UL1 = UL2 = UL3 < phase to earth
voltage when the response voltage is reached.)
HV ON: Relay 2 open (In at least one phase,
U / 3 > phase to earth voltage when
the response voltage is reached, or
auxiliary voltage has failed.)
Auxiliary voltage required for the relays

relays

Auxiliary voltage required for

Two relay contacts

Integrated self-test

LRM
KVDS

LC-display

System

Technical characteristics

Additional indicator unit required

Table 7.8.1: Scope of function of the capacitive voltage indicator systems

Three phase

CAVIN

40 | Technical catalogue ZX0.2 TK 503 - Revision 01

Low impedance

7.9 Current and voltage detection devices


The areas of application for current and voltage detection devices
are

Abb. 7.9.1.1: Ring core current transformer up to 1250 A

Protection applications,
Measurement,
Billing metering.

7.9.1 Ring core current


transformers
Ring core current transformers are used for feeder metering in
termination panels. They are located on the outer cone outside
the gas compartment. Two cones per phase are used in panels for
currents > 1250 A. In these cases, a ring core current transformer
as shown in fig. 7.9.1.2 is to be used.
The winding of the ring core current transformer is enclosed in
cast resin. The cross-section of the connecting wiring is 2.5 mm
(larger cross-sections on request). Current transformers as shown
in fig. 7.9.1.2 are optionally available with terminal boxes.
The possible technical data can be found in the following table.

Abb. 7.9.1.2: Ring core current transformer up to 2500 A

Panels with one cable per phase can also be fitted with straightthrough current transformers on request.

Table 7.9.1.1: Technical data of the ring core current transformers


Current transformer type

kV

0,72

0,72

Ud

kV

fr

Hz

Rated voltage

Ur

Rated short duration power-frequency withstand voltage


Rated frequency
Rated thermal short-time current

31,5 kA - 3 s

Itherm

Rated impulse current

Ip

Panel width
Rated primary current

Ir

Rated secondary current

kA
600

1200

...1250

...2500

Capacity

VA

Class
Protection cores

1 or 5
1

...20

...20

0,2 / 0,5 / 1

0,2 / 0,5 / 1

1)

Measuring cores

1)

80

mm

Max number of cores


Core data

3
50 / 60

Capacity

VA

1 to 10

2,5 to 15

Class

5P

Overcurrent factor

20

Dependent on rated primary current.

Technical catalogue ZX0.2 TK 503 - Revision 01 | 41

7.9.2 Dimensioning of current transformers


The stipulations and recommendations of IEC 61936, section
6.2.4.1 Current transformers, lEC / EN 60044-1 and lEC 600446 are to be observed in the design of current transformers. The
rated overcurrent factor and rated burden of current transformer
cores are to be selected in such a way that protection devices can
function correctly and measuring systems are not damaged in the
event of a short-circuit.
Protection purposes
Protection cores are, logically, operated at above rated current.
The function of the selected protection system is essentially determined by the connected current transformer. The requirements to
be fulfilled by the current transformers for the selected protection
or combination device can be found in the documentation from
the protection equipment supplier. For an accurate switchgear
proposal, these current transformer data are to be provided with
the product enquiry and then finally agreed by the operator and
manufacturer in the order.
The direct path to the right current transformers is via the technical documentation of the selected protection device. The current
transformer requirements of the relay can be found there.
Measuring purposes
In order to protect measuring and metering devices from damage
in the case of a fault, they should go into saturation as early as
possible. The rated burden of the current transformer should be
approximately the same as the operating burden consisting of the
measuring instrument and cable. Further details and designations
can be found in EN 60044-1.
Recommendations
In principle, we recommend a rated secondary current of 1 A. The
current transformer ratings for ABB protection devices are known.
The transformer data can be selected to suit the protection application and the network parameters. If, however, third party devices
are to be connected, we recommend a review by our engineers
at an early stage. Taking account of the burdens and overload
capacities, our experts can examine the entire current transformer
requirements of the third party protection devices on request.
Further information for different protection systems
If the current transformers to be used in the network concerned
(e.g. on the opposite side of the network) have already been specified, early coordination of the switchgear configuration is advisable.
This requires, but is not limited to, the provision of data on the ratio,
rated capacity, accuracy class, and the resistance of the secondary winding and secondary wiring. Further configurations for the
particular application can then be requested.

42 | Technical catalogue ZX0.2 TK 503 - Revision 01

7.9.3 Voltage transformers


The voltage transformers are always located outside the gas compartments. They can be permanently mounted or of the plug-in
type (plug size 2 to DIN 47637 and EN 50181). Feeder voltage
transformers are equipped with a series isolating system. After
operation of the isolating system, the voltage transformers are
earthed. Busbar voltage transformers are of the plug-in type.
The possible electrical data can be found in the table below.

