UniGear type ZVC

Medium voltage, arc-proof, air-insulated,

fused vacuum contactor switchgear

PowerIT

Installation, Operation and Maintenance Manual

 1
TABLE OF CONTENTS
1) INTRODUCTION................................................................................................................................................................2

2) STANDARDS AND SPECIFICATIONS .......................................................................................................................3

3) TYPE TEST REPORTS .....................................................................................................................................................3

4) TECHNICAL SPECIFICATION.....................................................................................................................................5
A) ELECTRICAL DATA .......................................................................................................................5
B) INTERNAL ARC W ITHSTAND...........................................................................................................5
C) ENVIRONMENTAL DATA ................................................................................................................6
5) DIMENSIONS & WEIGHTS ............................................................................................................................................7

6) RECEIPT AND INSPECTION.........................................................................................................................................8

7) STORAGE AND INSPECTION.......................................................................................................................................9

A) SHORT TERM STORAGE ( MAX FOUR WEEKS ONLY ).............................................................................9
B) LONG TERM STORAGE ( ONE MONTH TO SIX MONTHS ) .........................................................................9
8) BASIC STRUCTURE..........................................................................................................................................................9
A) COMPARTMENTS AND PARTITIONS ..................................................................................................9
B) INTERLOCKS AND LOCKING FACILITIES .......................................................................................... 12
9) INSTALLATION................................................................................................................................................................13
A) FOUNDATION ............................................................................................................................ 13
B) BOLTING PANELS TOGETHER....................................................................................................... 13
C) BUSBARS ................................................................................................................................. 13
D) POWER CABLE CONNECTION....................................................................................................... 14
E) CONTROL CABLE CONNECTION.................................................................................................... 15
F) EARTHING ................................................................................................................................ 15
G) CONNECTING TO U NIG EAR TYPE ZS1........................................................................................... 15
10) OPERATION...................................................................................................................................................................16
A) EARTH SWITCH.......................................................................................................................... 16
B) CONTACTOR............................................................................................................................. 16
C) RACKING.................................................................................................................................. 17
D) R EMOVAL OF CONTACTOR TRUCK ................................................................................................ 18
E) INSERTION OF C ONTACTOR TRUCK ............................................................................................... 18
F) FUSE O PERATION...................................................................................................................... 18
11) MAINTENANCE............................................................................................................................................................19
A) GENERAL................................................................................................................................. 19
B) INSPECTION AND SERVICING ........................................................................................................ 19
C) R EPAIRS /R EPLACEMENT ............................................................................................................. 21
i) Recommended Spare parts.........................................................................................................................................21
ii) Corrosion Repair .........................................................................................................................................................21
iii) Trip Coil Replacement................................................................................................................................................21
iv) Feeder Unit Replacement...........................................................................................................................................22
v) Fuse Replacement........................................................................................................................................................22
12) TROUBLESHOOTING................................................................................................................................................23

We reserve all rights to this publication. Misuse, particularly including duplication and the making
available of this manual – or extracts – to third parties is prohibited. The information supplied is without
liability. Subject to alteration.

© 2002 ABB Australia Pty Limited

 2
1) INTRODUCTION
UniGear type ZVC is three-phase, air-insulated indoor switchgear designed for
the operation, control and protection of motors and transformers at rated voltages
up to 7.2kV and rated current up to 400A. Other applications are possible and
should be referred to the manufacturer.

UniGear type ZVC’s combination of maximum accessibility at minimum

dimension and innovative integration of components offers a lightweight cubicle
with small footprint providing greater utilisation of switchroom space.

The UniGear type ZVC enclosure is constructed from 2mm thick zinc coated
steel sheet. The indoor, metalclad, IP4X design using vacuum switching
technology and epoxy resin enclosed conductors ensure long service life is
possible. An integral fault-making cable earthing switch is included and ALL
operations, ON-OFF-ISOLATION-EARTHING, are conducted with the front door
closed to ensure maximum personnel protection in the event of an internal arcing
fault and to avoid contamination and electrical deterioration of the switchgear.

UniGear type ZVC comprises a fixed portion for the connection of the main
busbars and the outgoing cables. It houses fixed isolating contacts, current
transformers and earthing switch. The low voltage control and protection
equipment is housed in a separate compartment mounted on top of the cubicle.
A withdrawable truck mounted fused vacuum contactor with primary and
secondary isolating contacts is located in the fixed portion and is moved between
the isolated and service positions by rotation of a racking screw by a special
handle provided with the switchboard. Widely available tag type fuses are used
as the short circuit protection device and two parallel fuses per phase can be
accommodated.

