Medium voltage products

UniGear ZS1
Medium voltage, arc-proof, air insulated
switchgear up to 24 kV insulated voltage
Index

1. UniGear ZS1
4 Description
8 IEC Classification
10 Design features
12 Fully type tested
14 Safety
18 Vacuum circuit-breaker
22 Gas circuit-breaker
24 Vacuum contactor
26 Switch-disconnector
28 Service trucks
30 UFES - Ultra fast earthing switch
32 Is-limiter fault-current limitation
34 Instrument transformers
36 Measurement sensors
40 Cable terminations
42 Distribution automation
56 Automatic transfer system
58 Typical units
60 Technical data

2. UniGear ZS1 - Double Busbar System

64 Description
66 Characteristics
68 Typical units
70 Technical data

3. Marine Applications
74 Description
76 Characteristics
78 Typical units
80 Technical data

UniGear ZS1 - Double Level

82 Description
84 Characteristics
86 Typical units
88 Technical data

3
1. UniGear ZS1
Description

• UniGear ZS1 is the ABB mainline global switchgear up to 24 kV, 4000 A,

50 kA and is produced close to you in all the six continents
• More than 150,000 panels produced and installed in more than 100
countries
• Each UniGear ZS1 panel consists of a single unit which can be equipped
with a circuit-breaker, contactor or switch-disconnector, as well as with all
the accessories available for conventional switchgear units

4
• Approved to be used for special applications such marine, seismic,
nuclear and type tested for IEC, GB/DL, GOST and CSA standards
• Units can be coupled together directly with the other products of the
UniGear family
• The switchgear does not require rear access for installation or
maintenance, all the operations are carried out from the front

Characteristics of Applications
UniGear ZS1
Range Utilities and Power Plants
•  Up to 12-17.5 kV, …4000 A, …50 kA • Power generation stations
•  Up to 24 kV, …3150 A, …31.5 kA • Substations
•  Standard IEC • Main and auxiliary switchgear
•  Highly customized versions
Industry
Safety
• Pulp and Paper
•  Fitted with safety interlocks
• Cement
•  Internal arc classification IAC AFLR
• Textiles
•  Classified LSC-2B, PM
• Food
•  CB racking with closed door
• Automotive
Flexibility • Quarrying
•  Wide applications • Petrochemical
•  Vacuum and SF6 circuit-breaker • Oil and gas
•  Vacuum contactor • Metallurgy
•  Switch-disconnector • Rolling mills
•  Traditional CT/VT and sensors • Mines
•  Wall and free-standing solution
Marine
Quality
• Drilling platforms
•  ABB quality
• Off-shore oil rigs
•  Large installed base
• Cruise ships
•  Installed in high number of countries
• Container ships
Design includes • Tankers
•  Protection and control • Cable ships
•  Earthing switch • Ferries
•  Ultra fast earthing switch
•  IS Limiter Transport
•  Integrated capacitor banks • Airports
•  Bay computer • Ports
• Railways
• Underground transport

Infrastructure
• Shopping malls
• Hospitals
• Large infrastructure and civil works

5
1. UniGear ZS1
Description

UniGear ZS1 is medium voltage switchgear with a metal

enclosure, suitable for indoor installations.
Metal partitions segregate the compartments from each
other and the live parts are air-insulated.
Since the switchgear is highly modular type, this
make simple selection of components required by any
application.
The functional units of the switchgear are guaranteed arc
proof in accordance with the IEC 62271-200 Standards,
appendix AA, class A accessibility, criteria 1 to 5.
All the installation, operation and maintenance operations
can be carried out from the front of the unit.
The switchgear and the earthing switches are operated
from the front with the door closed.
The switchgear can be back to wall installed.

Apparatus Normal operation conditions

The range of apparatus available for UniGear ZS1 switchgear The rated characteristics of the switchgear are guaranteed
is the most complete on the market, including: under the following ambient conditions:
•  withdrawable vacuum circuit-breakers with mechanical or • minimum ambient temperature: – 5 °C
magnetic actuator, • maximum ambient temperature: + 40 °C
•  withdrawable gas circuit-breakers, For different temperature ranges, please contact your ABB
•  withdrawable vacuum contactors with fuses, sales representative.
•  fixed version of switch-disconnectors. • Ambient humidity:
This makes it possible to offer a single switchgear-user - maximum 24 h average of relative humidity 95% RH
interface, with the same operational and maintenance - maximum 24 h average of water vapour pressure 2.2 kPa
procedures. - maximum monthly average of relative humidity 90% RH
The switchgear can be fitted with instrument transformers or - maximum monthly average of water vapour pressure 1.8 kPa
sensors for current and voltage measurement and protection •  The normal operational altitude is up to 1,000 m above sea
and any type of protection and control unit. level. For higher altitude applications, please contact your
ABB sales representative.
Switchgear, busbar configuration •  Presence of normal, non-corrosive and uncontaminated
atmosphere.
In the completion of the traditional functional units in single
level-single busbar arrangement, the UniGear ZS1 switchgear
platform is fitted with:
•  Double-level,
•  Compact units equipped with contactors with fuses,
•  Double Busbar Systems.
The use of these units allows extremely efficient use of
space. In addition UniGear ZS1 single busbar is possible to
combine to other members of UniGear family like:
•  UniGear 550,
•  UniGear 500R,
•  UniGear MCC.

6
Standards Degrees of protection
The switchgear and main apparatus contained in it comply The degrees of protection of the switchgear conform with IEC
with the following Standards: 60529 Standards.
• IEC 62271-1 for general purposes. UniGear ZS1 switchgear is normally supplied with the
• IEC 62271-200 for the switchgear. following standard degrees of protection:
• IEC 62271-102 for the earthing switch. • IP4X for the enclosure.
• IEC 62271-100 for the circuit-breakers. • IP2X for the partition between compartments.
• IEC 60071-2 for the insulation coordination. On request, the external housing can be supplied with a
• IEC 60470 for the contactors. higher degree of protection; in this case please contact your
• IEC 60265-1 for the switch-disconnectors. ABB sales representative.
• IEC 60529 for degree of protections.
The electrical characteristics of the switchboard can vary for
Colour of the external surfaces ambient conditions other than those described in the previous
section and also if a higher degree of protection is used.
RAL7035 - ligh grey (front doors and side sheets).
Other colours available on request.

IEC electrical characteristics of UniGear ZS1 - Single Busbar System

Rated voltage kV 7.2 12 17.5 24
Rated insulation voltage kV 7.2 12 17.5 24
Rated power frequency withstand voltage kV 1min 20 28 38 50
Rated lightning impulse withstand voltage kV 60 75 95 125
Rated frequency Hz 50/60 50/60 50/60 50/60
Rated short time withstand current kA 3 s …50 …50 …50 …31.5
Peak current kA …125 …125 …125 …80
Internal arc withstand current kA 1 s …50 …50 …50 …31.5
Main busbar rated current A ...4,000 ...4,000 ...4,000 ...3,150
630 630 630 630
1,250 1,250 1,250 1,250
1,600 1,600 1,600 1,600
Circuit-breaker rated current A
2,000 2,000 2,000 2,000
2,500 2,500 2,500 2,300
3,150 3,150 3,150 2,500
3,600 3,600 3,600 2,500
Circuit-breaker rated current with forced ventilation A
4,000 4,000 4,000 3,150
1) For other versions, please refer to the chapters no. 2 (Double Busbar System) and chapter no. 3 (Marine Applications).
2) GB/DL version is available with higher request in dielectric characteristics (42 kV) and short time withstand current (4 s).
3) The values indicated are valid for both vacuum and SF6 circuit-breaker.
4) For panel with contactor the rated current value is 400 A.
5) CSA version is available for 27,6 kV.

7
1. UniGear ZS1
IEC Classification

With the release of the IEC 62271-200 standard, new Partition Metallic - PM
definitions and classifications of Medium Voltage
With regard to the type of partitions or shutters between
switchgear have been introduced.
live parts and an open compartment, a distinction is made
One of the most significant changes is that classification
between two partition classes:
of switchgear into metal-enclosed, compartmented and
•  Class PM (Partition made of Metal);
cubicle types has been abandoned.
•  Class PI (Partition made of Insulating material).
The revision of switchgear classification rules has been
UniGear ZS1 is defined with PM partition class having the
based on the user’s point of view, in particular on aspects
segregation between compartments made of metallic sheets/
like service and maintenance of the switchgear, according
shutters.
to the requirements and expectations for proper
management, from installation to dismantling.
In this context, Loss of Service Continuity (LSC) has been Interlock-controlled accessible
selected as a fundamental parameter for the user. compartment
According to the IEC 62271-200, UniGear ZS1 switchgear
The front side of UniGear ZS1 is classified interlock-controlled
can be defined as follows.
because the access of the compartments containing high-
voltage parts, intended to be opened for normal operation
and/or normal maintenance, is controlled by the integral
Loss of service continuity - LSC-2B design of the switchgear.
The various LSC categories describe the possibility of
keeping other compartments and/or panels energized while Tool-based accessible compartment
a compartment in the main circuit is opened. The defined The rear part of the UniGear ZS1 is classified tool-based
categories are: because it is possible to open the compartment containing
•  LSC-1: The whole switchgear shall be put out of service for high-voltage parts, that may be opened, but not for normal
opening a main circuit compartment for normal operation operation and maintenance, only using a tool. Special
and/ornormal maintenance or for gaining access to any procedures are required.
switchgear components.
•  LSC-2A: The same as LSC-1 with the exception that the
main busbars and the functional units adjacent to the one
Internal arc classification – IAC AFLR
under maintenance can remain energized. UniGear ZS1 switchgear is classified IAC AFLR.
•  LSC-2B: The same as LSC-2A with the exception that the When the switchgear is specified and installed, some
cable compartment can remain energized. fundamental points must be taken into consideration:
UniGear ZS1 is classified as LSC-2B because the busbar, • Level of the fault current (16...50 kA).
circuit-breaker and cable compartments are physically and • Duration of the fault (0.1...1s).
electrically segregated.This is the category that defines the • Escape routes for the hot and toxic gases produced by
possibility of accessing the circuit-breaker compartment combustion of materials.
with the busbars and cables energized. In case of using the • Dimensions of the room, with special attention to the height.
fixed version of the switch-disconnector, the panel is defined Please consult your ABB representatives for detailed
LSC-2A because the cable and apparatus compartments are information.
not phisically segregated.

8
9
1. UniGear ZS1
Design features

Compartments Earthing switch

Each switchgear unit consists of three power compartments: Cable compartment can be fitted with an earthing switch for
circuit-breaker [A], busbars [B] and cables [C]; please refer to cable earthing.
figure 1. The same device can also be used to earth the busbar system
Each unit is fitted with a low voltage compartment [D], where (measurements and bus-tie units).
all the auxiliary instruments are housed. It can also be installed directly on the main busbar system in a
Arc-proof switchgear is normally provided with a duct [E] for dedicated compartment (busbar applications).
evacuation of the gases produced by an arc; different types of The earthing switch has short-circuit making capacity.
gas ducts are available. Control of the earthing switch is from the front of the
All the compartments are accessible from the front and switchgear with manual operation, and optionally, can also be
maintenance operations can correctly carried out with the motor operated.
switchgear installed up against a wall. The position of the earthing switch can be seen from the
The compartments are segregated from each other by front of the switchgear by means of a mechanical coupled
metallic partitions. indicator.

Main busbars Earthing busbar

The busbar compartment contains the main busbar system The earthing busbar is made of electrolytic copper and it runs
connected to the upper isolating contacts of the circuit- longitudinally throughout the switchgear, thereby guaranteeing
breaker by means of branch connections. maximum personnel and installation safety.
The main busbars are made of electrolytic copper.
For ratings up to 2500 A, the busbars are flat bars; while for Insulating bushings and shutters
currents between 3150 A and 4000 A, a special D-shape
The insulating bushings in the circuit-breaker compartment
busbar is used.
contain the contacts for connection of the circuit-breaker with
The busbars are covered with insulating material.
the busbar compartment and cable compartment respectively.
There is a single busbar compartment along the whole length
The insulating bushings are of single-pole type and are made
of the switchgear up to 31,5 kA, which optionally can be
of epoxy resin. The shutters are metallic and are activated
divided into compartments. For 40/50 kA these bushings are
automatically during movement of the circuit-breaker from the
a standard feature.
racked-out position to the operation position and vice versa.

Cable connections Cables

The cable compartment contains the branch system for
Single and three-core cables up to a maximum of twelve per
connection of the power cables to the lower contacts of the
phase can be used depending on the rated voltage, the unit
circuit-breaker.
dimensions and the cable cross section (please refer to page
The feeder connections are made of electrolytic copper and
40).
they are flat busbars for the whole range of currents.
The switchgear can be back to wall installed as the cables are
For 17.5 and 24 kV they are covered with insulating material.
easily accessible from the front.