Fig. 7.9.3.1: Voltage transformer for fixed mounting

Fig. 7.9.3.2: Voltage transformer, plug-in type

Table 7.9.3.1 Technical data of voltage transformers

Type of
voltage

Max. capacity

Class

transformer

[VA]
plug-in type

fixed mounted

30

0,2

75

0,5

150

20

0,2

50

0,5

100

Rated thermal current limit

Rated secondary

Rated secondary

voltage of the

voltage of the earth

metering winding

fault winding

[V]

[V]

100 / 3

100 / 3

110 / 3

110 / 3

100 / 3

100 / 3

110 / 3

110 / 3

Rated thermal long duration

of the metering winding

current of the earth fault

with rated voltage factor

winding with rated voltage

1.2 / continuous

factor 1.9 / 8 h

[A]

[A]

Table 7.9.3.2: Rated power frequency withstand voltage of voltage transformers


Rated voltage

Rated power frequency withstand voltage (1 min)

[kV]

[kV]

<6

5 x Ur

6 - 12

28

> 12 - 17.5

38

> 17.5 - 24

50

Technical catalogue ZX0.2 TK 503 - Revision 01 | 43

7.10 Protection and control units


ABB provides the right protection and automation solution for
every application.
Table 7.10.1 below provides an overview of the most important
protection devices with notes on their range of applications. Further information can be obtained in the Internet (http://www.abb.
de/mediumvoltage) or from the responsible ABB contact for you.

Range

Middle
Range

REM 543
REM 545

High
Range

RET 541
RET 543
RET 545
REF 541
REF 543
REF 545
REC 523

REF 542plus

Motor
Generator
Motor
Generator
Control
Basic
Multi
Control
Basic
Multi
Basic low
Basic
Multi low
Multi
Differential
Distance

REF 630
RET 630
REM 630
1)

Control of a circuit-breaker is possible

44 | Technical catalogue ZX0.2 TK 503 - Revision 01

1)

1)

1)

1)

protection

Cable differential

Feeder automation

Back-up protection

Voltage

regulation

protection

Transformer

Generator

protection

Motor

protection

protection

Capacitor bank

measurement

Bay control and

Metering panel

Feeder

Basic

SPAM 150 C
SPAJ 140 C
SPAJ 160 C
SPAU 140 C
SPAF 140 C
REC 501
REU 610
REM 610
REF 610
SPAU 341 C
SPAD 346 C
REX 521B01
REX 521B02
REX 521M01
REX 521M02
REX 521H01
REX 521H02
REX 521H03
REX 521H04
REX 521H05
REX 521H06
REX 521H07
REX 521H08
REX 521H09
REX 521H50
REX 521H51
REF 615
RED 615
RET 615
REM 615

Incomer

Device designation

Table 7.10.1: Range of application of protection and control units

7.11 Sulphur hexafluoride


SF6 is a non-toxic, inert insulating gas with high dielectric strength
and thermal stability.
Its unique electrical and thermal properties have made the design
of new, more efficient switchgear possible. The change from conventional insulation to the non-flammable, chemically inactive and
non-toxic heavy gas sulphur hexafluoride has led to significant
savings in space and materials, and to greater safety of the installations. Switchgear systems insulated with sulphur hexafluoride
have become highly successful especially in applications where
space is constricted and compact design is required. On account
of their insensitivity to air pollution, enclosed SF6 systems are also
used in the chemicals industry, in desert areas and at coastal locations. Thanks to SF6 technology, new substations can also be
erected at load centres in densely populated areas where high
land prices prohibit other solutions.
SF6 has been used in HV-switchgear since 1960.

7.12 Gas system in the


panels
SF6 is used as the insulation medium. Furthermore, SF6 is used as
the quenching gas in panels with switch disconnector and fuses
for interruption of operating currents.
The gas compartments are designed as hermetically sealed pressure systems. As they are filled with SF6, constant ambient conditions are permanently ensured for the entire high voltage area of
the panel. It is not necessary to top up the insulating gas during

Fig. 7.12.1: Gas filling connector (1) and density sensor (2)

the expected service life of the system. Under normal operating


conditions, no checks on the insulating gas are necessary. The
insulating gas is maintenance-free.
Each panel module has a gas filling connector (fig. 7.12.1 - see
also section 6), through which the panel modules can be filled
with gas, for instance in the case of repairs.
The service pressure of the individual gas compartments is monitored by separate density sensors (temperature-compensated
pressure sensors, fig. 7.12.1). A shortfall below the alarm signal
level for insulation (120 kPa) or below the minimum filling pressure
for switching (140 kPa) in a panel with three position switch disconnector and fuses is indicated on the protection and control unit
or by signal lamp (fig. 7.12.2). Temporary operation of the panel at
atmospheric pressure (> 100 kPa) is in principle possible if the SF6
content of the insulating gas is at least 95 %. (Caution: A panel
with three position switch disconnector and fuses may not be operated at less than the minimum filling pressure for switching (140
kPa), as the blowing of fuses leads to the tripping of the three position switch disconnector).
Leakage testing of the gas compartments during manufacturing process
The leakage rate of the gas compartments is determined by integral leakage testing:
The block is placed in a test cabin. The block and the test cabin
are evacuated. The gas compartment at the block are filled with
helium. In this condition, the leakage rate is determined by measurement of the helium content in the test chamber. The helium is
recovered after measurement, and the gas compartment is simultaneously evacuated. Finally, the panel module is automatically
filled with SF6 to the rated filling pressure for insulation (= 130 kPa
at 20 C) or to the rated filling pressure for switching (= 150 kPa at
20 C) in the case of the panel with three position switch disconnector and fuses.This means that systems can only be filled with
SF6 when they have passed the leakage test.