Figure 1 Illustrates the main features of a typical UniGear type ZVC cubicle.

A Busbar 1 Busbars
compartment
B Contactor and HRC 2 Withdrawable fused contactor’s
fuses compartment contacts

C Cable compartment 3 Vacuum contactor

D Low voltage 4 HRC fuses

compartment
5 Instrument current transformer

6 Earthing switch

7 Auxiliary voltage transformer

8 Cable connection terminals

Figure 1
 3

2) STANDARDS AND SPECIFICATIONS

UniGear type ZVC switchgear cubicles comply with standards and specifications
for factory assembled high voltage switchgear to IEC 60694 (AS 2650-1986).

Other relevant standards for components include:

IEC 60470 (AS1864-1976) Motor Starter & Contactor

IEC 60282-1 and 60644 Isolators (HV Fuses)
(AS1033.1-1990)
IEC 60129 (AS1306-1985) Earthing Switch
IEC 60529 (AS1939-1990) Degree of Protection
IP4X external closure
IP2X internal shutters &
partitions
IEC 60298 (AS2086-1995) Arc fault containment
IEC 60044-1 (AS1675-1986) Current transformers

Special requirements in compliance with regulations issued by local authorities

should be checked with the manufacturers.

3) TYPE TEST REPORTS

TYPE TEST STANDARD CLAUSE TEST VALUE AUTHORITY REPORT NO. RESULT

SHORT TIME & PEAK

WITHSTAND CURRENT TEST
- Main Bus System IEC60298 6.5.101 50kA/3 sec Pehla 0047Ra OK
- Earthswitch IEC60129 6.5 12.0kA/1 sec Pehla 0049Ra OK
- Earthing circuit IEC60298 6.5.102 12.0kA/1 sec Pehla 0049Ra OK

OVERLOAD CURRENT IEC60470 6.103 6kA/1 sec Pehla 0048Ra OK

WITHSTAND TEST IEC60470 6.103 2.7kA/30 sec Pehla 0048Ra OK

VERIFICATION OF MAKING &

BREAKING CAPACITIES
- Earthswitch making IEC60265 6.107.1 31.5kA Peak Pehla 0051Ra OK
- Fused contactor making IEC60470 6.102.4 4kA - C x100 Pehla 0001Ma OK
- Vacuum contactor breaking (max) IEC60470 6.104 6kA SACE LBRP5158 OK
- Fused contactor breaking (max) IEC60470 6.102.5 3.2kA - O x25 Pehla 0001Ma OK
- Fused contactor breaking (min) IEC60470 6.102.5 90A - O x25 Pehla 0001Ma OK

VERIFICATION OF
CO-ORDINATION TEST WITH
 4
TYPE TEST STANDARD CLAUSE TEST VALUE AUTHORITY REPORT NO. RESULT
SCPD'S - CLASS 'a' ASSESSMENT
- Test duty A - 100% break IEC60470 6.106 50kA Pehla 0052Ra OK
- Test duty B - 100% make IEC60470 6.106 50kA/125kAp Pehla 0134Ra OK
- Test duty C - take over point IEC60470 6.106 4.6kA / 7.2kV Pehla 0052Ra OK

VERIFICATION OF INTERNAL
ARCING FAULT
- Load side IEC60298 Appx AA 50kA Pehla 0135Ra OK
- Line side IEC60298 Appx AA 50kA Pehla 0135Ra OK
- Main bus IEC60298 Appx AA 50kA/0.5 sec Pehla 0135Ra OK

DIELECTRIC TESTS
- Partial discharge IEC60298 6.1.9 < 100 pc ABB T & D TR-168 UNDER
PREPARATION
- Lightning and switching IEC60298 6.1.6 40/60kV ABB TPT C1144 OK
impulse voltage test
- Power frequency withstand IEC60298 6.1.7 10kV/1 min ABB T & D TR-169 OK
voltage test - 10kV
- Power frequency withstand IEC60298 6.1.7 20kV/1 min ABB T & D TR-170 OK
voltage test - 20kV
- Power frequency withstand IEC60298 6.1.7 32kV/1 min ABB T & D TR-179 OK
voltage test - Special