10
Gas exhaust duct
The gas exhaust duct is positioned above the switchgear and
runs along its whole length.
Each power compartment is fitted with a flap on its top
surface. The pressure generated by the fault makes it open,
allowing the gas to pass into the duct.
Evacuation from the room of the hot gases and incandescent
particles produced by the internal arc must normally be
carried out. The UniGear ZS1 switchgear can be fitted with a
complete range of solutions to satisfy all requirements, either
in the case where evacuation is possible directly at the end
of the switchgear, or when solutions from the front or rear are
requested.
Some installations, such as marine applications, do not
allow evacuation of the gases to the outside of the room and
therefore a dedicated solution has been developed to
guarantee personnel safety and conformity with the
Standards, such as longitudinal evacuation chimneys.
Please contact your ABB sales representative for more
information.

Busbar applications
Each switchgear unit can optionally be fitted with an
accessory busbar application:
• current or voltage transformers for busbar measurements.
• busbar system earthing switch.
• top entry duct or cables to make interconnections between
different sections of switchgear.

Unit compartments
A Circuit-breaker compartment
B Busbar compartment
C Cable compartment
D Low voltage compartment
E Compact gas duct channel

Figure 1: UniGear ZS1 single level section view

11
1. UniGear ZS1
Fully type-tested

The UniGear ZS1 switchgear has undergone all the tests Description of IEC type tests
required by the international (IEC) Standards and local
Standards organizations (for example, the Chinese GB/DL
• Short-time and peak withstand current
and Russian GOST standards).
The test shows that the main power and the earthing circuits
In addition, the tests required by the main shipping
resist the stresses caused by the passage of the short-circuit
registers (LR, DNV, RINA, BV and GL) have been carried
current without any damage.
out for use of the switchgear in marine installations.
It should also be noted that both the earthing system of the
As indicated in these standards, the tests were carried
withdrawable circuit-breaker and the earthing busbar of the
out on the switchgear units considered most sensitive
switchgear are subjected to the test.
to the effects of the tests and therefore the results were
The mechanical and electrical properties of the main busbar
extended across the whole range.
system and of the top and bottom branch connections remain
Each switchgear unit is subjected to routine tests in the
unchanged even in the case of a short-circuit.
factory before delivery.
These tests are intended to provide a functional check of
the switchgear based on the specific characteristics of • Temperature rise
each installation. The temperature rise test is carried out at the rated current
value of the switchgear unit and shows that the temperature
does not become excessive in any part of the switchgear unit.
During the test, both the switchgear and the circuit-breaker or
IEC type tests contactor it may be fitted with are checked.
•  Short-time and peak withstand current
•  Temperature rise • Internal arc capability
•  Internal arc capability Please refer to page 14.
•  Dielectric test
•  Making and breaking capacity of circuit-breaker and
• Dielectric test
contactors
These tests verify that the switchgear has sufficient capability
•  Earthing switch making capacity
to withstand the lightning impulse and the power frequency
•  Mechanical operations of circuit-breaker and earthing
voltage.
switch
The power frequency withstand voltage test is carried out as a
•  IP protectiondegree
type test, but it is also a routine test on every switchgear unit
manufactured.
IEC routine factory tests
•  Visual inspection and check
•  Mechanical sequence operations
•  Cabling check
•  Electrical sequence operations
•  Power frequency withstand voltage
•  Measurement of the resistance of the main circuits
•  Secondary insulation test

Special type tests required by shipping

registers for marine application
•  High ambient temperatures (+ 45 °C)
•  Inclination
•  Vibration

Figure 2: UniGear ZS1 during internal arc test

12
• Circuit-breaker making and breaking capacity Type tests required by the shipping
The circuit-breaker or contactor is subjected to the rated
current and short-circuit current breaking tests.
registers
Furthermore, it is also subjected to the opening and closing of
capacitive and inductive loads, capacitor banks and/or cable • High ambient temperature
lines. The service conditions for the electrical apparatus in marine
installations are generally more severe than those in normal
• Earthing switch making capacity land applications.
The earthing switch of the UniGear ZS1 switchgear can be Temperature is a main factor and for this reason the shipping
closed under short-circuit. Although, the earthing switch is register regulations require the switchgear to be able to
normally interlocked to avoid being operated on circuits which operate at higher ambient temperatures (45 °C or higher) than
are still live. those stated in the IEC Standards (40 °C).
However, should this happen for any one of several reasons,
personnel safety would be fully safeguarded. • Inclination
The test is carried out by inclining the switchgear for a defined
• Mechanical operations time up to 25° alternately on all four sides and operating the
The mechanical endurance tests on all the operating parts apparatus.
ensures the reliability of the apparatus. General experience in The test proves that the switchgear is able to resist these
the electro-technical sector shows that mechanical faults are extreme service conditions and that all the apparatus it
one of the most common causes of a fault in an installation. contains can be operated without any problems and without
The circuit-breaker is tested by carrying out a high number of being damaged.
operations - higher than those which are normally carried out
by installations in the filed. • Vibration
Furthermore, the switchgear components are part of a quality The reliability and sturdiness of the UniGear ZS1 switchgear
control program and samples are regularly taken from the has been definitively proved by the result of the withstand test
production lines and subjected to mechanical life tests to verify to mechanical stresses due to vibration. The service
that the quality is identical to that of the components subjected conditions on shipping installations and marine platforms
to the type tests. require the switchgear to work in environments strongly
affected by vibrations, such as those caused by the motors
• IP protectiondegree on large cruise ships or the drilling plants of oil rigs.
The IP protection degree is the resistance offered by the – 1 mm amplitude in the frequency range between 2 and
UniGear ZS1 against penetration of solid objects and liquids. 13.2 Hz.
This degree of resistance is indicated by the prefix IP followed – 0.7 g acceleration amplitude in the frequency range
by two charachters (i.e. IP4X). between 13.2 and 100 Hz (see picture on the previous
The first number identifies the degree of protection against the page).
entrance of solid objects, the second one is related to liquids.

Figure 3: inclination test Figure 4: vibration/seismic test

13
1. UniGear ZS1
Safety

When developing modern medium voltage switchgear, The test also ensure that no holes are produced in external
personnel safety must necessarily take priority. This is accessible parts of the housing, and finally, that all the
why the UniGear ZS1 switchgear has been designed and connections to the earthing circuit remain intact, hence
tested to withstand an internal arc due to a short-circuit guaranteeing the safety of personnel who may access the
current of the same current level as the maximum short- switchgear after the fault.
time withstand level. The IEC 62271-200 Standard describes the methods to
The tests show that the metal housing of UniGear be used for carrying out the test and the criteria which the
ZS1 switchgear is able to protect personnel near the switchgear must conform to.
switchgear in the case of a fault which evolves as far as The UniGear ZS1 switchgear fully conforms to all the five
striking an internal arc. criteria indicated by the IEC standards.

An internal arc is a highly unlikely fault, although it can The IAC classification is proved by the test according to the
theoretically be caused by various factors, such as: following designations:
•  Insulation defects due to quality deterioration of the •  General: classification IAC (Internal Arc Classified)
components. The reasons can be adverse environmental •  Accessibility: A, B or C (switchgear accessible to authorized
conditions and a highly polluted atmosphere. personnel only (A), to all (B), not accessible due to
•  Overvoltages of atmospheric origin or generated by the installation (C)
operation of a component. •  F, L, R: access from the front (F – Front), from the sides (L –
•  Inadequate training of the personnel in charge of the Lateral) and from the rear (R – rear).
installation. •  Test values: test current in kiloamperes (kA), and duration in
•  Breakage or tampering of the safety interlocks. seconds (s).
•  Overheating of the contact area, due to the presence
of corrosive agents or when the connections are not The parameters of each specific plant mean that evacuation
sufficiently tightened. of the hot gases and incandescent particles must be checked
•  Entry of small animals into the switchgear (i.e. through very carefully in order to ensure and maintain personnel safety.
cable entrance).
•  Material left behind inside the switchgear during Fault limiting systems
maintenance activities.
The structure of the UniGear ZS1 switchgear offers complete
passive type protection against the effects of a fault due to an
The characteristics of the UniGear ZS1 switchgear notably
internal arc for a time of 1 second up to 50 kA.
reduce the incidence of these causes for faults, but some of
ABB has also developed excellent active protection systems
them may not be eliminated completely.
which allow very important objectives to be achieved:
The energy produced by the internal arc causes the following
•  Detection and extinction of the fault, normally in less than
phenomena:
100 ms, which improves network stability.
•  Increase in the internal pressure.
•  Limitation of damage on the apparatus.
•  Increase in temperature.
•  Limitation of outage time for the switchgear unit.
•  Visual and acoustic effects.
For active protection against an internal arc, devices
•  Mechanical stresses on the switchgear structure.
consisting of various types of sensors can be installed in the
•  Melting, decomposition and evaporation of materials.
various compartments, which detect the immediate outburst
of the fault and carry out selective tripping of the circuit-
Unless suitably protected, these phenomena have very
breakers.
serious consequences for the personnel, such as wounds
The fault limiting systems are based on sensors which use the
(due to the shock wave, flying parts and the doors opening)
pressure or light generated by the arc fault as trigger for fault
and burns (due to emission of hot gases).
disconnection.
The internal arc test verifies that the compartment doors
remain closed and that no components are ejected from the
switchgear even when subjected to very high pressures, and
that no flames or incandescent gases penetrate, thereby
ensuring safety of the personnel near the switchgear.

14
ITH REA
The ITH sensors consist of micro-switches positioned on the This system offers the same functionality as TVOC. The REA
top of the switchgear near the gas exhaust flaps of the three system consists of the main unit (REA 101) and optional
power compartments (busbars, circuit-breaker and cables). extension units (REA 103, 105, 107) which make it possible to
The shock wave makes the flaps open and operate the create customized solutions with selective tripping. For more
micro-switches connected to the shunt opening release of the information, please see the dedicated chapter at page 50.
circuit-breaker. Total tripping time is 62,5 ms (2,5 ms REA + 60 ms circuit-
Total tripping time is 75 ms (15 ms ITH + 60 ms circuit- breaker).
breaker).
Arc protection in IED
FRD (Fast Recovery Device) The REF615, RET615, REM615 and REF610 IEDs (Intelligent
This system consists of pressure sensors located in the low Electronic Device) can optionally be fitted with a fast and
voltage compartment and connected to the three power selective arc flash protection. It offers a two-to three-channel
compartments by means of small tubes. arc-fault protection system for arc flash supervision of the
The sensors detect the rising front of the pressure wave which circuit breaker, cable and busbar compartment of switchgear
develops on the outburst of the arc and react by making the panels.
circuit-breakers open. Total tripping time is 72 ms (12 ms IED + 60 ms circuit-
The sensors are protected against the external environment breaker).
and they can be checked even with the switchgear in
operation. UFES (ultra fast earthing switch)
Total tripping time is 75 ms (15 ms FRD + 60 ms circuit-
The UFES is an innovative design of an extremely fast-acting
breaker).
earthing switch, grounding all 3 phases within < 4 ms after
detection of an internal arc fault.
TVOC For more information please see the dedicated chapter at
This system consists of an electronic monitoring device located page 30.
in the low voltage compartment which is connected to optic
sensors. These are distributed in the power compartments and
are connected to the device by means of optic fibres.
kA2 s
When a certain pre-set light level is exceeded, the device
opens the circuit-breakers.
To prevent the system from intervening due to light occasionally
generated by external phenomena (flash of a camera,
reflections of external lights, etc.), current transformers can also
be connected to the monitoring device.
The protection module only sends the opening command to the
circuit-breaker if it receives the light and short-circuit current
signal simultaneously.
Total tripping time is 62 ms (2 ms TVOC + 60 ms circuit-
breaker).
Melting
of Steel

Melting of
Copper

Melting
of Cables

0 100 200 500 ms

Figure 5: Arc duration and damage caused

15
1. UniGear ZS1
Safety

The UniGear ZS1 switchgear is fitted with all the

interlocks and accessories needed to guarantee the
highest level of safety and reliability for both installation
and personnel.

Interlocks
The safety mechanical interlocks are standard ones [1÷5],
please see the dedicated table at page 17.
They are set out by the IEC standards and are therefore
necessary to guarantee the correct operation sequence.
ABB safety interlocks guarantees the highest level of reliability,
even in the case of an accidental error, and enables highest
operator safety system of interlocks.