Fig. 7.12.2: Signal lamp for gas density (used when the signal is not integrated in the protection device)

Technical catalogue ZX0.2 TK 503 - Revision 01 | 45

7.13 SF6 density sensor


Fig. 7.13.1 shows the function of the SF6 density sensor. Between
the measuring chamber and a reference chamber there is a moving mounting plate which operates electrical contacts.
Temperature compensation
The pressure in the monitored gas compartment rises with increasing temperature. As, however, the temperature in the reference chamber and thus the pressure of the reference volume
increases to the same extent, this does not lead to any movement
of the mounting plate.
Self-supervision
A drop in pressure of the reference volume results in a movement
of the mounting plate (to the right in fig. 7.13.1). The self-supervision contact is operated. As the system is designed as a closed
circuit, both wire breakages and defective plug and terminal connections are signalled as faults.

Gas losses
A loss of gas in the monitored gas compartment results in a drop
in pressure in the measuring volume and thus a movement of the
mounting plate (to the left in fig. 7.13.1). The contact for the pressure loss signal is operated.
Two versions of SF 6 density sensors
Two versions of the density sensors (figs. 7.13.2 and 7.13.3) are
used.
1. A common indication for gas loss, wire breakage, defective plug
connection and defective pressure sensor for the reference volume.
2. Separate indications for a) gas loss, wire breakage and defective plug connection, and b) defective pressure sensor for the reference volume, wire breakage and defective plug connection.
-

Fig. 7.13.1: Schematic diagram of the function of the SF6 density sensor

5
1
2
3
4

5
6

Monitored gas compartment


Measuring volume
Enclosed volume for temperature compensation (reference volume)
Mounting plate moved by interaction of forces (pressure of measuring volume
against pressure of reference volume)
Contact for self-supervision (p > 150 kPa 1) )
Contact for gas loss (p < 120 kPa 2) )

Fig. 7.13.3: Version 2 of the SF 6 density sensor

Fig. 7.13.2: Version 1 of the SF6 density sensor

> 150 kPa 1)


a)
< 120 kPa 2)
> 120 kPa 2)
Gas loss

1)

2)

Self-supervision

< 150 kPa 1)

> 150 kPa 1)

< 120 kPa 2)


< 150 kPa

1)

Self-supervision

170 kPa for panels with three position switch disconnector and fuses
140 kPa for panels with three position switch disconnector and fuses

46 | Technical catalogue ZX0.2 TK 503 - Revision 01

b)

Gas loss
> 120 kPa 2)

7.14 Pressure relief systems

8. Range of panels

In the unlikely event of an internal arc fault in a gas compartment,


the relevant pressure relief disk opens. In the case of wall mounting installation, the pressure created by a fault in the panel module
or in the cable termination compartment is discharged upwards
behind the switchgear system, and in the case of free-standing
installation upwards through the pressure relief duct at the rear (fig.
7.14.1).

The following panel variants are available:

7.15 Surfaces
The gas-tight enclosures of the panel modules consist of stainless steel sheets. The cable termination compartments and low
voltage compartments mechanism bays and busbar covers are
manufactured from galvanised sheet steel.

Feeder panels
Panels with circuit-breaker and three position
disconnector
Panels with three position switch disconnector
and fuses
Cable termination panels
Sectionaliser
Riser
All the panels shown in section 8 are available as versions
for free-standing and wall mounting installation. All the illustrations show the free-standing versions.
The assignment of the panel variants to the relevant panel
widths can be found in table 8.1.

The low voltage compartment doors, the covers on the operator


control areas, the cable termination compartment covers and end
covers are coated with a powder stove enamel in RAL 7035 (light
grey). Other colours for the painted parts are available on request.
Fig. 7.14.1: Pressure relief of the switchgear

Table 8.1: Panel widths


Panel variants
Feeder panel with three position
switch disconnector and fuses

Rated normal current

Panel width

[A]

[mm]

Dependent on the fuses

600

Feeder panel

... 1250

600

Sectionaliser panel

... 1250

600

Riser panel

... 1250

600

Transfer panel

... 1000

600

Incomer panel

... 2500

1200

Sectionaliser panel

... 2500

900

Riser panel

... 2500

900

Technical catalogue ZX0.2 TK 503 - Revision 01 | 47

8.1 Feeder panels


8.1.1 Incoming and outgoing feeder panels with
circuit-breaker
Fig. 8.1.1.1: Feeder panel with circuit-breaker 1250 A, voltage transformers (isolatable in the off-circuit condition) on the cables and plug-in voltage transformers on the busbars

1330

2400

2400

Fig. 8.1.1.1: Feeder panel with circuit-breaker 630 A

1330

2400

Fig. 8.1.1.3: Feeder panel with circuit-breaker 2500 A, voltage transformers


(isolatable in the off-circuit condition) on the cables and plug-in voltage
transformers on the busbars

1330

48 | Technical catalogue ZX0.2 TK 503 - Revision 01

or

Current transformer 1)

Voltage
transformer,
plug-in type 1)