POWER FREQUENCY
WITHSTAND VOLTAGE TEST
- Aux Circuit IEC60298 6.1.10 2kV/1 min ABB T & D TR-170 OK

TEMPERATURE RISE TEST IEC60298 6.3 TABLE 3 ABB T & D TR-175 OK

- Starter IEC 60694 (1/2/4/7AA) OK

TEMPERATURE RISE IEC60298 6.3 TABLE 3 Pehla

- Main busbars IEC 60694

MECHANICAL TESTS
- Earthswitch mechanical endurance IEC60129 6.102 1000 CO OPS. ABB T & D TR-176 OK
- Earthswitch & starter operation IEC60298 6.102 50 CO ABB T & D TR-181 OK
- Interlocks E/Sw/Starter IEC60298 6.102 25 Attempts ABB T & D TR-181 OK
- Fuse Striker Mechanism IEC60470 6.101.4 min/max energ ABB T & D TR-180 UNDER
PREPARATION

DEGREE OF PROTECTION
- External surface IEC60470 5.13 IP4X ABB T & D TR-177 OK

- Internal barriers & partitions IEC60470 5.13 IP2X ABB T & D TR-178 UNDER
PREPARATION
 5
4) TECHNICAL SPECIFICATION
a) Electrical Data

Rated Voltage kV 3.6 7.2

Rated Frequency kV 50/60 50/60
Rated Insulation Level kV 3.6/10/40 7.2/32/60
Maximum Busbar Current A 4000
Rated Current of Tee-Off A 400
Rated Peak Withstand kA 130
Current 3 sec
Rated Short Time Current 3 sec kA 50
Auxiliary Voltage:
- Fused Contactor Feeder Unit V 100-250V AC/DC
- Mechanically Latched Trip V 48-60V DC
100-130V DC
Coil
100-130V AC 220-250V AC
Earthing Switch Rated Making kA 31.5
Current
Earthing Switch Short Time kA 12.5
current 1 sec
HV Fuse type Tag type to BS2692-1986 type II
454mm centres maximum
CT rated secondary current A 1
Main Circuit Resistance:
- Bus risers to top spout µΩ 40 ± 10
bushing
- Cable tags to bottom spout µΩ 139 ± 15
bushing

b) Internal Arc Withstand

Accessibility type “A” restricted to authorised personnel only.

Minimum ceiling height1 ≥ 4.0 m
Internal Arc Fault rating is 40 kA/1 sec, and 50 kA/0.5 sec.

1
To use a lower ceiling height contact ABB for a solution
 6

c) Environmental Data

UniGear type ZVC is suitable for clean, dry indoor environments

complying with IEC 60694 (AS 1939) rated values.

Max ambient temperature +40°C

Max 24 hour average ambient temp +35°C
Minimum ambient temperature -5°C
Maximum average relative humidity
Over 24 hour period 95%
Over 1 month period 90%

The ambient air must not be significantly contaminated by dust, smoke,

corrosive or combustible gases, vapour or salt.

Altitude category does not exceed 1000m

Special performance and operating conditions to meet customer needs can

sometimes be provided. Refer to the manufacturer for details if equipment is to
be installed or operated in conditions exceeding the ratings above.

For technical data of individual components included as part of the switchgear

refer to the ABB Equipment list for the project, together with the associated
operating instructions.
 7

5) DIMENSIONS & WEIGHTS

Maximum Weight of Panel without Truck : 275 kg

Maximum Weight of Contactor Truck : 95 kg
Weight of Palette and Both End Covers : 90 kg

Total Maximum Weight of Panel and Truck : 460 kg

A – Busbar compartment
B – Contactor and HRC
fuses compartment
C – Cable compartment
D – Low voltage compartment
E – Gas exhaust duct

Width (mm) 325

Height (mm) 2200 2400 2595

LV Box Height (mm) 665 865 1060

Height with 2670

Arc duct (mm)

Depth (mm) 1124 1304 1304 1304 1504

Power Cable Bottom Entry Bottom Entry Bottom Entry Top Entry Top Entry
Entry Front Access Front Access Rear Access Rear Access Rear Access

Control Cable Bottom Entry Bottom Entry Bottom Entry Top Entry Top Entry
Entry Front Access Front Access Front Access Front Access Front Access

Arc Duct No Yes Yes/No No Yes

Floor plan
Power cable:

Bottom entry

Top entry
1504
1304
1304

1304
1124

Control Cable:

Bottom entry

Top entry
 8

6) RECEIPT AND INSPECTION

UniGear type ZVC is shipped in groups of one, two or three cubicles. The
withdrawable vacuum contactor is shipped inside the cubicle locked in the
service position. Loose items, usually comprising items such as service trolley
(for removal of contactor from cubicle), door key, operating handles, connecting
busbars, connecting hardware and inter-cubicle wiring, accessories, spare parts,
HV fuses are packed separately.