Keys
The use of key interlocks is very important in realising the
interlocking logics between panels of the same switchgear, or
of other medium, low and high voltage switchgear. The logics Figure 6: Double key lock on earthing switch
are realised by means of distributors or by ringing the keys.
The apparatus truck [6] can be locked in the racked-
outposition and the relevant lock key can only be removed The padlock can also be applied to the earthing switch of
with the apparatus in this position. busbar applications.
The earthing switch closing [7] and opening [8] operations can The metallic segregation shutters [15] between circuit-breaker,
be locked by means of keys, key logic is explained in the table busbars and cables compartments can be locked by means
at page 15. of two independent padlocks in both the open and closed
These locks can also be applied to the earthing switch of positions.
busbar applications. Padlocks from 4 to 8 mm diameter can be accommodated.
The circuit-breaker racking-in/out operations [9] and earthing
switch opening/closing [10] can be prevented by means of
Locking magnets
key locks, which prevent insertion of the relevant operating
levers. The locking magnets enable automatic interlocking logics
The key lock can also be applied to the earthing switch of without human intervention.
busbar applications. The keys can always be removed. The circuit-breaker racking-in/out [16] and the earthing switch
closing/opening [17] operations can be interlocked.
This magnet can also be applied to the earthing switch of
Padlocks busbar applications.
The circuit-breaker [11] and cables [12] compartment doors The magnets operate with active logics and therefore the lack
can be locked in the closed position by means of padlocks. of auxiliary voltage leaves the interlocking system active in
These can be applied to both door closing versions –with safety condition.
central handle (standard) or screws (optional).
The operations for apparatus racking-in/out [13] and earthing
switch opening/closing [14] can be prevented by applying the
padlocks to the insertion slots of the relevant operating levers.

16
Types of interlocks
Standard safety interlocks (mandatory)

Type Description Condition to be met

A Apparatus racking-in/out Apparatus in open position
1
B Apparatus closing Defined truck position
A Apparatus racking-in Apparatus multi-contact plug plugged
2
B Apparatus multi-contact plug unplugging Truck in test position
A Earthing switch closing Truck in test position
3
B Apparatus racking-in Earthing switch in open position
A Apparatus compartment door opening Truck in test position
4
B Apparatus racking-in Apparatus compartment door closed
A Feeder compartment door opening Earthing switch in ON position
5
B Earthing switch opening Cable compartment door closed
Note: Apparatus are circuit-breakers and contactors.

Keys (on request)

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

Padlocks

11 Apparatus compartment door opening

12 Cable compartment door opening
13 Insertion of the apparatus raking-in/out crank lever
14 Insertion of the earthing switch operating lever
15 Shutters opening or closing

Locking magnets (on request)

16 Apparatus racking-in/out Magnet energized

17 Earthing switch ON/OFF Magnet energized

Accessory devices

The device locks the shutters in the closed position when the
apparatus is removed from the compartment. The operator cannot
20 Shutters fail-safe open the shutters manually. The shutters can only be operated by
the apparatus truck or the service trucks (please see the dedicated
chapter at page 28).

The apparatus multi-contact plug and relative switchgear unit socket

21 Apparatus-switchgear unit compatibility matrix are equipped with a mechanical matrix, that disables apparatus
racking-in into a switchgear unit with an inappropriate rated current.

The apparatus compartment is equipped with a mechanical device,

that enables circuit-breaker closing and/or opening directly by means
22 Circuit-breaker mechanical operating mechanism of the front operating mechanism pushbuttons, keeping the door
closed. The controls can be operated with the circuit-breakers in the
operation and racked-out position.

17
1. UniGear ZS1
Vacuum circuit-breaker

UniGear ZS1 switchgear can be fitted with the widest vacuum interrupters is today reflected in the range of
range of apparatus available on the market today, and of ABB circuit-breakers, which stand out for their
these the vacuum circuit-breaker now occupies a position exceptional electrical and mechanical characteristics,
of prime importance in all sectors of primary distribution. extremely long life, low maintenance, compactness and
Vacuum circuit-breakers cover the whole range of the use of highly innovative construction techniques.
switchgear parameters and therefore the whole range of ABB develops and produces a complete range of
applications. interrupters for use in circuit-breakers and contactors and
Many years of experience gained in developing and using for all medium voltage applications.

Figure 7: UniGear ZS1

18
VD4 circuit-breaker The vacuum interrupter houses the contacts and provides the
interruption chamber.
The VD4 medium voltage circuit-breaker interrupters use
ABB circuit-breakers use the most advanced vacuum-
vacuum to extinguish the electric arc and as the insulating
breaking techniques: with radial magnetic flow for circuit-
medium.
breakers with medium-low ratings and with axialmagnetic flow
Thanks to the unequalled properties of vacuum and the
for those with high breaking capacity.
breaking technique used, current interruption takes place
Both techniques guarantee even distribution of the arc roots
without arc chopping and without overvoltages. Restoration
over the whole surface of the contacts, allowing optimum
of the dielectric properties following interruption is extremely
performance at all current values.
rapid.
The structure of a vacuum interrupter is relatively simple. The
The VD4 circuit-breakers are used for protection of cables,
housing is made up of a ceramic insulator closed at the ends
overhead lines, motors, transformers, generators and
by stainless steel covers. The contacts are made of pure
capacitor banks.
copper and sintered chrome and are welded to the copper
terminals. A metallic bellows allows movement of the moving
Poles contact-terminal group, at the same time guaranteeing that
The VD4 medium voltage circuit-breakers use vacuum the vacuum is maintained in the interrupter. The interrupter
interrupters embedded in poles (1). components are welded in an environment under a very
Embedding the interrupter in the pole makes the circuit- strong vacuum to guarantee a vacuum of less than 10-5 Pa in
breaker particularly sturdy and protects the interrupter itself the interrupter.
against shocks, deposits of dust and humidity. This means that the interrupter does not any ionisable
material. In any case, on detachment of the contacts, an
electric arc is generated which only consists of the melted
and vaporised material of the contact.
A metallic shield is integrated inside the interrupter to capture
the metallic vapours given off during interruption, as well as
for controlling the electric field. The particular shape of the
contacts generates a magnetic field which forces the arc to
rotate and to involve a much wider surface than that of a fixed
contact arc.
Apart from limiting the thermal stress on the contacts, this
makes contact erosion negligible and, above all, allows
theinterruption process to be controlled even with very high
short-circuit currents.
The electric arc remains supported by the external energy until
the current passes through its natural zero.
The ABB vacuum interrupters are zero current interrupters and
are free of any re-striking phenomena.
The rapid reduction of the current density and fast
condensation of the metallic vapours, that happens at the at
the instant that the current passes through zero, allow the
maximum dielectric strength between the interrupter contacts
to be re-established within a few milliseconds. Supervision of
the vacuum level is not necessary as the circuit-breaker poles
are sealed-for-life and do not require any maintenance.
Figure 8: VD4 circuit-breaker with mechanical actuator

(1) Circuit-breakers up to 17.5 kV - 1250 A - 31.5 kA are made off

polyamide poles.

19
1. UniGear ZS1
Vacuum circuit-breaker

Operating mechanism eVD4 circuit-breaker

The VD4 circuit-breaker is fitted with a mechanical stored The eVD4 circuit-breaker is a complete plug and play medium
energy type operating mechanism. voltage electrical feeder protection system. It is an evolution
The trip free mechanism allows opening and closing operations of the traditional concept of a circuit-breaker that with a single
independent of the operator. device, can carry out the breaking, measurement, protection,
The operating mechanism spring system can be recharged control and communication functions.
either manually or by means of a geared motor. The apparatus The eVD4 circuit-breaker is derived from the VD4 series with its
can be opened and closed by means of the pushbuttons on renowned reliability and robust characteristics.
the front of the operating mechanism or by means of electric eVD4 integrates the ABB Relion® family RBX615 series
releases (shunt closing, shunt opening and undervoltage). protection device with combined current and voltage
The circuit-breakers are always fitted with an anti-pumping sensors.
device to eliminate the possibility of simultaneous opening and With this integrated solution, the MTTR – Mean Time to
closing commands, closing commands with springs discharged Repair – of the system managed by eVD4 is much lower than
or with the main contacts not yet in their run-end position. traditional solutions. This makes the eVD4 the ideal solution
for all installations where a high degree of continuity of service
is required.
Truck The eVD4 is available in fixed and withdrawable versions for
The poles and operating mechanism are fixed onto a metal UniGear ZS1 switchgear and it is mechanically
support and handling truck. interchangeable with the VD4 circuit-breaker.
The truck is provided with a wheel system which makes
the operations for racking the apparatus into and out of the
switchgear unit possible with the door closed. The truck allows
efficient earthing of the circuit-breaker by means of the metallic
structure of the switchgear unit.
The vacuum circuit-breaker truck can be motor-operated.
The racking-out and racking-in operations can be carried out
by means of electrical controls, either locally by the operator or
by a remote system.

Apparatus-operator interface
The front part of the circuit-breaker provides the user interface.
It features the following equipment:
• ON pushbutton.
• OFF pushbutton.
• Operation counter.
• Indicator of the circuit-breaker open and closed state.
• Indicator of the charged or discharged state of the operating
mechanism springs.
• Manual charging device for the operating mechanism
springs.
• Override selector of the undervoltage release (optional).

Figure 9: eVD4 circuit-breaker with on bord sensors, protection and control unit RBX 615.

20
VM1 circuit-breaker Standards
The conventional mechanical stored energy type of operating IEC 62271-100 for the circuit-breaker.
mechanism used on the VD4 circuit-breakers can be replaced
with an operating mechanism with magnetic actuator, creating
the VM1 series of circuit-breakers.
All the characteristics of the circuit-breakers described in
this chapter remain unchanged except for the operating
mechanism.
The operating mechanism is based on a greatly reduced
number of components:
• Actuator with permanent magnets. The heart of the operating
mechanism consists of the magnetic actuator which carries
out the closing and opening operations, and keeps the main
contacts in their positions taken up after the operation.
The magnet transmits the operating mechanism to the
interrupters by means of a single transmission lever.
• Electronic control device. All the functions (trip, operation,
energy charging and watchdog) are carried out by the
integrated electronic controller. The circuit-breaker is fitted
with a multivoltage direct and alternating current feeder.
•  Capacitors. The energy required to switch the operating
mechanism is provided by an incorporated capacitor
bank. The stored energy guarantees the complete O-C-O
reclosing sequence.
• Position sensors. The position of the circuit-breaker contacts
is detected by means of electronic proximity sensors.

Figure 10: VM1 circuit-breaker with magnetic actuator

21
1. UniGear ZS1
Gas circuit-breaker

UniGear ZS1 switchgear can also be fitted with SF6 gas The combination of the compression and self-blast techniques
circuit-breakers. allows the best performance to be obtained at all current
The ABB vacuum and gas series of circuit-breakers are values. Both techniques are always present, but whereas the
mechanically interchangeable and the same switchgear former operates optimally in switching low currents, the latter
unit can therefore take either type of apparatus. Only ABB acts effectively during operation at higher current values.
can offer apparatus representing both techniques for the The autopuffer technique allows the use of a smaller quantity
whole range of applications, voltage levels (12-17.5-24 of gas than that required by circuit-breakers based on other
kV), rated current (630...4000 A) and breaking capacity techniques. For the same reason, the gas pressure is also
(16...50 kA). considerably reduced. The autopuffer technique guarantees
This makes it possible to specify the optimum solution the insulating withstand voltage and the breaking capacity up
for the installation characteristics and the feeders to be to 30% of the rated value, even with zero relative pressure.
switched and protected. The whole range of HD4 circuit-breakers uses the same gas
ABB’s long practical experience shows that the two types pressure for all rated voltage levels (12-17.5-24 kV). SF6 gas
of circuit-breakers are equally valid and complementary. pressure level monitoring is not necessary, since the circuit-
breaker poles are sealed-for-life pressure systems and are
maintenance-free.
HD4 circuit-breaker They are fitted with a pressure control device for checking
that the characteristics are not altered due to transport or
The HD4 medium voltage circuit-breakers use
incorrect operations.
sulphurhexafluoride gas (SF6) to extinguish the electric arc
and as the insulating medium.
Thanks to the excellent properties of SF6 gas, interruption
of the currents takes place without arc chopping and
overvoltages. There is no restriking phenomenon after
interruption and the dielectric properties following interruption
are recovered extremely rapidly.
Gas circuit-breakers are available for all electric power
distribution applications. They are particularly recommended
for use on capacitor banks, motors, transformers insulated
in oil and in installations where components which are
particularly sensitive to dielectric and dynamic stresses are
installed (for example, old cables or transformers).

Poles
The HD4 circuit-breaker poles use the autopuffer breaking
system, combining the compression and self-blast techniques
in a single solution.
The autopuffer system is the most innovative technique in the
field of gas circuit-breakers and originates from high voltage
apparatus.