Capacitive
voltage indicator
system
or

Voltage
transformer,
isolatable

Voltage transformer,
plug-in type
and isolatable

Max. 3 cables
per phase

Max. 2 cables
per phase
+ surge arrester

Table 8.1.1.1: Overview of variants for incoming and outgoing feeder panels with circuit-breaker, I r up to 1250 A

Panel width: 600 mm

1)

U r:

... 24 kV

I r:

... 630 A, ... 1250 A

I p:

... 25 kA, ... 31.5 kA

Either current transformers or voltage transformers

Technical catalogue ZX0.2 TK 503 - Revision 01 | 49

or

Current transformer 1)

Voltage
transformer,
plug-in type 1)

Capacitive
voltage indicator
system

or

Voltage
transformer,
isolatable

Voltage transformer,
plug-in type
and isolatable

Max. 6 cables
per phase

Max. 4 cables
per phase
+ surge arrester

1)

Either current transformers or voltage transformers

Table 8.1.1.2: Overview of variants for incoming and outgoing feeder panels with circuit-breaker, I r over 1250 A and up to 2500 A
U r:

... 24 kV

I r:

... 1600 A, ... 2000 A, ...2500 A

I p:

... 25 kA, ... 31.5 kA

Panel width: 1200 mm

1)

Either current transformers or voltage transformers

50 | Technical catalogue ZX0.2 TK 503 - Revision 01

8.1.2 Feeder panels with three position switch disconnector


and fuses

2400

Fig. 8.1.2.1: Feeder panel with three position switch disconnector and fuses

1330

Current transformer

Voltage
transformer,
plug-in type 1)

1)

1 cable
per phase

Table 8.1.2.1: Overview of variants for feeder panels with three position switch disconnector

Panel width: 600 mm

1)

U r:

...12 kV

I r:

...80 A

U r:

...24 kV

I r:

...63 A

Either current transformers or voltage transformers

Technical catalogue ZX0.2 TK 503 - Revision 01 | 51

8.1.3 Cable termination panels

Fig. 8.1.3.1: Cable termination panel 1250 A

2400

2400

Fig. 8.1.3.2: Cable termination panel 2000 A

1330

1330

or

Current transformer 1)

Voltage
transformer,
plug-in type 1)

Current transformer

Max. 3 cables
per phase

Table 8.1.3.1: Overview of variants for cable termination panels, I r up to 1250 A


U r:

... 24 kV

I r:

... 1250 A

I p:

... 25 kA, ... 31.5 kA

Panel width: 600 mm

1)

Either current transformers or voltage transformers

52 | Technical catalogue ZX0.2 TK 503 - Revision 01

Capacitive
voltage indicator
system

Max. 2 cables
per phase
+ surge arrester

or

Voltage
transformer,
plug-in type

Current transformer

Capacitive
voltage indicator
system

Current transformer

Max. 6 cables
per phase

Max. 4 cables
per phase
+ surge arrester

Table 8.1.3.2: Overview of variants for cable termination panels, I r up to 2500 A

Panel width: 1200 mm

1)

U r:

... 24 kV

I r:

... 1600 A, ... 2000 A, ... 2500 A

I p:

... 31.5 kA

Either current transformers or voltage transformers

Technical catalogue ZX0.2 TK 503 - Revision 01 | 53

8.2 Busbar sectionaliser


and riser panels

8.2.1 Couplings within a


switchgear block

A sectionaliser and a riser panel are required for the implementation of bus couplings. In addition, a transfer panel containing a
circuit-breaker and a three position disconnector is also available.

Sectionaliser panels are equipped with a combination of circuitbreaker and three position disconnector. Riser panels contain a
three position disconnector. The current transformer is located
on the solid insulated bar below the panel module. Sectionaliser
and riser panels can be fitted with voltage transformers for busbar
measurement.
The installation variants sectionaliser left riser right and vice
versa are possible.
A riser panel can be installed at the end of the switchgear system
for future extension without interruptions.

Bus couplings can be integrated in a switchgear block. The riser


and sectionaliser panels are connected by a solid insulated bar
below the panel module.
Couplings between two system blocks can be effected by means
of cables.

Fig. 8.2.1.2: Riser panel 1250 A

1330

2400

2400

Fig. 8.2.1.1: Sectionaliser panel 1250 A

1330

Fig. 8.2.1.4: Riser panel 1600 A

1330

54 | Technical catalogue ZX0.2 TK 503 - Revision 01

2400

2400

Fig. 8.2.1.3: Sectionaliser panel 1600 A

1330

or

Voltage
transformer,
plug-in type 1)

Current transformer 1)

Capacitive
voltage indicator
system

Current transformer

Table 8.2.1.1: Overview of variants for sectionaliser and riser panels for installation within a switchgear block

Panel width: 2 x 600 mm

Panel width: 2 x 900 mm

1)

U r:

... 24 kV

I r:

... 1250 A

I p:

... 25 kA, ... 31.5 kA

U r:

... 24 kV

I r:

... 1600 A, ... 2500 A

I p:

... 25 kA, ... 31.5 kA

Either current transformers or voltage transformers

Technical catalogue ZX0.2 TK 503 - Revision 01 | 55

8.2.2 Transfer panel

2400

The transfer panel contains a circuit-breaker and a three position


disconnector. In this panel variant, the three position disconnector
is located between the left-hand busbar section and the circuitbreaker. The bushings on the left-hand busbar section can be
fitted with voltage transformers. Voltage transformers for voltage
detection in the right-hand busbar section can be located on the
busbar of the adjacent panel on the right. Current transformers
can be positioned on the busbars of the adjacent panels.