Each package in the shipment is secured to a pallet base and is clad to suit
airfreight, sea freight, road freights or to customer requirements as appropriate.

! Always lift from base using forks or slings.

2 Check all packages on the consignment note have been received. Check
the consignment for signs of rough handling and damage to packaging,
particularly to dessicant. Check the contents of each package against the
packing list and notify the manufacturer within seven days of any damage
or discrepancies.

Equipment should be left on a pallet until it is delivered to the switchroom and is

ready for placing in its final position.
 9

7) STORAGE AND INSPECTION

If storage is required after ex-works delivery the consignee has responsibility to

ensure the receipt and inspection procedures outlined in section 6 above are
completed.

a) Short term storage (max four weeks only)

Return the equipment to its original packaging and store in dry conditions
complying with manual section 4c. Make sure fresh packs of desiccant
drying agent are included in the packaging. Conduct weekly inspections to
ensure packing and storage conditions are unchanged.

! DO NOT STACK PACKAGES; STORE IN THE UPRIGHT POSITION.

b) Long term storage (one month to six months)

Unpack the equipment (Do NOT remove from pallet) and store in a dry,
well ventilated room with conditions complying to manual section 4c.
Store the cubicles in an upright position

! DO NOT STACK PACKAGES; STORE IN THE UPRIGHT POSITION.

Loosely cover cubicles with plastic sheeting to prevent contamination.

Adequate air circulation must be maintained to prevent corrosion. Perform
regular (weekly) check for any condensation.

8) BASIC STRUCTURE

The enclosure and partitions are manufactured from zinc coated sheet steel to
provide the highest degree of protection against corrosion. In addition, the front
doors and the rear cover have a powder coat stoving enamel finish ABB standard
colour RAL 7035 light grey 50% gloss. Other colours are available as special
order options.

a) Compartments and Partitions

(Refer figure 3)

UniGear type ZVC component layout is categorised as metal clad

compartmented switchgear according to the definitions of IEC 60298. The
external enclosure and the internal partitions between compartments are
earthed metal barriers providing absolute protection of personnel against
contact with high voltage conductors.
 10

The cubicle comprises three high voltage compartments. On top of each

compartment a pressure relief flap (1) is fitted to release internal
overpressure in the event of an arcing fault. A separate compartment for
low voltage equipment (2) is fitted on top of the cubicle at the front.
External wiring to this compartment is housed inside the front of the
cubicle in earthed metal wiring ducts (3).

Flat copper busbars are supported on the epoxy resin encapsulated riser
conductors (4). These are located in the busbar compartment (5). No
additional support is necessary to withstand the rated short circuit current
of the busbar system. Unit busbar lengths are factory installed between
cubicles in a shipping suite and are joined at the riser conductors.

The cable compartment (6) is arranged for front access terminating cables
entering through the glandplates in the bottom of the panel in the basic
version. Current transformers are installed on spout bushings (7) which
are integrated into the bus riser moulding. Cable connection tags (8) and
earthing switch contacts (9) are segregated by epoxy resin phase barriers.
The earthing switch (10) is manually operated using its handle inserted in
its mechanism (11) at the front of the cubicle.

The contactor compartment (12) includes guide rails for the withdrawable
fused contactor (13). The withdrawable contactor truck is locked to the
cubicle with bar operated by a bit key (14) and moves between isolated
and service position on racking screw (15). Automatic metal shutters (16)
cover the bus-side spout bushings (17) when the truck is in the isolated
position (optional cable side shutters can be provided). Self-aligning tulip
contacts in the spout bushings connect with disconnecting contacts (18)
when the truck is in the service position. Secondary contacts (19) are
automatically connected, via the plug on the rear of the truck, when the
truck is installed in the cubicle. Contactor operating mechanism (20) is
mounted on the truck chassis and is connected to the vacuum interrupters
(21) by a lever and pushrod assembly. The fixed contact of the interrupter
is rigidly connected to resin encapsulated conductors in fuse module (22)
while, the moving contact is connected by flexible conductor (23). Tag
type HRC fuses (24) complete the primary circuit. Control VT (25)
(optional) with primary fuses is mounted to the chassis and connect to
terminals on the load side of the main power fuses. A mechanical latched
operating mechanism (optional), is resettable by energising the trip coil
(26) or a manual pushbutton (27) fitted to the front of the panel.