Fig. 11: HD4 circuit-breaker

22
Operating mechanism Truck
The HD4 circuit-breaker is fitted with a mechanical The poles and operating mechanism are fixed onto a metal
storedenergy operating mechanism. This is trip free and support and handling truck.
therefore allows opening and closing operations independent The truck is provided with a wheel system which makes
of the operator. the operations for racking the apparatus out of and into the
The operating mechanism spring system can be recharged switchgear unit possible with the door closed.
either manually or by means of a geared motor. The operating The truck allows effective earthing of the circuit-breaker by
mechanism is of the same type for the whole series and has a means of the metallic structure of the switchgear unit.
standardised range of accessories and spare parts.
All the accessory components can easily be replaced by Apparatus-operator interface
means of plug-socket connectors.
The front panel of the circuit-breaker provides the
Opening and the closing of the apparatus can be carried
userinterface. It features the following equipment:
out by pushbuttons on the front of the operating mechanism
• ON pushbutton.
or by electric releases (shunt closing, shunt opening and
• OFF pushbutton.
undervoltage).
• operation counter
The circuit-breakers are always fitted with an anti-pumping
• indicator of the circuit-breaker open and closed state
device to eliminate the possibility of simultaneous opening
• indicator of the charged and discharged state of the
and closing commands, closing commands with springs
operating mechanism springs
discharged or with the main contacts not yet in their run-end
• manual charging device for the operating mechanism
position.
springs
• override selector of the undervoltage release (optional)
• LED gas pressure indicator (optional)

HD4-HXA circuit-breaker for high

unidirectional components
The range of HD4 circuit-breakers is extended by the HD4-
HXA version.
This series of circuit-breakers maintains all the features
described in this chapter, but is notable for its ability to switch
loads with strong unidirectional components.
For breaking capacities of 40 kA or lower, HD4-HXA
circuit-breakers are able to switch loads with unidirectional
components IDC = 100%, up to service voltage 13.8 kV;
at 50 kA the unidirectional component percentage IDC is
reduced to 50%.They can be used in all installations affected
by strong unidirectional components, but their natural field of
application is found in switching and protecting transformers
of the auxiliary circuits in power generating stations.

Standards
IEC 62271-100 for the circuit-breaker.
IEC 60376 for the SF6 gas.

Figure 12: HD4-HXA circuit-breaker

23
1. UniGear ZS1
Vacuum contactor

V-Contact VSC medium voltage contactors are apparatus Both versions are available with an operating mechanism with
suitable for operating in alternating current and are electrical or mechanical latching.
usually used to control feeders which require a high The V-Contact VSC contactors are mechanically
number of operations per hour. interchangeable with the former V-Contact V/P contactor and
They are suitable for operating and protecting motors, with the whole series of ABB circuit-breakers, the same
transformers and power factor correction banks. switchgear unit can therefore take both types of apparatus
Fitted with appropriate fuses, they can be used in circuits without modification.
with fault levels up to 1000 MVA. A version of V-Contact VSC contactors is also used in the
The electrical life of V-Contact VSC contactors is defined UniGear MCC compact switchgear up to 400 A.
as being in category AC3 with 100,000 operations
(closing/opening), 400 A interrupted current.
Operating mechanism
Due to the magnetic actuator, V-Contact VSC contactors
need negligible auxiliary power in all configurations (15W
V-Contact VSC contactor inrush - 5W continuous).
The contactors consist of a monobloc of resin containing the The V-Contact VSC is available in three different
following components: configurations.
• vacuum interrupters •  SCO (single command operation).
• moving equipment The contactor closes the supply of auxiliary voltage to
• magnetic actuator the multivoltage feeder input, when the auxiliary is cut the
• multivoltage feeder contactor opens.
• accessories and auxiliary contacts. •  DCO (double command operation).
The contactor closes the supply of auxiliary voltage to the
The V-Contact contactors are provided in the following multivoltage feeder closing input and opens when opening
versions: input is supplied; anti pumping function is supplied as a
• VSC7/P for voltages up to 7.2 kV. standard.
• VSC7/PG for voltages up to 7 kV with 32 kV power •  DCO configuration is also available, on request, with a
frequency withstand voltage. delayed undervoltage function. This function enables
• VSC12/P for voltages up to 12 kV. automatic opening of the contactor when the auxiliary
• VSC12/PG for voltages up to 12 kV with 42 kV power voltage level drops below IEC defined levels.
frequency withstand voltage. Opening can be delayed from 0 to 5 seconds (customer
setting by dip switches).
All configurations are suitable for 1,000,000 mechanical
operations.

Fuses
The contactor is fitted with medium voltage fuses for
protection of the operated feeders.
Coordination between the contactor, fuses and protection unit
is guaranteed in accordance with the IEC 60470 Standards
for apparatus in class C.
The fuse-holder frame is usually preset for installation of a set
of three fuses per phase with average dimensions and type of
striker, according to the following Standards:
• DIN 43625.
• BS 2692.

Figure 13: V-Contact VSC contactor

24
The following fuses can be applied:
• DIN type with a length of 192, 292 and 442 mm
• BS type with a length of 235, 305, 410, 454 and 553 mm.
The fuse-holder frames are fitted with a device for automatic
opening when even just one fuse blows.
This same device does not allow contactor closing when even
a single fuse is missing.
The ABB range of fuses for transformer protection is called
CEF, whereas CMF is for motors and capacitors.

Standards
• IEC 60470 for the contactor
• IEC 60282-1 for the fuses Figure 14: Fuse according to DIN Standards

Electrical characteristics
VSC7/P VSC12/P
Rated voltage kV 7.2 12
Rated insulation voltage kV 7.2 12
Rated power frequency withstand voltage kV 1min 20 (3)
28 (3)
Rated lightning impulse withstand voltage kV 60 75
Rated frequency Hz 50/60 50/60
Rated short-time withstand current kA (1)
…50 …50
Peak current kA …125 …125
Internal arc withstand current (2)
kA 1s …50 …50
Maximum rated current of the contactor A 400 400
(1) Limited by the fuses.
(2) The internal arc withstand values are guaranteed in the compartments on the supply side of the fuses (busbars and apparatus) by the structure of the switchgear and on the load side (feeder)
by the limiting properties of the fuses.
(3) VSC7/PG for 32 kV power frequency withstand voltage and VSC12/PG for 42 kV power frequency withstand voltage are available on request in a dedicated panel.

Maximum performances of the contactor with fuses

3.6 kV 7.2 kV 12 kV
Motors kW 1,000 1,800 3,000
Transformers kVA 2,000 2,500 2,500
Capacitors kVAR 1,000 1,800 3,000

Maximum load currents of the fuses

Feeder Transformers Motors Capacitors
Rated voltage Fuse Maximum load Fuse Maximum load Fuse Maximum load
3.6 kV 200A 160A 315A 250A 450A 360A
7.2 kV 200A 160A 315A 250A 355A 285A
12 kV 200A 160A 200A 160A 200A 160A

25
1. UniGear ZS1
Switch-disconnector

The UniGear panels can be fitted with ABB NAL type This leads to a gradual increase in the arc resistance which
switch-disconnectors. causes its extinction. The movement of the pistons is
These units are used to switch and protect feeders and synchronised with the arc-breaking contacts of the switch-
transformers or the auxiliary services transformers in sub disconnector -this guarantees the highest inflow of air at the
and power station. moment of separation of the contacts and there by ensures
The NAL switch-disconnectors are medium voltage reliable arc extinction.
air-insulated apparatus consisting of a fixed support to The unit can be fitted with insulating bars (NAL switch-
which the post insulators are applied (top and bottom), disconnector unit) or with medium voltage fuses (NALFswitch-
the system of contacts (fixed and moving) and latching disconnector unit with fuses).
pliers (of the fuses or of the insulating bars). The NALF switch-disconnector is fitted with an automatic
release mechanism for fuse tripping and uses fuses in
accordance with DIN 43625 Standards. The ABB range of
NAL-NALF switch-disconnector fuses for transformer protection is CEF. Each unit is fitted
with an earthing switch with making capacity for earthing the
The switch-disconnector is fitted with two systems of moving
cables.
blade contacts, the main one (through which the load current
Switch-disconnector control, like that of the earthing switch,
passes with the switch in the closed position) and the arc-
is carried out manually from the switchgear front panel.
breaking one (through which the current passes during the
The position of both items of apparatus can be seen directly
opening and closing operations).
from the front of the switchgear through an inspection
This solution means the main contacts are not stressed and
window.
therefore keeps the electrical characteristics of the apparatus
The switchgear panel can be fitted with a set of three current
unchanged.
transformers or with measurement sensors.
During switch-disconnector opening air is compressed by
The Disconnector Feeder unit (DF) consists of two power
the pistons contained in the top insulator cylinders. At the
compartments: busbars and switch-disconnector/cables.
moment of opening and separation of the contacts, a blast of
The latter contains both the switch-disconnector and the
compressed air is emitted through special nozzles, so the arc
connection terminals of the power cables.
is cooled and deionised.

Figure 15: NALF switch-disconnector

26
Segregation between the power compartments takes place to guarantee maximum safety for the personnel and correct
automatically with earthing switch closure. An insulating operation.
shutter creates complete separation between the fixed Each switchgear panel is fitted with an auxiliary compartment,
contacts of the switch-disconnector, making the top ones where the instruments and auxiliary cabling are housed.
inaccessible to the operators. This makes maintenance All the switchgear panels are accessible from the front and
operations on the cables and fuses possible, keeping the maintenance and service operations can therefore be carried
remainder of the switchgear in operation. out even when the switchgear is wall-mounted.
UniGear ZS1 panel with fixed switch-disconnector is classified
LSC-2A because the cable and apparatus compartments are Standards
not phisically segregated. • IEC 60265-1 for the switch-disconnector
The switch-disconnector, earthing switch and access door • IEC 60282-1 for the fuses
to the cables compartment are interlocked with each other

Electrical characteristics
Rated voltage kV 12 17.5 24
Rated insulation voltage kV 12 17.5 24
Rated power frequency withstand voltage (1) kV 1 min 28 38 50
Rated lightning impulse withstand voltage kV 75 95 125
Rated frequency Hz 50/60 50/60 50/60
(1) GB/DL version is available with higher request in dielectric characteristics.

NALF switch-disconnector unit with fuses

Rated short-time withstand current kA (1) ...25 ...25 ...20
Peak current kA ...100 ...100 ...63
Maximum rated current of the fuses A 100 63 63
Internal arc withstand current (2) kA 1 s ...40 ...40 ...25
(1) Limited by the fuses.
(2) The internal arc withstand values are guaranteed in the compartment on the supply side of the fuses (busbars) by the structure of the switchgear and on the load side (cables)
by the limiting properties of the fuses.

Selection table of the fuses for protection transformers

Transformer Transformer rated output (kVA) Fuse rated
rated voltage voltage
[kV] 25 50 75 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 [kV]
CEF Fuse-link In [A]
3 16 25 25 40 40 50 63 80 100 125
5 10 16 25 25 25 40 40 50 63 80 100 125 3.6/7.2
6 6 16 16 25 25 25 40 40 50 63 80 100 125
10 6 10 16 16 16 20 20 25 31.5 40 50 63 80 100 125
12
12 6 6 10 16 16 16 20 20 25 40 40 50 63 80 100 125
15 6 6 10 10 16 16 16 20 20 25 40 40 50 63 80 100 125 17.5
20 6 6 6 10 10 16 16 16 20 20 25 31.5 40 50 63 80
24
24 6 6 6 6 10 10 16 16 16 20 20 25 40 40 50 63 80
The table was calculated according to standards IEC 60787 and IEC 62271-105 (for operating voltages up to 24 kV). The following transformer work conditions were assumed:
• Maximum long-lasting overload – 150%
• Magnetizing inrush current – 12×In during 100 ms
• Transformer short-circuit voltage according to IEC 60076-5
• Standard ambient working conditions of fuses
The table above details the rated current of a particular fuse link for a given line voltage and transformer rating. For different criteria, the fuse selection must be recalculated.
The given limits of the rated current of fuse are not mandatory for use in the NALF disconnector / NAL without fuse tripping system. Rated current values of the corresponding fuses for these
applications are given in the ABB catalogue “FUSES”.

27
1. UniGear ZS1
Service trucks

The UniGear ZS1 range is equipped with all the service The earthing truck of the power cables, during the racking-
trucks needed for service maintenance activities. in phase, only activates the bottom shutter and earths the
The trucks are divided into four different types: contacts connected to the bottom branch connections (and
• Earthing without making capacity therefore to the power cables) by means of the switchgear
• Earthing with making capacity structure.
• Cable test These trucks can also be used in the bus-tie unit. In this case,
• Isolation they earth one of the two sides of the main busbar system.