1330

Voltage
transformer,
plug-in type

Current transformer

Table 8.2.2.1: Transfer panel


U r:

... 17.5 kV

... 24 kV

I r:

... 1250 A

. .. 1250 A

I p:

... 31.5 kA

... 25 kA

Panel width: 600 mm

56 | Technical catalogue ZX0.2 TK 503 - Revision 01

Capacitive
voltage indicator
system

8.2.3 Couplings (Connection of two system blocks)

2400

Fig. 8.2.3.1: Couplings by cables, example configuration with circuit-breaker, three position disconnectors and integrated busbar voltage
measurement, 2500 A

1330

1330

The overview of variants can be found in section 8.1.

Table 8.2.3.1: Overview of variants for sectionaliser and riser panels (Connection of two system blocks)

Panel width: 600 mm

Panel width: 1200 mm

U r:

... 24 kV

I r:

... 1250 A

I p:

... 25 kA, ... 31.5 kA

U r:

... 24 kV

I r:

... 2000 A, ... 1600 A, ... 2500 A

I p:

... 25 kA, ... 31.5 kA

Technical catalogue ZX0.2 TK 503 - Revision 01 | 57

9 Busbar earthing

is earthed via the closed feeder disconnector and closed circuitbreaker downstream (see fig. 9.1.1). Earthing can also be effected
similarly via a switch disconnector panel with cable termination.

This section outlines the ways in which the busbar can be earthed.
The details of these operations can be found in the relevant instruction manuals.

9.2 Earthing the busbar by


means of a sectionaliser
and riser or bus coupler

9.1 Earthing the busbar by


means of an earthing set
With the feeder earthed, the cable connectors can be fitted with
an earthing set connected to the main earthing bar. The earthing sets considered suitable by the cable connector manufacturer
for the type of connector concerned are to be used. The busbar

Fig. 9.1.1: Busbar earthing by earthing set

Earthing set

Fig. 9.2.1: Busbar earthing by sectionaliser and riser

58 | Technical catalogue ZX0.2 TK 503 - Revision 01

Earthing is effected by the three position disconnector and the


circuit-breaker in a bus sectionaliser (see fig. 9.2.1).

10. Building planning


10.1 Site requirements
The switchgear can be installed

Ventilation of the switchroom

on a concrete floor, or
on a raised false floor.

Lateral ventilation of the switchroom is recommended.


Climate

Concrete floor
If the switchgear installation consists of several panel blocks, a
foundation frame set into the floor topping is required. The foundation frame ensures that the necessary evenness and straightness tolerances at the base of the switchgear system are maintained. The foundation frame can be supplied by ABB. If the
switchgear installation consists of a single panel block (without
plug-in busbar connections), no foundation frame is required.
Floor openings for power cables can be configured as cutouts for
each panel, as continuous cutouts (one each for power and control cables) or as drill holes. The floor openings are to be free from
eddy currents (drill holes for power cables three phase without
ridges in between).
False floor
Below the switchgear, the supporting sections of the raised floor
serve as a base for the panels. A foundation frame is not as a rule
necessary. The floor panels must be fixed to the supporting frame
of the false floor.

The specified temperature conditions according to IEC 62271-1


(>-5C) are to be ensured by room heaters if necessary.
Service conditions
The service conditions according to IEC 62271-1 for indoor
switchgear are to be ensured.
The ambient air is not significantly polluted by dust, smoke, corrosive and/or flammable gases, vapours or salt.
The conditions of humidity are as follows:
the average value of the relative humidity, measures over a
period of 24 h, does not exceed 95 %:
the average value of the water vapour pressure, over a
period of 24 h, does not exceed 2.2 kPa;
the average value of the relative humidity, over a period of
one month, does not exceed 90 %;
the average value of the water vapour pressure, over a
period of one month , does not exceed 1,8 kPa.

Pressure stress on the switchroom


With pressure relief inside the switchroom or to the cable basement, a pressure rise in the room can be expected in the highly
unlikely event of an internal arc fault. This is to be taken into account when planning the building. The pressure rise can be calculated by ABB on request. Pressure relief openings in the switchroom may be necessary.

Heaters are to be fitted in the low voltage compartments to preclude condensation phenomena (outside the gas-tight enclosures)
resulting from major rapid temperature fluctuations and corresponding humidity. The specified temperature conditions according to IEC 62271-1 (> -5 C) are also to be ensured by means of
room heating.

