ABB ZX0, Product Manual

Page 1: ...Greener Smarter Safer More reliable PRODUCT MANUAL PrimeGear ZX0 Gas insulated medium voltage switchgear...

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Page 3: ...ispatch and storage 2 Installation of the switchgear at site 3 Commissioning 4 Operation 5 Test procedures 6 Service 7 Actions at the end of the service life 8 Overview of the busbar parts and assembl...

Page 4: ...the instructions in the documentation when performing any work on switching devices and switchgear Keep all documentation accessible to all persons concerned with installation operation and maintenanc...

Page 5: ...ident prevention regulations of the country in which the switchgear is operated and the safety data sheets for the used auxiliary materials IEC 60364 IEC 61936 DIN EN 50110 National technical accident...

Page 6: ...gear of series PrimeGear ZX0 This switchgear is notable for the following features Gas insulated with hermetically sealed pressure systems Solid insulated busbar Rated voltages up to 24 kV Up to 1250...

Page 7: ...tchgear Use only chlorine free cleansers for cleaning of the switchgear 1 0 Gas compartment 1 1 Circuit breaker pole 1 2 Circuit breaker operating mechanism 1 3 Outer cone bushing 1 5 Socket for capac...

Page 8: ...n the order documents If the panels are packaged they are mounted on a pallet and secured to prevent them from slipping The possible packaging methods are as follows No packaging Packaged in plastic s...

Page 9: ...n each case Attach suspension ropes of a sufficient load bearing capacity see section 11 Technical data for the panel weights and sufficient length to the lifting brackets using shackles thread the su...

Page 10: ...n Do not stack the panels Protect the transport units from damage The conditions for optimum intermediate storage without packaging or with basic packaging are as follows The storeroom must comply wit...

Page 11: ...ther DryAir AirPlus or SF6 Reference to table 11 1 In normal case no gas work is required during installation Please contact ABB if gas work is required in case of repairs See manual 1YHA000334 for de...

Page 12: ...r Evenness tolerance 1 mm m Straightness tolerance max 1 mm m but max 2 mm for the entire length Consult the order documents for the Fig 2 1 1 position of the foundation bars in the switchgear room If...

Page 13: ...count of any deviation in floor level in the direction of the foundation frames which are still to be laid Fasten the brackets 2 of the foundation frame to the floor using one knock in anchor 5 and on...

Page 14: ...ZX0 PRODUCT MANUAL 1 front Rear A A 6 7 1 2 1 5 3 55 5 3 2 4 Section A A Top of finished floor Floor topping Only in the case of reinforced foundation frames Fig 2 2 1 2 Installation of the floor fram...

Page 15: ...th a filling connector Fig 2 3 1 1 3 The filling connector is located in the operating mechanism bay behind the operator controls on the panel Each panel contains a gas density manometer and is locate...

Page 16: ...emove the covers from the cable termination compartments on all panels Fitting the stud bolts for the solid insulated busbars The stud bolts are part of the busbar supply Use original stud bolts only...

Page 17: ...uments supplied INSTALLATION OF THE SWITCHGEAR AT SITE 17 Fig 2 3 2 7 Fitting guide pins Fig 2 3 2 1 Fastening points for panels of various widths 2 3 2 Erection of the panels Set up the furthest pane...

Page 18: ...n the foundation frame section Fastening of the panel to the foundation frame T nut M 8 Fig 2 3 2 2 Fig 2 3 2 1b Remove the pressure relief plate from rear side of panel Fig 2 3 2 1c Fasten from here...

Page 19: ...on frame To fasten the panels use bars for each panel as a support screws M 10 x 50 and washers Fig 2 3 2 3 a Refer to Fig 2 3 2 3 b for the position and number of fastening elements 6 x Washer 10 6 x...

Page 20: ...nt 1 and 2 are for panel connection point 3 is for end cover connection Fit the coupling link at the rear of the panels Fasten the panel to the foundation frame as described above Measure the centre t...

Page 21: ...ensions for distance L busbars up to 1250 A Fig 2 3 2 5 Panel widths of the adjacent panels mm 450 450 450 500 500 450 450 600 600 450 500 500 500 600 600 500 450 600 BT BR 1 600 BT BR 1 450 600 600 B...

Page 22: ...w voltage compartment of the relevant adjacent panel Fit the control wiring plugs into the corresponding connector sockets as shown in the circuit diagram Connect the earthing bars of the panels toget...

Page 23: ...can as a rule be installed directly without cleaning If cleaning should nevertheless be necessary clean the components immediately before installation as follows Remove surplus or dirty grease from th...

Page 24: ...apters are to be earthed at the earthing lugs and additionally by means of earthing clamps Depending on the position and design of the bars the corresponding clamps as shown in Fig 2 3 4 3 1 are to be...

Page 25: ...common earthing point on the earthing plate Fig 2 3 4 3 2 and 2 3 4 3 3 using an M8 cheese head screw two dished washers 8 and an M8 hexagon nut Connect the earthing leads from earthing clamps B in t...

Page 26: ...th capacitive indicator for busbar is available as option in PrimeGear ZX0 The length of the cable is relevant to the function of the indicator The cable must therefore not be shortened or lengthened...