Earthing truck with making capacity

Earthing truck without making capacity These trucks carry out the same function as the earthing
These trucks carry out the same function as the earthing switches with making capacity.
switches without making capacity. They consist of circuit-breakers provided with top (earthing of
They therefore have no capacity to earth live circuits in fault the main busbars) or bottom (earthing of the power cables)
conditions. terminals only. The contacts without terminals are short-
They are used to ensure an additional fixed earth, as is circuited by means of a copper bar and connected to earth by
required by certain installation service and maintenance means of the apparatus truck.
procedures, as a further safety guarantee for personnel. They keep all the characteristics of the circuit-breakers, such
The use of these trucks require the removal of the apparatus as full making and breaking capacity on live circuits under
(circuit-breaker or contactor) from the switchgear and its fault conditions.
replacement with the truck. They are used to ensure extremely effective earthing on
The switchgear panels preset for use of the earthing trucks circuits stressed by a fault. They allow opening and closing
must be provided with a key lock which, when activated, operations to be carried out rapidly with electric remote
prevents their racking-in. control.
This truck is available in two versions: The use of these trucks require the removal of the apparatus
• Earthing of the main busbar system. (circuit-breaker or contactor) from the switchgear and its
• Earthing of the power cables. replacement with the truck.
The earthing truck of the main busbars, during the racking- The switchgear panels preset for use of the earthing trucks
in phase, only lifts the top shutter and earths the contacts must be provided with a key lock which, when activated,
connected to the top branch connections (and therefore to the prevents their being racked-in.
main busbar system) by means of the switchgear structure.

Figure 16: HD4 service truck

28
This truck is available in two versions: The truck, during the racking-in phase, only activates the
• Earthing of the main busbar system. bottom shutter and, by means of the connectors it is fitted
• Earthing of the power cables. with, allows connection of the test apparatus cables.
The earthing truck of the main busbars, during the racking- This truck can only be used in the incoming/outgoing feeders
in phase, only lifts the top shutter and presets the contacts with the door open.
connected to the top branch connections (and therefore to
the main busbar system) for closing to earth by means of Isolating truck
operating mechanism.
The isolating truck allows the top switchgear contacts to
be connected directly to the bottom ones. Connection
The earthing truck of the power cables, during the racking-
is made extremely safe by using the poles of the circuit-
in phase, only activates the bottom shutter and presets the
breakers to insulate the connection busbars from the
contacts connected to the bottom branch connections (and
external environment. In the incoming/outgoing feeder units
therefore to the power cables) for closing to earth by means
it connects the main busbar system to the power cables,
of operating mechanism.
whereas in the bus-tie, to the two sides of the busbar system.
These trucks can also be used in the bus-tie unit. In this case,
This truck has its application in UniGear switchgear for
they earth one of the two sides of the main busbar system.
making incoming/outgoing feeders without a circuit-breaker
in radial networks, for making cable connections between
Power cable test truck two items of switchgear placed in front of each other, in
These trucks allow the insulation tests on the power cables to making interconnection units and in creating the bus-tie riser
be carried out without accessing the feeder compartment or configuration with double insulation (in this case, both the
disconnecting the cables from the switchgear. units are made up of bus-ties, the former fitted with a circuit-
The use of these trucks require the removal of the apparatus breaker and the latter with an isolating truck).
(circuit-breaker or contactor) from the switchgear and its The switchgear panels preset for use of the isolating trucks
replacement with the truck. must be fitted with a key lock which, when activated, prevents
their being racked-in.

Main busbar system earthing Power cable earthing truck, Cable test truck.
truck, without making capacity. without making capacity.

Main busbar system earthing Power cable earthing truck, Isolating truck.
truck, with making capacity. with making capacity.

29
1. UniGear ZS1
Ultra Fast Earthing Switch

The UFES (Ultra Fast Earthing Switch) is an innovative The UFES is available to fulfil a variety of applications in the
design of an extremely fast-acting earthing switch, UniGear ZS1 switchgear:
grounding all 3 phases within less than 4 ms after •  Busbar installation with top-housing box
detection of an internal arc fault. •  Cable compartment installation (12/17.5 kV 50 kA version)

The extremely short operating time of the primary switching

element, in conjunction with rapid and reliable detection of Unbeatable advantages in case of an arc fault event
fault current and light, ensures that an internal arc fault is •  Drastic reduction of repair costs: no damages on the
extinguished nearly immediately after its formation. Thermal switchgear equipment to be expected. No exchange of the
and mechanical damage inside of the protected switchgear faulty panel.
system are thus effectively prevented. •  Greatly increased system availability: after inspection and
elimination of the fault reason the switchgear can be taken
into service again within shortest possible time.
•  Greatly increased operator safety for human mal-operation
under maintenance conditions.

Figure 17: Electronic device for measurement, Figure 18: Primary switching element type U1
logic and tripping, type QRU1

Electrical maximum characteristics in UniGear ZS1   IEC

Rated insulation voltage (rms) ( ) 1
kV 12 17.5 24
Rated power frequency withstand voltage (rms) kV 28 38 50
Rated lightning impulse withstand voltage (peak) kV 75 95 125
Rated frequency Hz 50/60 50/60 50/60
Rated short-time withstand current (rms) (1) kA 50 50 31.5
Rated short-circuit making current kA 125 125 80
Rated duration of short-circuit s 3 3 3
(1) GB/DL version is available with higher request in dielectric characteristics (42 kV) and short-time withstand current (4 s).

30
 Overpressure in bar
1.6

1.4
I(t)
1.2

1.0

0.8

0.6

0.4

0.2

0.0 20.0 40.0 60.0 80.0 100.0 120.0 0

Time in ms 0 10 20 30 40 50 60 70 80 90 100
Short-circuit current In t + < 4 ms Time in ms
TC
DC component
Arcing time with UFES Pressure curve with UFES (4 ms) Pressure curve without UFES
Final clearing of fault current by upstream circuit-breaker - 80 ms + timex
tTC Reaching time for tripping criteria
tTC Reaching time for tripping criteria

Figure 19: In rare cases, failure inside a switchgear cubicle due either to a Figure 20: Avoidance of the severe effects of an internal arc fault, such as …
defect, an exceptional service condition or mainly by human mal-operation - Rapid temperature rise (up to 20,000 °C)
may initiate an internal arc. The faster the arc will be interrupted, the less - Rapid pressure rise (see figure)
destruction on the switchgear equipment will occur. - Burning of materials
… by fastest possible extinction.

1. 2. 3. 4. 5.

CB CB CB CB CB

CT CT CT CT CT

I k“ I k“ I k“ I k“ I k“

UFES QRU UFES QRU UFES QRU UFES QRU UFES QRU

(Optional)

I(t) I(t) I(t) I(t) I(t)

0.0 5.0 10.0 15.0 20.0 25.0 0.0 5.0 10.0 15.0 20.0 25.0 0.0 5.0 10.0 15.0 20.0 25.0 0.0 5.0 10.0 15.0 20.0 25.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0

Time in ms Time in ms Time in ms Time in ms Time in ms

Figure 21: Event sequence description

1. Internal arc formation.
2. Arc detection by the electronic device (light and current).
3. ~ 1-2 ms after detection: Tripping signal to the UFES primary switching elements
4. ~ 3-4 ms after detection: Bolted 3-phase earthing by operation of the UFES primary switching elements.
à Interruption of the arc voltage: Immediate extinction of the arc.
à Controlled fault current flow via UFES primary switching elements to earth potential.
5. Final clearing of the fault current by the upstream circuit-breaker.

31
1. UniGear ZS1
IS-limiter: fault-current limitation

Short-circuit currents too high? A short-circuit downstream from an outgoing feeder breaker is
The IS-limiter, a switching device with extremely short assumed. The oscillogram shown below indicates the course
operating time, solves the problem. of the short-circuit currents in the first half wave.
A short-circuit current of 31.5 kA can flow to the fault location
The rising global demand for energy requires more powerful through each transformer. This would result in a total short-
or additional transformers and generators, and an increasing circuit current of 63 kA, which is twice as much as the
interconnection of the individual supply networks. switchgear capability.
This can lead to the permissible short-circuit currents for the The course of the current through the IS limiter in such an
equipment being exceeded causing severe dynamic or event is shown below as current i 2.
thermal damage or even complete destruction. It can be seen that the IS-limiter operates so rapidly, that
The replacement of existing switchgear and cable connections there is no contribution via the transformer T2 to the total
by new equipment with a higher short-circuit strength is often peak short-circuit current (i 1 + i2). Therefore, a switchgear
technically impossible or uneconomical for the user. with a rating of 31.5 kA is suitable for this application.
The use of IS-limiters reduces the short-circuit current in both
new systems and expansions of existing systems, thus saving
cost.

Single line diagram

of a bus tie for a
T1 T2
lnk = 31.5 kA lnk = 31.5 kA system with
lnk = 31.5 kA
and with an
l1 l2 lS - limiter

l = l 1+ l 2
lnk perm.= 31.5 kA

i
160 kA i = i 1+ i 2
whithout Is-limiter

Current i = i1+ i2
at the fault location

80 kA
(31.5 kA x H x √2)

i = i 1+ i 2
with Is-limiter
l1

l2

Figure 22: IS-limiter application diagram Figure 23: IS-limiter

Technical Data
Rated voltage kV 12.0 17.5 24.0 36.0/40.5
1250/2000/2500/ 1250/2000/2500/ 1250/1600/2000/
Rated current A 1250/2000/25001)
3000/40001) 3000/40001) 2500 1)/3000 1)
Interrupting current kARMS Up to 210 Up to 210 Up to 140 Up to 140
1) with cooling fan

32
Potential applications 31.5 MVA 110 kV
Such a fast switching device caters for a variety of applications 12%
which cannot be fulfilled by conventional switches. The most
important of these are presented below. Option
B 40 MVA
Advantages of all IS-limiter applications:
8%
– Reduction of short-circuit currents at the fault location
– No upgrading of the existing switchgear.
10 kV/31.5 kA 10 kV/40 kA

Option A, figure 24
Coupling-parallel operation of two systems.
Advantages: Option Option
A C
– Improving power quality
– Increasing the reliability of the system
– Reduction of the network-impedance
– Optimal load flow
Figure 24: Three possible applications of IS-limiters in one figure
(Option A, B, C)
Option B, figure 24
IS-limiter in the generator feeder to protect the high voltage system.
Advantages: IııkT = 15 kA
– Generator can be connected independent of the short-
circuit capability of the system
– Existing busbar system does not need to be changed 10 kV/25 kA

– No need for expensive generator breaker

10 kV/16 kA
IııkG = 3 kA
Option
Option C, figure 24 D

IS-limiter and reactor connected in parallel.

Advantages:
– Avoid copper losses of the reactor
– Avoid voltage drop over the reactor
– No electro-magnetic field of the reactor
Figure 25: Is-limiter in connecting point with a public supply network

Option D, figure 25 (Option D)

Station service supply and public network.

Advantages:
– Private/industrial generator feeder can be connected to the
(fully loaded) grid
– Selective tripping of the IS-limiter (IS-limiter will operate only
for short-circuit faults in the grid)
T1 T2 T3
Option E, figure 26
If in the case of two IS-limiters being installed in a switch- IT IT IT
1 2 3
board selective tripping is required, a measurement of the
total current becomes necessary. A IS-1 B IS-2 C
Advantage: The I S-limiter trips as follows:
•  Short-circuit in section A: Only I S-limiter no. 1 trips.
•  Short-circuit in section B: I S-limiter no. 1 and no. 2 trip.
•  Short-circuit in section C: Only I S-limiter no. 2 trips.

Figure 26: Use of more than one Is-limiter with selectivity (Option E)

33
1. UniGear ZS1
Instrument transformers

Block type current transformers

The block type current transformers are epoxy resin insulated
and used to supply the measurement devices and protection
instruments. These transformers can have a wound core or a
bushing bar with one or more cores, with performance and
accuracy classes suitable for the installation requirements.
They conform to the IEC 60044-1 Standards.
Their dimensions are in accordance with the DIN 42600
Narrow Type Standard, in the Medium and Long Size versions
up to 2500 A, where they are of the toroidal type in the
range of currents from 3150 A to 4000 A (KOKS type).
The current transformers can also be provided with a
capacitive socket for connection to voltage signalling devices.
The current transformers are normally fitted on the load
side of the apparatus compartment for measurement of the
phase currents of the switchgear unit. Fitting on the supply
Figure 28: TPU 1250 A
side of the apparatus compartment is also possible (busbar
applications) for measuring the busbar currents or for realising
particular protection schemes. The ABB range of current
transformers is designated TPU.

Ring core current transformers

The toroidal transformers are of the epoxy resin insulated type
and are used to supply measurement and protection devices.
These transformers can feature either a closed or openable
core.
They can be used both for measuring phase currents or for
detecting the earth fault current.
They conform with the IEC 60044-1 Standards.