Technical catalogue ZX0.2 TK 503 - Revision 01 | 59

10.2 Space required


Fig. 10.2.1: Wall mounting installation, example of a single row installation (Top view, dimensions in mm)

50 1)

> 800 3)

2)

5)

> 100

> 1500

1330

50 1)

> 800 6)

Fig. 10.2.2: Wall mounting installation, example of a double row installation (Top view, dimensions in mm)

50 1)

2)

> 1500

5)

1330

> 1200 4)

1330

50 1)

> 100

1)
2)
3)



4)




5)
6)

> 800 6)

End cover
Recommended minimum door height: 2550 mm
Conditions for a minimum clearance of 800 mm in front of the system: 1. The low voltage compartment doors close in the direction of the emergency exit. 2. No door holders
are used, (see also IEC 61936).
Note: A minimum clearance of 1500 mm in front of the panel is required for installation of a panel in an existing row.
Conditions for a minimum clearance of 1200 mm between the system blocks: 1 The low voltage compartment doors close in the direction of the emergency exit. 2. No door
holders are used, (see also IEC 61936).
A minimum clearance of 1500 mm between the system blocks is required for installation of panels in an existing row.
If escape routes are provided at both ends of the system, we recommend a minimum clearance of 1700 mm between the system blocks.
Observe IEC 61936 with regard to the necessity to provide escape routes and emergency exits at both ends of the system when the system exceeds a certain length.
The width of the escape route can be reduced to 500 mm with a corresponding reduction in the IAC qualification as per table 10.3.1. IEC 62271-200 provides for a distance of
300 mm between the indicators and the panel for arc fault testing. According to the standard, the frame with the mountings for the indicators has a depth of 500 mm, resulting
in a minimum distance of 800 mm between the panels and the wall. With smaller distances, therefore, no statements can be made on accessibility
at the
side of the switchgear system. A minimum escape route width of 500 mm is recommended in IEC 61936.

60 | Technical catalogue ZX0.2 TK 503 - Revision 01

Fig. 10.2.3: Free-standing installation, example of a single row installation (Top view, dimensions in mm)

50 1)

> 800 3)

2)
5)

Operator side

> 1500

1330

> 800 6)

50 1)

> 800 6)

> 100 5)

Fig. 10.2.4: Free-standing installation, example of a double row installation (Top view, dimensions in mm)

50 1)

2)

> 1500

Operator side

5)

> 800 6)

1330

> 1200 4)

1330

> 800 6)

50 1)

> 100 5)

1)
2)
3)



4)




5)
6)

> 800 6)

End cover
Recommended minimum door height: 2550 mm
Conditions for a minimum clearance of 800 mm in front of the system: 1. The low voltage compartment doors close in the direction of the emergency exit. 2. No door holders
are used, (see also IEC 61936).
Note: A minimum clearance of 1500 mm in front of the panel is required for installation of a panel in an existing row.
Conditions for a minimum clearance of 1200 mm between the system blocks: 1 The low voltage compartment doors close in the direction of the emergency exit. 2. No door
holders are used, (see also IEC 61936).
A minimum clearance of 1500 mm between the system blocks is required for installation of panels in an existing row.
If escape routes are provided at both ends of the system, we recommend a minimum clearance of 1700 mm between the system blocks.
Observe IEC 61936 with regard to the necessity to provide escape routes and emergency exits at both ends of the system when the system exceeds a certain length.
The width of the escape route can be reduced to 500 mm with a corresponding reduction in the IAC qualification as per table 10.3.1. IEC 62271-200) provides for a distance of
300 mm between the indicators and the panel for arc fault testing. According to the standard, the frame with the mountings for the indicators has a
depth
of 500 mm, resulting in a minimum distance of 800 mm between the panels and the wall. With smaller distances, therefore, no statements can be made on accessibility
at the side of the switchgear system. A minimum escape route width of 500 mm is recommended in IEC 61936.

Technical catalogue ZX0.2 TK 503 - Revision 01 | 61

10.3 Minimum aisle widths and emergency exits


Table 10.3.1: IAC qualification on reduction of escape route widths to the minimum of 500 mm
Escape route width at the side

Escape route width behind the

of the switchgear system

switchgear system

[mm]

[mm]

Wall mounting installation

Free standing installation

IAC - classification

> 800

> 500

AFL
AF

> 800

> 800

AFLR

> 800

> 500

AFL

> 500

> 800

AFR

> 500

> 500

AF

Table 10.3.2: Recommended aisle widths (in front of the system)


Aisle width in front of the switchgear system, single row installation

Aisle width between the system blocks, two row installation

[mm]

[mm]

> 800

> 1200

(without door holders, doors close in the direction of the emergency exit)

(without door holders, doors close in the direction of the emergency exit)

> 1100

> 1500

(escape route width 500 mm with doors open)

(for installation of panels in an existing row)

> 1500

> 1700

(for installation of panels in an existing row)

(escape route width 500 mm with doors open on both sides)

Aisles shall be at least 800 mm wide. ... Space for evacuation


shall always be at least 500 mm, even when removable parts or
open doors, which are blocked in the direction of escape, intrude
into the escape routes. ... Exits shall be arranged so that the
length of the escape route within the room ... does not exceed
20 m. ... If an operating aisle does not exceed 10 m, one exit
is enough. An exit or emergency possibilities shall be provided at
both ends of the escape route if its length exceeds 10 m. ... The
minimum height of an emergency door [possibly the 2nd door] shall
be 2 000 mm [clear height] and the minimum clear opening 750
mm. 1)

10.4 Minimum room heights


Fulfilment of the IAC qualification requires a clear ceiling height of
min. 3000 mm for the switchgear room.