Page 27: ...cable to the clamping nut on top busbar bushing pressplate Fig 2 3 4 4 3 using a M4 x 8 screw a dished washer and a nut Connect the cables for the other two phases in the same way Check the function...

Page 28: ...ll different width panels Due to the weight of busbar current transformer during the assembly a lifting device is recommended There are four steps in total to install the busbar current transformer St...

Page 29: ...wo screws between phase support Step 4 During installation of the busbars guide the busbar through the aperture in the current transformer Avoid damage to the conductive layer of the busbar On complet...

Page 30: ...ates If the transformer is fitted with a terminal board wire this up as shown in the circuit diagram Slide the reducer rings over the transformer leads During assembly of the busbar cover or pressure...

Page 31: ...illustrations in this section refer to Bus Tie and Bus Riser panels with a width of 600 mm Assemble the busbars considering the assembly instruction delivered by the manufacturer The assembly instruct...

Page 32: ...ig 2 3 4 6 3 can be found in tables 2 3 2 1 and 2 3 2 2 Observe the dimensions in Fig 2 3 1 3 2 Insert the bars through the current transformers outside the panels In the further course of installatio...

Page 33: ...s fastening plate on the stud bolts provided The nuts on the stud bolts hold the transformer in position Fit the washers and nuts onto the stud bolts in the bushings see manufacturer s instruction Th...

Page 34: ...NUAL Fig 2 3 4 7 7 Completely assembled arrangement Fig 2 3 4 7 7 Install the further busbars in the manner described above Refit the main earthing bar and the connections between the main earthing ba...

Page 35: ...plugs from the relevant end or cross adapters The voltage transformer support is compatible for 12 24 kV VT for each width of panel But it just has one different material between different wide panel...

Page 36: ...ds as shown in Fig 2 3 4 7 3 Step 4 Screw the support roof with landing plate Only showing the exploded view and rendered picture of 600 mm wide support as reference Fig 2 3 4 7 4 Fig 2 3 4 7 3 6x Che...

Page 37: ...busbar adapters Only use intensive cleaner M X T 60 forte as the cleaning agent Clean the silicone surface with the cleaning agent and a soft clean non fraying cloth Only moisten the cloth slightly w...

Page 38: ...et installed of 500 mm wide panel Fig 2 3 4 7 7 Three phase voltage transformer set installed of 450 mm wide panel Connect the plugs on the instrument transformer secondary wiring with the connectors...

Page 39: ...hing leads to grounding points e g welding stud bolts of the encapsulation After the assembly of all sensors has been completed route the sensor cables to the low voltage compartment In case of busbar...

Page 40: ...busbar adapters Only use intensive cleaner M X T 60 forte as the cleaning agent Clean the silicone surface with the cleaning agent and a soft clean non fraying cloth Only moisten the cloth slightly wi...

Page 41: ...INSTALLATION OF THE SWITCHGEAR AT SITE 41 Fig 2 3 4 9 1 Mounting the voltage sensor Fig 2 3 4 9 2 Fully assembled voltage sensor set Fig 2 3 4 9 1 Fig 2 3 4 9 2...

Page 42: ...transformers in the cable compartment Fig 2 3 5 1 are supplied fitted and ready for operation In individual cases voltage transformers may also be supplied loose Please contact ABB for installation in...

Page 43: ...transformer with one secondary winding Wiring the voltage transformers The cable harnesses for wiring of the transformers are prepared at the works and wired to the low voltage compartment Wire the tr...

Page 44: ...which earthing method applies to your system Remove the earthing wire of the open delta windings from the terminal boards of the voltage transformers in accordance with the circuit diagrams Fig 2 3 5...

Page 45: ...ake the required resistance from the circuit diagram and connect the damping resistor according to the wiring diagram Attach the damping resistor according to the supplied assembly drawings Resistor F...

Page 46: ...gs onto the cables Connect the cable connectors to the cables in accordance with the manufacturer s instructions Checking the outer cones Check the outer cones for damage If there is damage to the out...

Page 47: ...le There are no active Insulating gas pressure alarms Visual examination and sample checks on installation in accordance with this document have been performed External control cables and wiring have...

Page 48: ...arthing of a busbar section using the Bus Tie and Bus Riser on the basis of an example switchgear installation In order to avoid maloperation the operating mechanisms are mechanically or electrically...

Page 49: ...of two busbar sections in operation Fig 4 1 4 Opening the circuit breakers in the feeder panels in the area of the busbar section to be earthed Feeder disconnected Earthing prepared Feeder earthed Ear...

Page 50: ...in the feeder panels in the area of the busbar section to be earthed Fig 4 1 6 Closing the disconnector in the Bus Tie Fig 4 1 7 Closing the earthing switch in the riser panel Fig 4 1 8 Closing the ci...

Page 51: ...e human machine interface of a control device are fitted Fig 4 1 2 1 Securing to prevent cancellation of earthing interlock in the deblocked condition Fig 4 1 2 1 Note on securing to prevent cancellat...