Figure 29: TPU 2500 A

Figure 27: Toroidal current transformer Figure 30: KOKS 3150 A

34
Voltage transformers
The voltage transformers are of the epoxy resin insulated type
and are used to supply measurement and protection devices.
They are available for fixed assembly or for installation on
removable and withdrawable trucks.
They conform with the IEC 60044-2 Standards.
Their dimensions are in accordance with the DIN 42600
Narrow type Standard.
These transformers can have one or two poles, with
performance and precision classes suited to the functional
requirements of the instruments connected to them.
When they are installed on removable or withdrawable trucks
they are fitted with medium voltage protection fuses.
The withdrawable trucks also allow replacement of the fuses
with the switchgear in service. Truck racking-out with the
door closed automatically operates closure of a metallic
Figure 32: Single pole VTs - type TJC
segregation shutter between the live parts of the switchgear
and the instrument compartment.
Fixed voltage transformers can be installed directly on the
main busbar system in a dedicated compartment (busbar
applications).
The ABB range of voltage transformers is designated TJC,
TDC,TJP.

Figure 33: Double-pole VTs - type TDC

Figure 31: VT truck with fuses Figure 34: Single-pole VTs with fuse - type TJP

35
1. UniGear ZS1
Measurement sensors

Electronic instrument transformers Characteristics of the sensors

Future for measuring currents and voltages in intelligent Construction of current and voltage sensors is done without
UniGear is a low-power instrument transformer (according to the use of ferromagnetic core. This fact results in several
present IEC standards they belong to the group of Electronic important benefits for the user and the application:
instrument transformers) called a “sensor” for short. These – sensor behavior is not influenced by non-linearity and
products replace conventional instrument transformers of width of hysteresis curve; that results in accurate and
both block and ring core types. linear response over a wide dynamic range of measured
The characteristic feature of advanced ABB sensors is quantitites
the level of output signal, which is fully adapted to fit new – single device/sensor could be used for both protection and
microprocessor-based equipment without the need of having for measurement purposes (no need for a separate design/
unnecessary power. product)
The analogue output signal level depends on the principle – there are no hysteresis losses, so sensors are having
used and can be: excellent frequency response also at frequencies different
– In the range of mV for current sensor (typical value is 150 from the rated one, thus providing very precise input to
mV at rated primary current). protection functions, allowing more precise fault analysis
– In the range of volts for voltage sensors where the division and efficient fault location.
ratio is 1:10000 (e.g. output 1/√3 V for 10 000/√3 kV – sensors do not have dangerous states in operation (no
nominal system voltage at primary/input side). problem to keep output short-circuited or left open),
The UniGear ZS1 can be fitted with KEVCD block type sensor resulting in high safety for surrounding devices and
– KEVCD is block type sensor with shape that conforms personell. The output signal remains very low even in fault
to DIN size standard. Two versions could be selected: situations of the network.
one providing current measurement together with voltage – the use of sensors disable the possibility of related
indication capability or second one, providing, in addition ferroresonance phenomena, thus even more increasing the
to these, also voltage measurement possibility. All safety and reliability of the power network; furthermore,
measurements/sensings for each phase is realized within a there is no need for additional protection equipment, special
single body, so there is no need for additional devices. burden or wiring.

Figure 35: Linearity of advanced ABB sensors and example of output signal waveforms compared to conventional saturated CT

36
ABB sensors are connected to the measurement and
protection evaluation devices by means of shielded cables
and connectors, providing a high degree of immunity to
electromagnetic disturbances.
Accuracy of these sensors is verified and tested including the
cabling, so precise information is assured up to the evaluation
device.

Figure 36: KEVCD block type current and voltage sensor

Benefits of the sensors

Due to the linear response and wide dynamic range, sensors
are much more standardized devices (compared to a number
of different designs of CTs and VTs). Therefore, it is much
easier to select the appropriate design (it simplify engineering
tasks) and there could be also reduction in spare parts on
user side.
Significantly decreased power consumption during operation
of sensors due to negligible losses introduced by sensors
(no iron = no hysteresis losses; less winding and negligible
output current = small losses in sensor winding) results in
huge savings for lost energy and minimized temperature rise
(thus improving temperature conditions and ageing within
application). It also results in significantly lighter devices,
having weight only a fraction of that provided by conventional
CTs or VTs. Therefore, no special machines/tools are needed
to cary them and transport costs can be smaller.
Fast connection of sensors to IEDs without any tools and
material needed simplify and reduce assembly effort.

37
1. UniGear ZS1
Measurement sensors

Current sensor Output voltage is phase shifted of 90° from the primary
current waveform.
The current sensor is based on Rogowski Coil principle.
Rogowski Coil work in the same manner as conventional iron-
Therefore, for simple and rough information about the
core current transformers (CTs). The main difference between
measured current signal, it is possible to use voltmeters with
Rogowski Coils and CTs is that Rogowski Coil windings are
high input impedance. Nevertheless, more exact and precise
wound over a non-magnetic core, instead of over an iron
information under transient conditions, content of different
core. As a result, Rogowski Coils are linear since the non-
frequency components or current waveform distortions
magnetic core cannot saturate. Rogowski Coils produce
that appears in electric power network requires integration
output voltage (US) that is a scaled time derivative of the
of voltage signal comming out of Rogowski Coil. This
measured primary current (I P).
functionality is already available inside of IEDs provided by
ABB, so very precise measurement of the primary current is
available.

Output voltage of Rogowski Coil linearly depends on

frequency, therefore rated value of output voltage is 150mV
at 50Hz and 180mV at 60Hz. Once the rated frequency is
set in the IED, sensor provides precise information about the
measured primary current signal even for different harmonics
(no hysteresis losses and no saturation applies) and thus
correct performance for all protection functions is assured.
In theory, response of Rogowski coil output is linear in
unlimited dynamic range of the measured primary current.
Constraints in their use originates from other limitations, e.g.
application size, fixations etc. Only single coil is sufficient to
dip (t)
cover whole range of primary currents needed, e.g. KEVCD
uS (t)=M –––––––
dt sensor type contains a primary conductor and due to this fact
just two types are needed to cover the primary current range
from 0 to 3200A.
Figure 37: Working principle of Rogowski Coil
They conform to the IEC 60044-8 standard.

Integration of the current sensor output signal is performed

within the connected IED in order to obtain the information
about actual current value.

In case of purely sinusoidal primary current (I ) at rated

frequency defined as:

ip (t) = √2Ip sin(ωt)

the output voltage from the Rogowski Coil is

us (t) = √2Ip Mωcos(ωt)

For this case, r.m.s. value of the output signal could be
easily measured even without integrator, using a voltmeter or
oscilloscope, observing a phase shift of 90° from the primary
current waveform.

38
Voltage sensor Standard division ratio used in ABB sensors is 10000/1. This
assures the output signal to be sufficient and safe for further
The voltage sensor is based on a principle of resistive voltage
processing within IED.
divider. It consists of 2 resistive elements which divide the
input signal to the level that is possible to connect to a
standard LV measuring devices. For information about the measured voltage signal, it is
The main difference between resistive voltage divider and possible to use voltmeters with high input impedance,
conventional voltage transformer (VT) is their working nevertheless the use of ABB IEDs is recommended as this
principle. In case of VTs, voltage is induced in the winding. In connection has been tested and verified.
case of voltage divider, voltage is simply divided in relation to Resistive voltage divider has no ferromagnetic core and
resistances of the resistive elements thus no induction takes no winding. Therefore, there is no risk of ferroresonance
place. phenomena as in case of VTs and no additional damping
devices are needed for that purpose. The use of such dividers
significantly increase safety and reliability of the network
as well as enhance safety towards the personnel under all
circumstances. There is also no problem or danger in case
the secondary terminals are short-circuited. Furthermore, the
sensor can remain connected even during switchgear voltage
tests at power frequency.
The resistive divider correctly operates even during transients
where DC as well as other frequency components are
present (no ferromagnetic core inside of the divider means no
possibility for saturation at different frequencies). This enable
undistorted evaluation of transients and precise analysis of
protection functions. Apart from the possibility to measure
DC components during transients, resistive voltage divider
enables also precise continuous DC voltage measurement at
steady-state.
Due to linear response and no possibility of saturation a single
divider is sufficient to cover the range of voltages from 0 to
R2 24kV. Nevetheless, in case of overall voltage sensor body,
US = ––––––– Up other mechanical requirements or dimensions/distances for
R1 + R2
different voltage levels may need to be taken into account.
For that case, two different heights of KEVCD sensor are
Figure 38: Working principle of resistive voltage divider
available, fitting to standard DIN dimensions. Selected sensor
version could then be used also for voltage levels lower then
Used resistors consists of a rod made of stable ceramic maximum rated primary voltage.
material on which the special non-inductive resistive pattern is They conform to the IEC 60044-7 Standards.
applied.
The output signal is a voltage directly proportional to the
primary voltage so no integration or any extra processing is
needed.
In case of purely sinusoidal primary voltage (UP) at rated
frequency defined as:
up (t) = √2Up sin(ωt)
the output voltage from resistive voltage divider is

R2
us (t) = ––––––– √2Up sin(ωt)
R1 + R2
Also for this case, value of the output signal could be easily
measured using a voltmeter or oscilloscope

39
1. UniGear ZS1
Cable terminations

Terminations for polymer insulated Applications and features

Depending on the cable design, it is necessary to use the
cables 1 – 24 kV correct type of cable accessory. When single core cables are
It is crucial that power cables connecting the switchgear are designed with copper wire screen only, it is sufficient to use
terminated properly, and for this purpose, ABB has developed just a cable lug and a termination that fits the actual size of
an excellent range of easy-to-use products for preparation the cable.
and termination of cables. The benefit of Cold Applied accessories is that no heat or
MV power cables are normally designed with a conductor open flame is necessary for installation (except for branch
of aluminium or copper, an insulation of polymer material, seals on 3-core cables). After the cable is prepared, the
an extruded insulation screen, a metallic screen, armouring termination is simply slid on without any tools. If a three
(optional) and a polymeric outer jacket. core cable is used, or a cable with copper tape screen,
To enable safe and reliable current carrying properties, it or aluminium foil screen, or a cable with armouring; then
is necessary to achieve sufficient mechanical connection additional material is required.
between the cable conductor and the bus bar. ABB offers Another very important factor is correct cable preparation,
mechanical cable lugs designed to fit the cable conductor by and ABB also offers excellent cable preparation tools.
bolting. It is also essential to guide the electrical field of the
cable correctly, and ABB offers Cold Applied terminations, Recommended cable termination products
made of rubber, that create an active pressure around the The pre-moulded cable termination type Kabeldon SOT
cable. Furthermore, if the cable is designed with another can be used on any polymer cable irrespective of design or
type of metallic screen than copper wires, special earthing conductor size. Type SOT 10 is designed for 7.2 kV cables,
kits must be used to achieve proper handling of possible while type SOT 24 covers 12, 17.5 and 24 kV. A few variants
fault currents. The armouring of the cable must have the of terminations fit a wide range of cable sizes. Extra material
same earth potential as the cable screen, so it might be such as earthing kits, crutch seals for 3-core cables and
necessary to use additional connection accessories that are screen potential material for cable armouring is also covered
also available. Detailed information can be found in separate by the ABB range of products. Please contact your ABB Sales
technical information for cable accessories. Representative for more information.