A hinged, screw fixed steel door (28) provides access to the contactor and
cable compartments. All operations, ON-OFF, isolation, earthing and
emergency manual trip must be conducted with the door closed. All
indicators, such as ON-OFF, isolated or in-service, earthed and fuse
blown can be seen with the door closed through viewing windows (29).
 11

2 5

4
12
18
22
17
24
7
13
29 23 16
14 21 25
27
11 19
15 20 9
26
10
8
28
6
3

Figure 3

Legend: 19. Truck Secondary Contacts

1. Pressure Relief Flap 20. Contactor Operating Mechanism
2. Low Voltage Equipment Compartment 21. Vacuum Interrupters
3. Metal Wiring Ducts 22. Flexible Conductor Connecting Items 21&23
4. Riser Conductors 23. Fuse Module
5. Busbar Compartment 24. HRC HV Fuses
6. Cable Compartment 25. Control VT (optional)
7. Current Transformers 26. Trip coil (optional - latched)
8. Cable Connection Tags 27. Contactor Manual Trip Operator (where trip
9. Earth Switch Contacts coil fitted)
10. Earth Switch 28. Contactor and Cable Compartment Door
11. Earth Switch Operating Mechanism 29. Contactor and Earth Switch Viewing
12. Contactor Compartment Windows
13. Truck Guide Rails
14. Withdrawable Fused Contactor Truck
15. Racking Screw
16. Shutters
17. Spout Bushings
18. Disconnect Contacts
 12

b) Interlocks and Locking Facilities

A series of interlocks is provided to protect personnel, the switchgear
itself and, to prevent dangerous situations and maloperation that may
otherwise lead to serious consequences. The individual effective
interlocks are as follows:

• The truck can only be moved from the test/isolated position into the
service position (and vice versa) when the fused contactor and
earthing switch are open and the door is closed.

• The fused contactor can only be closed when the truck is fully
engaged in the test or service position.

• The door cannot be opened when the truck is in the service

position.

• For a mechanically latched fused contactor, with the truck in the test
position, and without control voltage, it is only possible to open (not
close) it manually.

• With the truck in the test/isolated position the voltage transformer

secondary is isolated.

• The earthing switch can only be closed when the truck is in the
test/isolated position.

• With the earthing switch closed, the truck cannot be moved from the
test/isolated position into the service position.

• Details of any additional interlocks, e.g. in connection with a

blocking magnet on the truck and/or earthing switch operating
mechanism, can be found in the project specific documents.

• Interlock plates (optional), can be fitted so that only trucks of a

certain type (eg. fuse rating or contactor type) are able to be
inserted into matching panels.

The switchgear is also provided with facilities for padlocking the

contactor/cable compartment door, the contactor truck racking shaft
and the earth-switch operating shaft.
 13

9) INSTALLATION
a) Foundation
Lay switchroom floor with a tolerance of ±1mm per metre in all
directions under the switchboard including a metre in front of the
switchboard with a maximum ±3mm over the entire switchboard length.
To achieve these tight tolerances or to meet seismic requirements (if
applicable) we recommend using foundation frames. ABB can provide
foundation frames if required.

b) Bolting Panels Together

Precisely lineup shipping sections as per the project specific General
Arrangement drawing so that each section is not more than 2mm off in
all planes.

Bolt together using M8x16 (7 off), M10x16 (12 off) and M10x20 (6 off)
hex-head bolts (tensile 8.8) and Belleville washers to a tightening
torque of 25 Nm for M8 and 50 Nm for M10. Quantities and lengths of
bolts may vary for non-standard designs.

c) Busbars
Clean any greasy or sticky substance off the risers and busbars with a
soft dry cloth. Access to the buswork is gained by removing the
pressure relief flaps above the busbar compartment.

Install busbars supplied loose across each shipping section starting at

bottom bar and then continue to work upwards (figure 4). Remember to
fit the joining boots (if provided). Use M10 socket head bolts (tensile
8.8), nuts, spacers (when required) and two Belleville washers per bolt
to a tightening torque of 50 Nm.