Page 52: ...change the switching condition of the circuit breaker press the mechanical OFF button 1 or the mechanical ON button 2 1 OFF button for circuit breaker 2 ON button for circuit breaker 3 Switch positio...

Page 53: ...state of the spring mechanism is indicated mechanically Fig 4 1 2 2 1 Fig 4 1 2 2 1 Manual charging of the stored energy spring Manual charging of the stored energy spring Pump the Lever for manually...

Page 54: ...g the selector lever in the direction for earthing switch operation is only possible when the disconnector is switched off and turning in the direction for disconnector operation is only possible when...

Page 55: ...switch Turn the selector lever 4 in Fig 4 1 3 1 3 clockwise and hold it fast Insert the operating lever through the released opening 7 onto the hexagon Earthing switch OFF ON Turn the operating lever...

Page 56: ...draw the operating lever Turn the selector lever into the vertical position without using force 4 1 3 3 Emergency operation of the three position disconnector motor operated mechanism If the mechanism...

Page 57: ...or voltage transformer or voltage sensor connected 1 mcb miniature circuit breaker 1 2 3 4 5 6 Fig 4 3 1 Fig 4 4 1 Fig 4 4 2 transformer isolating device is located in the cable termination compartmen...

Page 58: ...of the isolating device is ensured Secure the isolating device with a padlock Fig 4 4 3 Operation of the voltage transformer or voltage sensor isolating device Connecting the voltage transformers or...

Page 59: ...ig 5 1 6 Fig 5 1 3 Fig 5 1 1 LRM system with display unit Fig 5 1 2 KVDS system Fig 5 1 3 CAVIN system Fig 5 1 4 System Wega 1 2 C Fig 5 1 5 System Wega 2 2 C Fig 5 1 6 CVD system 5 1 1 LRM system Tes...

Page 60: ...with the manufacturer s directions for the test apparatus De earth the switchgear section to be tested before switching the test voltage on Perform the cable test in accordance with the manufacturer s...

Page 61: ...usion of testing Remove the high voltage testing sets Fit any surge arresters and voltage transformers required Close off free outer cones with insulating blanking plugs in accordance with the manufac...

Page 62: ...on tester or protection testing apparatus by network cables RJ45 interface see single line diagram in Fig 5 4 2 Changing of the existing wiring is not necessary Connect the test apparatus in accordanc...

Page 63: ...o not exceed the maximum values for the current testing plug see the section on accessories Dismantle the cover on the cable termination compartment of the relevant panel Fit the testing set in accord...

Page 64: ...r condition take appropriate action e g cleaning of the switchgear removal of corrosion or rectification of the cause of the moisture 6 2 Maintenance of the switching devices and their operating mecha...

Page 65: ...mantle the switchgear The switchgear is then professionally dismantled by ABB and the insulating gas which is normally reusable re moved before the switchgear is broken down into its remaining compone...

Page 66: ...kV P125 BB 1250 A 450 600 L 507 Ur 12 kV p125 BB 1250 A 500 500 L 482 Ur 12 kV P125 BB 1250 A 500 600 L 532 Ur 12 kV P125 BB 1250 A 600 600 L 582 Ur 12 kV P125 BB 1250 A BT BR 450 600 L 442 Ur 12 kV B...

Page 67: ...5 Across Adapter BT BR 1250 A Ur 12 kV Across Adapter 1250 A Ur 24 kV P125 Across Adapter 1250 A End Ur 24 kV P125 Across Adapter BT BR 1250 A Ur 24 kV Quantity 1 1 1 1 1 1 ABB part number 2RJA026392A...

Page 68: ...in 82 mm long for busbar installation busbar current 2500 A 1 Set of screwdrivers for slotted and crosshead screws sizes 1 to 3 1 Set of electrician s pliers end cutting nipper pointed pliers flat end...

Page 69: ...nlight cannot be ruled out please provide in your order for a reduced filling factor of 0 75 kg l for safety reasons 10 2 Auxiliary materials Assembly paste for silicone insulating parts Capacity 90 g...

Page 70: ...nsulation Minimal functional level for operation Rated voltage Rated power frequency withstand voltage Rated lightning impulse withstand voltage Rated normal current Rated short time withstand current...

Page 71: ...ent and the mechanism bay 7 Ambient air temperature maximum 8 Ambient air temperature maximum 24 hour averages 8 Ambient air temperature minimum Site altitude 9 Average humidity measured over 24 h 11...

Page 72: ...tion disconnector 2 4 Three position disconnector mechanism 3 0 Cable compartment 3 1 Cable connector 3 2 High voltage cable 3 3 Cable fastener 3 5 Main earthing bar 3 6 Floor plate 3 7 Surge arrester...

Page 73: ...MEMO 73 MEMO...

Page 74: ...a digital assistant that enables customers to connect to the broadest range of electrification solutions in one place Easy to find what you need by search Get all information about our products applic...

Page 75: ...TECHNICAL DATA 73...

Page 76: ...s subject to change without notice ABB Xiamen Switchgear Co Ltd No 885 FangShanXiEr Road Xiang an District Xiamen Fujian 361101 Tel 0592 602 6033 Fax 0592 603 0505 ABB China Customer Service Hot Line...