1)

IEC 61936

62 | Technical catalogue ZX0.2 TK 503 - Revision 01

10.5 Concrete floor



10.5.1 Floor openings
Fig. 10.5.1.2: Openings for cables, panel width 1200 mm

Fig. 10.5.1.1: Openings for cables, panel width 600 mm

450
75

75

450

Opening for
cables

1310 (1330) 1)

1310 (1330) 1)

Outlines of
the panel

50

50

500
600

1100
1200

Fig. 10.5.1.3: Floor openings for entry of secondary cables from below (optional) in sectionaliser
and riser panels (panel width 600 mm or 900 mm) and in the transfer panel (panel width 600 mm)

30

75

985
90

1310 (1330) 1)

140

510

50

180
900 (600)

1)
2)

Wallmounting: 1310 mm, free-standing installation: 1330 m


The opening is only necessary for cooling in sectionaliser panels for currents > 1600 A to 2500 A (panel width 900 mm). No opening is to be provided for the
corresponding riser panel.

Technical catalogue ZX0.2 TK 503 - Revision 01 | 63

10.5.2 Foundation frames


Standard foundation frames of 600 mm width are available for all
panel types (panel widths 600 mm, 900 mm and 1200 mm).

When installing the foundation frame at site, observe the form and
position tolerances stated in the order documents.

Two frames are to be provided for panels of width 1200 mm, and
three frames for panel width 2 x 900 mm (sectionaliser and riser >
1250 A).
The foundation frames are fastened to the concrete floor and embedded in the floor topping.

1083

1310 (1330)

Fig. 10.5.2.2: Foundation frame for panel width 1200mm

50

500

450
50

1100
1200

600

Fig. 10.5.2.3: Foundation frame

64 | Technical catalogue ZX0.2 TK 503 - Revision 01

75

27

75

27

450

1083

1310 (1330)

Fig. 10.5.2.1: Foundation frame for panel width 600mm

10.6 False floor


Fig. 10.6.1 is an aid to planning of the false floor.
The floor plates of the panels have L13 x 14 slots for fastening to the
frame sections. Provide M8 threads or bore holes for screws M8 in
the frame sections at the positions of the slots.

Fig. 10.6.1: False floor, planning aid

Panel width 1200 mm

300

max. 100

300

Outlines of
the panel

600

600

47

re

bo

ho

le

13

Detail A
14

or

150

max. 75

660

1330 (1310)

383

3 panels with a width of 600 mm


or 2 panels with a width of 900 mm

L13 x 14 slot in the floor plate of the panel


M8 thread or bore hole for screw M8 in the frame section
of the false floor

Technical catalogue ZX0.2 TK 503 - Revision 01 | 65

10.7 Earthing of the switchgear

10.7.1


Design of earthing
systems with regard
to touch voltage
and thermal stress

Limitation of the interference level within the switchgear system is


supported by suitable measures as listed below.
Separate laying of power, signal and control cables.
Suitable screening and earthing of the equipment.
Potential isolation: Galvanic isolation of the signal circuits
at the system boundary.

The earthing system for the station building and the earthing system for the switchgear are to be designed in accordance with
IEC61936.
The switchgear system is to be fitted with a continuous copper
earthing bar with a cross-section of 240 mm2 (ECuF30, 30 mm x
10 mm). The connection of this earthing bar to the station earthing
system is to be effected in accordance with the above standards.
The earthing system described in this section does not represent
EMC-compliant earthing of the switchgear (EMC = electromagnetic compatibility). EMC-compliant earthing is achieved by additional
measures which are explained in the following section.

10.7.2 EMC-compliant earth ing of the switchgear


Electromagnetic compatibility (EMC) is to be planned from quantitative points of view. The interface requirements regarding emissions and immunity are to be stipulated for delimited areas (EMC
zones). In the best possible case, these requirements can be met
directly, i.e. with no additional action. If, however, the requirements
are not fulfilled, additional action is necessary, and is in principle to
be applied in the order of the interference source, coupling path
and interference sink. It is useful to assess the hierarchical elements of a system, such as the complete plant equipment, room,
cubicle assembly, rack assembly, circuit board, circuit section and
component, with respect to their electromagnetic environments
on the various levels.
The design of the earthing system for the switchgear is of decisive importance for the EMC of the secondary equipment in the
switchgear installation. Information on this can be found in IEC
61936 standard, section 9.5. According to IEC 62271-1, the
secondary equipment in the switchgear system must satisfy the
requirements of section 6.9. It is then ensured that interference
which is permissible under the terms of the standard does not
impair the immunity to noise of the secondary equipment (see also
Annex J of the standard IEC 62271-1). The measures are to be
implemented in addition to the earthing system described in section 10.7.1.

66 | Technical catalogue ZX0.2 TK 503 - Revision 01

Equipotential bonding: For low-impedance connection of


system or circuit sections between which the potential difference should be as low as possible.
The earthing conductors of the cable screens should always be routed to the earthing bar in the shortest possible
distance.
The lengths of the external control cables should not
exceed 200 m. With greater lengths, use for example interposing relays or optical fibre cables.