Joining boot
(optional)

Busbar insulation
(optional)

Busbar connection
(left side)

Busbar connection
(right side)

Bus riser module

Typical Busbar and Riser

module connections (3150A) Spacer

Figure 4
 14

Replace pressure relief flaps ensuring the nylon bolts are used for
fixing the rear of the pressure relief flap only.

d) Power Cable Connection

Remove the contactor truck from the panel and remove the partition
plate between the contactor and cable compartments for easier access
by unscrewing the four socket head bolts (indicated by the red circles
on figure 5). Remove the cable gland plates from the bottom of the
cubicle and terminate the cables on the cable module using an
appropriate HV cable termination kit. Cut gland plates to fit around the
cable and refit to cubicle base. Connect the cable earth and seal any
remaining gaps with elastic sealing compound to prevent ingress of dirt
or vermin.

Cable
Termination
Module

Partition plate

Cable Screen

Gland plate

Earth bar

With partition Without partition

plate fitted plate fitted

Figure 5
 15

e) Control Cable Connection

Feed control cables through the small
entry gland (figure 6), which is in the
front left hand side of the cubicle base
plate. Run the cables up the vertical
duct, through the grommets in the base
of the instrument compartment into the
terminals nominated by the control
schematic.
Provision for top control cable entry into
the instrument compartment is optional.

f) Earthing
Join the inter-panel earthing bar located
in the front of the cable compartment
(figure 6) between each shipping
Control Cable Earthing
section with the connecting link supplied Duct Bar
loose. Connect one point of this inter-
panel earthing bar with the substation Figure 6
earth.

g) Connecting to UniGear type ZS1

Where a UniGear type ZS1 panel is
bolted to a UniGear type ZVC UniGear type
ZS1 cover
panel, special transition busbars plates
and earthing bars will be supplied
loose. Bolt panels together as
described previously. Quantities
and lengths of bolts may vary for
designs other than this basic one.
Three additional cover plates (figure
7) required to seal the UniGear type
ZS1 bus compartment are supplied
for each UniGear type ZS1 to
UniGear type ZVC transition.

For bolting alongside other designs

of switchgear, contact ABB for the
feasibility of preparing the design.

Figure 7
 16

10) OPERATION
a) Earth switch
Ensure the withdrawable contactor truck is in
the test position or removed from the panel.
Remove the padlock from the blocking plate
covering the earth switch operating screw. To
operate the earth switch, ensure that the
contactor/cable compartment door is
closed, insert the operation handle in the
earth switch operating hole and turn in the
direction indicated on the label (figure 8). The
earth switch status is shown in the label
window.

b) Contactor
Switching of the contactor is carried out via
the control features fitted to the instrument
compartment. The contactor status is
indicated on the front of the contactor (figure
9) and can be viewed through the top viewing
window. Switching operations can only be
carried out with the withdrawable contactor in
service or in the test position. We highly
recommend that all switching be done
with the front door closed.

For a mechanically latched contactor

(optional), manual emergency tripping is
achieved by using the special rod provided to
operate the emergency manual trip operator
(figure 10) fitted on the withdrawable Figures 8, 9 & 10
contactor.
 17

c) Racking
To rack the contactor truck from test position
into service ensure the following:
• The contactor truck is locked using the bit
key provided.
• The contactor compartment door is closed
• The earth switch is off
• The contactor is off
• The padlock is removed from the blocking
plate covering the racking hole.

Insert the racking handle in the racking

hole and rotate the handle 14 revolutions
clockwise (figure 11). While in service the
contactor compartment door cannot be
opened and the earth switch cannot be
closed.

To rack the contactor truck out of service Figure 11

into its test position please ensure the
contactor is off. Insert the racking handle in
the racking hole and rotate the handle 14
revolutions anti-clockwise (figure 11).

Where a voltage transformer (installed on the

contactor truck) powers the control circuit,
please note that this supply is active only
when the contactor truck is in service. If
supply is required to this circuit under other
conditions we recommend connecting a
temporary test supply via terminals in the
instrument compartment

A truck position indication label (figure 12) is

visible through the top viewing glass. Please
note that the contactor cannot be closed while
Figure 12
the truck is in an intermediate position
indicated by the yellow position indication.
 18

d) Removal of Contactor Truck

Ensure that the contactor truck is in test
position, and the earth switch is closed. Open
the contactor compartment door and move a
contactor trolley in front of the panel ensuring
that its hinged part is locked into the holes in
the partition plate under the contactor truck.
Unlock the contactor truck using a bit key
(figure 13) and pull the contactor truck onto
the trolley using the handle on the front of the
contactor truck. Lock the contactor truck
onto the trolley and unhinge the trolley from
the partition plate. The trolley and the
contactor truck can now be moved away from Figure 13
the panel.