40
Figure 39: ABB Kabeldon cable termination type SOT 10 Figure 40: ABB Kabeldon cable termination type SOT 24
with bi-metallic cable lug type SKSB with bi-metallic cable lug type SKSB

Designation and sizes

Voltage level Designation Diameter Conductor size

Kabeldon over insulation mm²
kV mm 7.2 kV 12 kV 17.5 kV 24 kV
1 - 7.2 SOT 101 10.5 - 15 10 - 35 - - -
1 - 7.2 SOT 102 12.9 - 25.8 50 - 150 - - -
1 - 7.2 SOT 103 21.4 - 34.9 185 - 300 - - -
12 - 17.5 SOT 241 A 11 - 15 - 10 - 35 - -
12 - 17.5 SOT 241 15 - 28 - 50 - 185 50 – 150 -
12 - 17.5 SOT 242 24 - 39 - 240 - 500 185 - 300 -
24 - - - - - -
12 - 17.5 SOT 242 B 38 - 54 - 630 (**) 630 (**) -
24 SOT 241 A 11 - 15 - - - 10
24 SOT 241 15 - 28 - - - 25 - 120
24 SOT 242 24 - 39 - - - 150 - 400
24 SOT 242 B 38 - 54 - - - 500 - 630 (**)
(**) Can be mounted on cables with 800 and 1000 mm by using silicone rubber tape 2342 as top seal.
2

41
1. UniGear ZS1
Distribution automation

ABB’s Power Protection Philosophy return the power system to its normal operating state, or,
isolate the fault to limit damage to the power system and
With deliveries of protection IEDs (Intelligent Electronic
injury to personnel. This provides a safe environment for all.
Devices) to more than 70 countries, ABB best understands
Power protection systems do not prevent power network
the requirements of diverse protection needs as a result
faults from arising, but it will be activated only when an
of wide ranging local legislation, safety requirements and
abnormality has occurred in the power system. However,
engineering practices. Therefore, ABB has developed a power
carefully matching the available protection functionality offered
protection philosophy that not only serves the specific needs
by ABB IEDs to the specific power protection requirements
and requirements of diverse power systems, but also creates
of the power system and its components not only provides
a feeling of confidence and peace of mind for both power
the best power protection for the power system, but also
system owners and users alike.
improves the performance and the reliability of the power
The main purpose of an ABB IED power protection system
protection system within it, thus minimizing the effects of
is to recognize any abnormal power system conditions, or
power network faults and preventing the abnormalities or
abnormally operating components within the power system.
disturbances from spreading to the healthy parts of the power
Then, based on the information gathered by the IED, the
network.
power protection system will initiate corrective actions to

42
Advantages of a complete power resistance earth faults and short circuits in the most distant
parts of the power network. Reliable selectivity is essential
protection system in order to limit the loss of power supply to as small an area
Operating speed, sensitivity, selectivity and reliability are as possible, and to allow the abnormal or faulted part of the
the integral elements of the power protection system and power network to be reliably located.
need mentioning. There is a strong correlation between Corrective actions can then be directed to the abnormal or
the operating speed of the power protection system and faulty part of the network, and the supply can be restored as
the damage and danger caused by a power network rapidly as possible.
fault. Substation automation provides remote control and The power protection system must also have a high degree
monitoring capabilities, which speeds up the location of of reliability. This also means that if for example a CB (circuit-
faults, and therefore the restoration of the power supply after breaker) fails to operate, the backup power protection will
a fault. Fast operation of the power protection IEDs also identify the fault and react.
minimizes post-fault load peaks, which together with voltage Substation Automation (SA) puts the operator in perfect
dips increase the risk of the power disturbance spreading control of the substation. In addition to the SA system
to healthy parts of the power network. The sensitivity of the improving the power quality of the power transmission
power protection must be adequate to detect relatively high and distribution network under normal operation, it
especially improves the quality of the power transmission
and distribution network’s available power in a situation of
disturbance and during substation maintenance. A SA system
or SCADA (supervisory control and data acquisition) system
brings the full benefits of numerical technology into protection
and control of power networks. The terminals are easily set
and power protection parameters configured to the specific
High requirement needs of the power system through easy and safe access via
the operator’s workplace.

Infeed from both ends Single-function and multi-function

terminals
Ring main feeders Correct power protection methods and comprehensive
Distance functionality increase the performance of the power protection
protection
Parallel feeders
system.
The definition of comprehensive functionality varies with the
requirements of the protected power network or system.
Single line While single-function power protection IEDs are sufficient for
IED Features

Feeders with
diagram HMI*
distributed some network applications, more complex power networks
Feeder type

generation
and systems need advanced multi-functional power protection
Fault locator IEDs. Single-function Power protection IEDs include a set of
Radial feeders power protection functions for, for instance, a specific feeder
with reclosers/ application type.
sectionalizers Power quality
monitoring The main advantages of these power protection IEDs are
redundancy and price. One or more single-function power
protection IEDs would provide sufficient protection in most
Radial Communication
feeders power protection application areas.

Auto re-closure

Single function * Human Machine

Interface

Standard requirement

Figure 41: Comparison between standard and high requirement feeders

43
1. UniGear ZS1
Distribution automation

Feeder protection Applications and features

The power protection applications can be roughly divided into Depending on the requirements a suitable IED type can be
two categories, namely standard applications (utilizing basic selected and configured in such a way that an overall solution
current based protection) and high requirement applications can be found for different feeder types.
(utilizing current and voltage based protection) and then also Generally, the required power protection functionality of these
the combinations of the two. feeder types differ greatly depending on, amongst other
The selected power protection scheme or system has to fulfill things, the characteristics of the source of the fault current
the application-specific requirements regarding sensitivity, and the type of advanced functions that may be additionally
selectivity and operating speed of the power protection. needed to fulfill the basic requirements of the power
The power protection requirements are mainly determined by protection application.
the physical structure of the power network or system and
in most cases the requirements can be fulfilled with non- Recommended products
directional/directional over-current protection IEDs.
The recommended products for feeder protection are part of
In power networks or systems with a more complex structure
ABB’s Relion® product family of power protection IEDs. These
more advanced power protection functions like distance
IEDs have been developed after many years of experience
protection or line differential protection may have to be
gathered from wide ranging application and functionality
introduced.
requirements of ABB customers globally. The popular RE500
The purpose of the over-and under-voltage power protection
series IEDs also played a big part in ABB’s success in this
system is to monitor the voltage level of the network. If the
area.
voltage level deviates from the target value by more than the
Relion ® products have been designed to implement the
permitted margin for a set time period, the voltage protection
core values of the IEC 61850 standard. The genuine
system is activated and it initiates actions to limit the duration
implementation of the IEC 61850 substation communication
of this abnormal condition and the resulting stresses caused
standard covers vertical as well as horizontal communication
to the power system or its components.
between IEDs.
To prevent major outages due to frequency disturbances,
the substations are usually equipped with under-frequency
protection IEDs, which in turn control various power load-
shedding schemes.These are just a few examples of the major
power protection functions for power feeders.

Figure 42: Feeder protection and control REF630

44
•  Feeder Protection and Control REF630 provides main neutrals. Furthermore, making use of the IED’s advanced
protection for overhead lines and cable feeders of power inter-station communication facilities, REF615 can also be
distribution networks. REF630 fits both isolated neutral applied for protection of ring-type and meshed distribution
networks and power networks with resistance or impedance networks as well of radial networks.
earthed neutral. As of now, the REF615 suite consists of eight standard
Four pre-defined configurations to match typical feeder configurations to suit the most common feeder protection and
protection and control requirements are available. control applications as well as your current and forthcoming
The pre-defined configurations can be used as such, or the feeder protection requirements.
IED can easily be modified or functionally extended with freely
selectable add-on functions to help fine-tune the IED to meet •  Feeder Protection REF610 is primarily intended for
even the most demanding individual application requirements the protection of incoming and outgoing feeders in power
-exactly. distribution substations of resistance earthed and solidly
earthed power systems. REF610 is suitable for employment in
•  Feeder Protection and Control REF615 is a dedicated marine and off-shore environments. Supplied with an optional
feeder IED perfectly aligned for the protection, control, arc protection function REF610 also provides fast substation
measurement and supervision of utility and industrial power busbar arc-fault protection. The REF610 is also used for
distribution systems. It provides mainly protection for back-up protection of motors, transformers and generators to
overhead lines, cable feeders and busbar systems of power increase protection redundancy in critical utility and industrial
distribution substations. It fits both isolated neutral networks applications.
and power networks with resistance or impedance earthed

Figure 43: Feeder protection and control REF615 Figure 44: Feeder protection REF610

45
1. UniGear ZS1
Distribution automation

Transformer protection Recommended products

The power transformer is one of the most important The recommended products for transformer protection are
components, as well as one of the most valuable individual part of ABB’s Relion® product family of power protection
units in the power distribution network. IEDs. These IEDs have been developed after many years
Therefore, the particular importance of preventing of experience gathered from wide ranging application and
disturbances in the power distribution system is almost functionality requirements of ABB customers globally.
completely dependent on a functioning power transformer. The popular RE500 series IEDs also played a big part in
Although high-quality power transformers are highly reliable, ABB’s success in this area.
insulation breakdown faults occasionally occur. These faults, Relion ® products have been designed to implement the
appearing as short circuits and/or earth faults generally cause core values of the IEC 61850 standard. The genuine
severe damage to the windings and transformer core. The implementation of the IEC 61850 substation communication
damage is proportional to the fault clearing time so the power standard covers vertical as well as horizontal communication
transformer must be disconnected as quickly as possible. between IEDs.
The power transformer has to be transported to a workshop
for repair, which is a very time-consuming process. The
operation of a power network where the power transformer
is out of service is always cumbersome. Therefore, a power
transformer fault often constitutes a more severe power
system fault than a line fault, which usually can be rectified
rather quickly. It is extremely important that fast and reliable
protection IEDs are used to detect transformer faults and
initiate tripping.
The size, voltage level and importance of the power
transformer determine the extent and choice of monitoring
and protection devices to be used to limit the damage at a
possible fault. When compared to the total cost of the power
transformer and the damages caused by a power transformer
fault, the cost of the power protection system is negligible.

Figure 45: Transformer protection and control RET630

46
•  Transformer Protection and Control RET630 is a •  Transformer Protection and Control RET615 is a
comprehensive transformer management IED for protection, dedicated transformer protection and control IED for two-
control, measuring and supervision of power transformers, winding power transformers, unit and step-up transformers
unit and step-up transformers including power generator- including power generator-transformer blocks in utility and
transformer blocks in utility and industry power distribution industrial power distribution systems.
networks. It provides main protection for two-winding power RET615 offers eight standard configurations to match applied
transformers and power generator-transformer blocks. transformer neutral earthing principles with either high
Two predefined configurations to match your typical impedance or numerical low impedance restricted earth-fault
transformer protection and control specifications are available. protection schemes. CT ratio differences and phase shifts of
The pre-defined configurations can be used as such, or the all commonly employed power transformer vector groups are
IED can easily be modified or functionally extended with freely numerically compensated for. RET615 features also local or
selectableadd-on functions to help fine-tune the IED to meet remote control of the transformer HV side circuit_breaker.
even the most demanding individual application requirements
-exactly.

Figure 46: Transformer protection and control RET615

47
1. UniGear ZS1
Distribution automation

Motor protection Recommended products

Motor protection is generally expected to provide overcurrent, The recommended products for motor protection are part of
unbalance, earth-fault and short-circuit protection. However, ABB’s Relion® product family of power protection IEDs.
the fundamental issue for motors is thermal protection, as These IEDs have been developed after many years of
overheating is the worst threat to the motor. experience gathered from wide ranging application and
Motors need to be protected not only against electrical faults functionality requirements of ABB customers globally.
but also against any improper usage. ABB’s solutions focus The popular RE500 series IEDs also played a big part in
on advanced thermal protection that prevents improper use ABB’s success in this area.
of the motors. The thermal overload protection is needed Relion ® products have been designed to implement the
to protect the motor against both short-time and long-time core values of the IEC 61850 standard. The genuine
overload and so it is of great importance for the performance implementation of the IEC 61850 substation communication
of the motor. Overload conditions of short duration mainly standard covers vertical as well as horizontal communication
occur during motor start-up. between IEDs.
Improper use of a running motor does not necessarily damage
the equipment but shortens its lifespan. Therefore, a reliable •  Motor Protection and Control REM630 is a
and versatile motor protection system not only protects comprehensive motor management IED for protection,
the motor but it also prolongs the motor’s life-cycle, which control, measuring and supervision of medium and large
contributes to improving the return on investment of your asynchronous motors in medium voltage industrial power
motor drive. systems.
REM630 is a member of ABB’s Relion® product family and
a part of its 630 product series characterized by functional
scalability and flexible configurability. It also features
necessary control functions required for the management of
industrial motor feeder bays.

Figure 47: Motor protection and control REM630 Figure 48: Motor protection and control REM615

48
REM630 provides main protection for asynchronous motors •  Motor Protection Relay REM610 is a motor IED for the
and the associated drives. The motor management IED protection, measuring and supervision of medium sized and
is intended for circuit-breaker and contactor controlled large asynchronous LV motors and small and medium-sized
medium sized and large asynchronous motors in a variety asynchronous HV motors in manufacturing and process
of drive applications, such as motor drives for pumps, industry.
fans, compressors, mills, crushers, etc. The pre-defined The REM610 IED can be used with both circuit-breaker and
configuration can be used as such or easily customized or contactor-controlled motor drives in a variety of applications.
extended with add-on functions, by means of which the motor Enhanced with an optional add-on card for RTD sensors
management IED can be fine-tuned to exactly satisfy the or thermistor elements, the IED can be used for direct
specific requirements of your present application. temperature measurement of critical motor items, such as
bearings and windings. It is also used for the protection of
•  Motor Protection and Control REM615 is a dedicated cable feeders and distribution transformers benefiting from
motor IED perfectly aligned for the protection, control, thermal overload protection besides phase overcurrent
measurement and supervision of asynchronous motors in protection, earth-fault protection and phase unbalance
manufacturing and process industry. Typically, REM615 is protection.
used with circuit-breaker or contactor controlled HV motors,
and contactor controlled medium sized and large LV motors
in a variety of drives. REM615 is available in three standard
configurations including all the basic motor protection
functions, voltage protection functions and power and energy
measurements. Local or remote start/stop control of the
motor is also facilitated.