10.7.3 Recommendations on configuration of the


switchgear earthing

We recommend that the switchgear be earthed as shown in figures 10.7.3.1 and 10.7.3.2.
A ring consisting of 80 mm x 5 mm copper strip is to be located
beneath the switchgear and connected at several points with a
maximum spacing of 5 m to the earthing system of the building.
The foundation frame, the main earthing bar in the panels and the

earthing bar in the low voltage compartments are to be connected at multiple points to the ring located beneath the switchgear.
Details on the use of materials and the number of connections
can be found in figure 10.7.3.1 and 10.7.3.2. When planning the
switchgear earthing, please observe the notes in sections 10.7.1
und 10.7.2.

Fig. 10.7.3.1: Earthing recommendation, schematic diagram showing the concrete floor

10
A

3
5
8

4
A

11

1
2

Technical catalogue ZX0.2 TK 503 - Revision 01 | 67

Fig. 10.7.3.2: Earthing recommendation, plan view (section A-A of figure 10.7.3.1)

11

9
8

4
10

2
7

Legend to figures 10.7.3.1 and 10.7.3.2

1

2

3


4


5


6


7
8
9
10
11

Ring below the switchgear, material ECuF30, cross-section


80 mm x 5 mm
Several connections from (1) to the building earth at distances
of max. 5 m, material ECuF30, cross-section 80 mm x 5 mm
Short-circuit proof earthing of the switchgear in both end panels and
at least every third panel, material: ECuF30, cross-section: 30 mm x
10 mm
Low impedance earthing of the earthing bar in each low voltage
compartment, material: tinned copper braid, cross-section:
20 mmx3 mm, cross section: 20 mm x 3 mm
Low impedance earthing of the switchgear in each panel, material:
tinned copper braid, cross-section: 20 mm x 3 mm,
cross section: 20 mm x 3 mm
Earthing of the foundation frame, at least every third foundation
frame, material: galvanised steel strip, cross-section:
30 mm x 3.5 mm
Outline of the panel
Foundation frame
Main earthing bar
Earthing bar in the low voltage compartment
Earthing point on the foundation frame

10.8 Panel weights


Table 10.8.1: Panel weights
Panel variants
Feeder panel with three position
switch disconnector and fuses

Panel width

Rated normal current

Weight, max

[mm]

[A]

[kg]

600

Dependent on the fuses

600

Feeder panel

600

... 1250

900

Sectionaliser panel

600

... 1250

900
700

Riser panel

600

... 1250

Transfer panel

600

... 1000 (...1250)

800

Incomer panel

1200

... 2500

2200

Sectionaliser panel

900

... 2500

1600

Riser panel

900

... 2500

1200

68 | Technical catalogue ZX0.2 TK 503 - Revision 01

11 Non-standard operating conditions


Non-standard operating conditions may require special action.
Our design team will be pleased to submit and implement technical proposals to fulfil your requirements.
The non-standard operating conditions include in particular
Site altitudes > 1000 m above sea level (Higher site
altitude on request),
Higher ambient air temperature (maximum > 40 C and
maximum 24h average > 35 C) (see fig. 11.1),
Ambient air contaminated by dust, smoke, corrosive or
flammable gases or salt.

Seismic withstand capability


The panels are tested to IEEE Std. 693 1).
Climate
With high humidity and/or major rapid temperature fluctuations,
electrical heaters must be fitted in the low voltage compartments.

3500
3000
2500
2000

Current carrying capacity / A

Fig. 11.1: Relationship between ambient air temperature and current carrying capacity

1500
1000

Panels
Panels
Panels
Panels

with
with
with
with

Ir
Ir
Ir
Ir

=
=
=
=

2500 A at 40 C
2000 A at 40 C
1250 A at 40 C
630 A at 40 C

500
-5

10

15

20

25

30

35

40

45

50

55

Ambient air temperature / C

1)

Additional measures required (on request)

Technical catalogue ZX0.2 TK 503 - Revision 01 | 69

70 | Technical catalogue ZX0.2 TK 503 - Revision 01

For your notes

ABB AG
Calor Emag Medium Voltage Products

Germany
Ratingen Factory

For more information please contact:


ABB AG
Calor Emag Medium Voltage Products
Oberhausener Strasse 33
Petzower Strasse 8
40472 Ratingen
14542 Werder (Havel) OT Glindow
GERMANY
GERMANY
Phone: 02102 12-0
Fax:
02102 12-17 77
E-mail: powertech@de.abb.com
Internet: http://www.abb.de/mediumvoltage

Note:
We reserve the right to make technical changes
or modify the contents of this document without
prior notice. With regard to purchase orders, the
agreed particulars shall prevail. ABB AG does not
accept any responsibility whatsoever for potential errors or possible lack of information in this
document.
We reserve all rights in this document and in the
subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or
utilization of its contents - in whole or in parts - is
forbidden without prior written consent of ABB
AG.
Copyright 2010 ABB
All rights reserved

DEABB/PTPM 1VBA 680 603 P0102 Printed in Germany (08.10-0)

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