e) Insertion of Contactor Truck

Open the contactor compartment door and
move a contactor truck and trolley in front of
the panel ensuring that its hinged part is
locked into the holes in the partition plate
under the contactor truck. Unlock the
contactor truck using a bit key (figure 13) and
push the contactor off the trolley into the
panel. Lock the contactor truck into the panel,
unhinge the trolley from the partition plate and
remove the trolley.

f) Fuse Operation
When any fuses are healthy the fuse condition
indication label (figure 14) is green. On fuse operation
this label changes to “BLOWN” on a red background.
An adjacent label (figure 15 – typical fuse rating) fitted
on the truck shows the fuse rating.

Figures 14 & 15
 19

11) MAINTENANCE
a) General
Maintenance serves to preserve trouble-free operation and achieve the
longest possible working life of the switchgear. It comprises the
following closely related activities:

Inspection: Determination of the actual condition

Servicing: Measures to preserve the specified condition
Repairs/Replacement: Measures to re-establish the specified
condition.

Note: Maintenance work must be carried out in a careful manner by

trained personnel familiar with the characteristics of the individual
switchgear installation, in accordance with all relevant safety regulations
to AS/IEC and of other technical and statutory authorities, together with
other overriding instructions. It is recommended that ABB service
personnel are called in to perform servicing and repair work, and for
some of the work described in greater detail, this is essential.

The inspection and servicing intervals for some of the

equipment/components (e.g. parts subject to wear) are determined by
fixed criteria such as switching frequency, length of service and number
of short-circuit breaking operations. For other parts, the length of the
intervals may depend, for example, on the different modes of operation
in individual cases, the degree of loading, and also environmental
influences (including pollution and corrosive atmosphere).

The equipment operating instructions must also be observed together

with this instruction manual in the individual cases concerned.

Further details can be taken from the technical documentation for the
switchgear installation (including, for example any agreed special
operating conditions).

b) Inspection and servicing

Inspection and servicing of the switchboard should be carried out
approximately every one to five years, depending on the operating
conditions and local environment. We recommend logging all
switchgear maintenance.

The inspection should include but not be limited to the following:

• Electrically isolate the area where work is to be carried out and
secure it against reconnection.
• Check the installation for abnormalities of any kind, dirt and the
effects of other environmental influences.
• Check the function of the switch equipment, the controls, interlocks,
protection, indicators and other devices.
• Check the surface condition of the isolating contact system for any
damage and retighten the fixing screws. The tulip contacts are
 20

fixed with hexagon socket head cap screws M10. After cleaning,
lightly grease the contact faces.
• Contact parts which are corroded or show signs of other damage or
overheating should be removed and replaced.
• Check all switchgear accessories and the auxiliary equipment such
as indicating lamps and the anti-condensation heaters.
• No external discharge may occur on the insulating material surfaces
of equipment at operating voltage. This can, for example, be
detected by characteristic noises, a clearly perceptible smell of
ozone, or visible glowing in the dark.

Basic servicing activities, and those which may be found necessary

during inspections, including the following:
• Carefully clean the unit, and in particular the insulating material
surfaces, when they are found to be dirty. Remove dry dust
deposits using a soft dry cloth. For more strongly adhering deposits,
e.g. sticky/greasy dust, use a cloth soaked in slightly alkaline
household cleaner. Wipe off with clean water and dry carefully.
Alternatively, use a safety cleaner with a fluoride hydrocarbon base
(check for compatibility with plastics and elastomers) Do not use
either trichlorethane, trichlorethylene, or carbon tetrachloride.
• Should external discharges occur as a result of condensation,
application of a thin silicone film on the surface concerned is often
effective as a temporary remedy. It is advisable to seek advice
from ABB on permanent solutions to such unusual problems.
• Close the contactor and measure the distance between the nut and
the washer on the moving end of the vacuum bottle. For new
vacuum bottles this gap is 1mm. When this gap is reduced to zero
please contact ABB to arrange refurbishing of the truck.
• Check that the bolt connections at the contact points in the busbar
system and the earth connections are tight, and that the racking
operation functions correctly.
• Replenish the grease on the contact points and mechanism of the
truck racking system. When lubrication is inadequate or missing,
thoroughly clean the areas concerned and regrease with Isoflex
Topas NB52.
• Replenish the grease on the sliding and bearing surfaces in the
cubicles – including the shutters, the interlock and guide systems,
the spindle mechanisms and the switch truck wheels. Where
necessary, thoroughly clean and regrease with Isoflex Topas NB52
lubricant.
 21

c) Repairs/Replacement
UniGear type ZVC is maintenance free switchgear. Please contact
ABB in the event of an equipment failure for replacements.

i) Recommended Spare parts

• Complete truck
• Trip coil
• Feeder unit
• Fuses

ii) Corrosion Repair

Repair work is to be carried out immediately after a defect has been
discovered. All rust is to be removed from damaged paintwork areas on
steel sheet and other steel parts mechanically. Lightly grind the
surrounding paint coat and carefully degrease the entire area. Then
immediately apply an anti-rust primer and, after an appropriate
hardening period, apply the topcoat. The total dry film thickness
should be approx. 60 um.

Only use suitable and compatible paint products. Topcoat is standard

colour light grey RAL 7035 or the relevant special colour.

iii) Trip Coil Replacement (figure 16)

Undo the three screws (1) attaching the microswitches’ mounting plate
to the truck traverse (on the left-hand side of the truck looking from the
front). Slide trip coil out of the trip operating mechanism (2), disconnect
its wires and remove the two screws holding it to the mounting plate
(3). Fit the new trip coil reversing the steps taken in the removal
process.

(2) Slide trip coil out

of operating mech.

Mounting
Plate

Trip Coil

(1) Remove these

(3) Remove these three screws
two screws Figure 16
 22

iv) Feeder Unit Replacement (figure 17)

Undo the two screws holding the feeder unit to the truck (on the right-
hand side of the truck looking from the front). Remove feeder unit from
the truck and disconnect its wires. Fit the new feeder unit reversing the
steps taken in the removal process.

Remove these
two screws

Feeder Unit

Figure 17

v) Fuse Replacement (figure 18)

If a fuse is blown we recommend that all fuses on the truck are
replaced. Unbolt the four screws connecting each fuse to the moulding
and remove each fuse. Replace with new fuses ensuring that the fuse’s
striker pin is nearest the front of the truck and the majority of the fuse is
facing into the moulding. Where two fuses per phase are used, the
fuses are fitted, in the same way, back-to-back.

Fuse striker to
this end (front)

Remove these
four screws (for
each fuse)

Fuses

25NM
PARALLEL FUSE

SINGLE FUSE

Figure 18
 23

12) TROUBLESHOOTING
a) Truck cannot enter cubicle.

i) Inhibited by current interlock

Select contactor truck of correct current rating.

ii) Racking mechanism not closed against the front of the truck.
Rotate racking handle to the anti-clockwise stop.

b) Truck cannot be locked in cubicle.

i) Earth switch open.

Close earth switch.

c) Truck cannot be racked in.

i) Handle not fully engaging the racking screw shaft.

Push firmly on the handle. Maintain positive forward pressure on the
handle during rotation.

ii) Truck locking bars not fully extended.

Rattle the truck in position and make sure the key spindle pops out at
the clockwise stop.

iii) Shutters padlocked.

Remove padlocks.

iv) Front door not completely closed.

Tighten door screws.

v) Earth switch is closed.

Open earth switch.

vi) Racking hole padlocked

Remove padlock.

d) Truck cannot be removed from cubicle.

i) Truck not fully in isolated/test position

Rotate racking handle to anti-clockwise stop.

ii) Truck locked in cubicle

Unlock truck.
 24

e) Vacuum contactor cannot be closed.

i) Racking operation not completed. (mechanical and electrical block)

Rotate handle fully to stop.

ii) Secondary control plug damaged.

Check secondary control plug for damage.

iii) No control supply available.

Check control fuses.

iv) Fuse blown auxiliary switch not reset.

v) Vacuum contactor auxiliary switches inoperative.

Check operation of auxiliary switches. Replace if necessary.

vi) Open circuit close coil.

Contact ABB to replace close coil.

f) Earth switch cannot be closed

i) Earth switch operating hole cover is padlocked.

Truck is not fully in isolated/test position.
Australia
? ??

Fax + 61 (0) 2 9602 2454

Phone +61 (0) 2 9821 0111
ABB Australia Pty Limited

Internet address: www.abb.com.au

Bapaume Road Moorebank 2170 NSW

Locked Bag 7315 Liverpool BC NSW 1871

25

The data and illustrations are not binding. We reserve the right to make changes in the course of technical development of the product.
UniGear type ZVC Installation, Operation and Maintenance Manual – 1VGA672002– Rev. B – Sep, 2003