Figure 49: Motor protection REM610

49
1. UniGear ZS1
Distribution automation

Voltage Protection Arc protection

REU615 is available in two predefined, off-the-shelf An electric arc short-circuit in a switchgear installation is
configurations, denoted A and B, targeted for two of the most normally caused by a foreign object entering the cubicle or a
common applications of the IED. component failure. The arc causes an explosion-like heat and
The A configuration of REU615 is pre-adapted for voltage and pressure effect usually causing vast damage to the switchgear
frequency based protection applications in utility and industrial and the operation personnel.
power systems and distribution systems including networks An adequate arc protection system protects your substation
with distributed power generation. against arc faults by minimizing the burning time of the arc,
The A configuration of REU615 is indented to be used in thus preventing excessive heat and damage. It minimizes
medium voltage switchgear systems with a separate voltage material damage and allows power distribution to be smoothly
measuring cubicle. and safely restored. The system can also bring cost benefits
The A configuration of REU615 provides busbar overvoltage even before an arc fault occurs. As older switchgear is more
and undervoltage supervision, network residual voltage and prone to arc faults, an arc protection system will effectively
frequency supervision. extend the life of your switchgear and make more of your
The B configuration is pre-adapted for automatic voltage investment. But what is even more important, this technology
regulation. Both configurations also allow CB control can help save lives.
and provide measuring and supervising functions. The B
configuration of REU615 featuring voltage regulation capability
is targeted for automatic and manual voltage regulation of
power transformers equipped with a motor driven on-load
tap-changer.
REU615 is a member of ABB’s Relion® protection and control
product family and its 615 product series. The 615 series IEDs
are characterized by their compactness and withdrawable-
unit design. Re-engineered from the ground up, the new 615
series has been designed to unleash the full potential of the
IEC 61850 standard for communication and interoperability
between substation automation devices.

Figure 50: Voltage protection REU615 Figure 51: Arc protection REA 101 with extensions REA 103,
REA 105 and REA 107

50
Applications and features Recommended products
Sources of arcing may be insulation faults, maloperating •  Arc protection system REA 101 with its extension units
devices, defective bus or cable joints, overvoltage, corrosion, REA 103, REA 105 and REA 107 are designed to be used
pollution, moisture, ferro-resonance (instrument transformers) for the protection of medium and low-voltage air-insulated
and even ageing due to electrical stress. Most of these arc switchgear.
fault sources could be prevented by sufficient maintenance. The central unit type REA 101 operates independently or
However, in spite of the precautions taken, human errors can together with other REA 101 units. REA is the fastest arc
lead to arc faults. protection system on the market, providing tripping times
Time is critical when it comes to detecting and minimizing down to 2.5 ms.
the effects of an electric arc. An arc fault lasting 500 ms may REA is equipped with a fast integrated overcurrent-sensing
cause severe damage to the installation. If the arc lasts for element and is thus working independently from other feeder
less than 100 ms the damage is often restricted, but if the arc protection units.
is extinguished in less than, for example, 4 ms The REF615 and REF610 feeder protection IEDs include an
the damage is insignificant. optional arc protection function for the feeder cubicle.
Generally applied, protection IEDs are not fast enough to
ensure safe fault clearance times at arc faults.
The operation time of the overcurrent IED controlling the
incoming circuit breaker may, for instance, have to be delayed
hundreds of milliseconds for selectivity reasons.
This delay can be avoided by installing an arc protection
system. The total fault clearance time can be reduced to max
2.5 ms plus the circuit breaker’s contact travel time.
Furthermore, at cable compartment faults, auto-reclosures
can be eliminated by employing arc protection.

Figure 52: Typical setup with REA 101 and subunits 103

51
1. UniGear ZS1
Distribution automation

Station automation COM600 Product

COM600, ABB’s station automation device, is an all-in- The Station Automation COM600 offers web server
one communication gateway, automation platform and functionality, providing a human machine interface (HMI) for
user interface solution for utility and industrial distribution local substation monitoring and control. Secure communication
substations. enables the access of the substation HMI over the internet
The gateway functionality provides seamless IEC61850 or LAN/WAN for any authorized user with a standard PC and
connectivity between substation IEDs and network-level control a web browser. By connecting a laptop computer to the unit
and management systems. locally, an HMI for full monitoring and control functionality is
The automation platform with its logic processor makes obtained on the substation level.
COM600 a flexible implementation platform for substation The Station Automation COM600 also provides gateway
level automation tasks. As a user interface solution COM600 functions for mapping data and signals between substation and
accommodates web technology based functionalities providing higher-level systems such as SCADA, DSC.
access to substation devices and processes via a web browser The COM600 is designed for smooth system integration and
based human machine interface (HMI). interoperability based on pre-configured solutions utilizing
connectivity packages for ABB IEDs.

Figure 53: Station Automation COM600

52
Application and features The COM600 is fully compliant with the IEC 61850 standard
for distribution automation. Thus it provides full interoperability
With their compact and robust design, the COM600 is well
with any IEC 61850 compliant IEDs, tools and systems, which
adapted for harsh environments. It meets the IP4x degree
simplifies system design and commissioning.
of protection by enclosure and contains no moving parts
The commissioning of ABB IEDs is straight forward due to the
subject to wear and tear. The COM600 is based on embedded
support of ABB’s unique connectivity package concept, which
technology for durability and maximum availability. The features
simplifies system configuration and reduces the risk of errors
and compact dimensions of the COM600 enable it to be easily
in the system integration, minimizing device configuration and
installed in the Low Voltage Compartment of most UniGear
set-up times.
ZS1 panels. COM600 is suitable for both industrial and utility
applications.
For more detailed information, the technical and product guides
The COM600 incorporates OPC Server functionality, which
for COM600 are available at
provides one entry point to all the information of a substation,
http://www.abb.com/substationautomation
and the IEC 61850 support enables connectivity and seamless
communication with application-specific equipment.

distributed Remote
EMS/ control Access-
scada system Engineering

OPC Client/Server wan

Ethernet switch
GPS

Serial protocols
(DNP3, IEC 60870-5-101)
LAN1

Ethernet switch
TCP/IC protocols Serial protocols
(IEC 61850, DNP3, (Modbus®)
Modbus®)

REF601 REF601
REF610 REF610 REF615 REF615 Secondary distribution switchgear

Figure 54: Overview of a system using Station Automation COM600

53
1. UniGear ZS1
Distribution automation

Selection table of relays

REF RED
Application
610 615 630 54_ 542+ 615
Voltage based protection • • •
Feeder application (Incomming and/or Outgoing) • • • • • •
High requirement feeder application • • •
Transformer application • •
High requirement transformer application •
Motor protection • •
High requirement motor protection •
Generator & synchronous motor protection
Distance protection • • •
Line differential protection • •
Back-up Protection • • •
Arc protection o o

Communication Protocols
IEC61850-8-1 o • • •* •* •
IEC60870-5-103 • • • • •
DNP 3.0 • • • • • •
SPA • • •
LON • •
Modbus • • • • •
Profibus o •* •* •* •*

Additional Functionality
Fault locator • • •
Auto re-closure 3 shots 5 shots 2 shots 5 shots 5 shots o(5 shots)
On load tap changer control
Disturbance recording • • • • •
Withdrawable release mechanism • • •
Single line diagram HMI** • • • • •
Local control • • • • • •
Remote control • • • • • •
Condition monitoring • • • • •
Power quality monitoring •
Analog inputs (VT/CT) -/4 9/8 -/5
Sensor inputs • • •
Binary Inputs / Outputs 5/8 18/13 32/27 42/24**** 18/13
RTD*** / mA inputs 8/- 6
mA outputs o(4) o(4)

* With interface protocol converter

** HMI - Human Machine Interface
*** RTD - Resistive Temperature Detector
**** 27 if outputs are static outputs
1) REU615 with A configuration, for voltage and frequency based protection
2) REU615 with B configuration, for tap changer control
o = optional
s = secondary application

54
 REM RET REU REX REA
610 615 630 54_ 615 630 54_ 610 615 521 10_
• • • •¹ •
s • •
•
s • • • •²
•
• • • • •
• •
• •

o o o •

•* • • •* • • •* o • •*
• • • • • • •
• • • • • • • •
• • • • •
•* • • •
• • • • • • • •
•* • •* •* o •* •*

5 shots 5 shots
• •
• • • • • • •² •
• • • • •
• • • • • • •
• • • • • • • • • •
• • • • • • • • •
• • • • • •
•
-/4 -/5 4/5 -/7 3/9 4/- -/3
• • •
5/8 12/10 32/27 14/13 32/27 5/8 1/3
6/- 6/2 8/- 6/2 8/- 6 / 2²

55
1. UniGear ZS1
Automatic transfer system

Automatic transfer systems are used to ensure ATS

maximum service continuity, supplying the power users
The REF542plus unit can be used in medium voltage
uninterruptedly.
switchgear to manage automatic and manual transfer
All this is possible using various systems based on
between two different incoming feeders.
different kinds of techniques.
The time needed for automatic transfer carried out by means
of the REF542plus unit is between 200 and 300 milliseconds
The most common of these are outlined below, with the
(including the circuit-breaker operating times).
relevant average transfer times:
This time can vary within the range indicated in relation to the
• Delayed: 1500 ms
complexity of the software transfer logics.
• Depending on the residual voltage: 400-1200 ms
Switchgear equipped with REF542plus, suitably programmed,
• Synchronised (ATS): 200-500 ms
are complete and efficient systems able to manage transfer
• High speed (HSTS): 30-120 ms
between one power supply system and an alternative one,
or to reconfigure the network, passing from double radial
The first two systems are the simplest and can also be
distribution to a simple system, in a fully automatic way.
achieved with conventional logics and instruments.
It is also possible to carry out the same operation manually
They guarantee average transfer times and can therefore be
from a remote control station, or from the front of the
used in installations where voltage gaps are not particularly
switchgear under user supervision.
critical.
Manual transfer means making the passage parallel: by means
On the other hand, the other two systems (ATS – Automatic
of the synchronism control function (synchro-check–code 25)
Transfer System and HSTS – High Speed Transfer System)
implemented from the REF542plus, the power supply lines
require microprocessor-based apparatus with high technology
are closed simultaneously with synchronisation of the voltage
content.
vectors to then return to being disconnected when transfer
They guarantee fast transfer times and their application is
has taken place.
in plants where the process is particularly critical, so that
The applications described do not require additional
transfers which are not extremely fast would cause serious
instruments.
malfunctions or interruption of the process itself.
ABB is able to offer all the transfer systems, from the simplest
to the most complex.

Figure 55: Single-line diagram of UniGear ZS1switchgear with REF542plus architecture applied, suitable for carrying out automatic
and manual transfer (ATS), as well as the switchgear protections and measurements

56
SUE3000 High Speed Transfer Device • Permanent network comparisons
An exceptionally important characteristic, that clearly
Voltage decreases or complete supply interruptions represent
distinguishes the SUE3000 High Speed Transfer Device
the most important and critical problems for the quality of
from competing concepts, is that synchronicity criteria are
energy supply today. The SUE3000 High Speed Transfer
continuously available, e.g. that they are computed online by
Device guarantees an optimum safeguarding of energy supply.
the SUE3000.
The device ensures the continued supply to the consumer
For that reason, in case of an initiation, the transfer mode
through automatic transferring of power to a stand-by feeder
which comes under consideration is already determined and
and protects the subsidiary process from expensive stoppage
can be immediately initiated. This means that the probability
time. Furthermore, through the possibility of manually-initiated
of a fast transfer is considerably enhanced. Systems which
power transfers –for targeted clearings, for example –the
wait for the instant of initiation to initiate the determination of
installation is considerably simplified.
the network status have no opportunity, when one considers
the physical givens, to perform a fast transfer with minimum
• Application areas
interruption time.
The SUE3000 High Speed Device can be implemented in
applications where a disturbance of the electrical power
• Transfer modes and times
supply would lead to a breakdown in production and the
Four different transfer modes are available in detail: Fast
resulting costs or loss in productivity.
transfer, Transfer at the 1st phase coincidence, Residual
Possible areas of utilization include for example:
voltage transfer, Time-operated transfer. The fast transfer is
•  Auxiliary installation serving power stations
the optimum transfer mode for ensuring in case of fault that
•  Environmental technology installations
only a minimum interruption of the voltage supply occurs. In
•  Voltage supply to continuous industrial processes.
case of fast transfer the total transfer time, counting from a
In order to realize a permanent availability of power, the load
fault in the main feeder until the standby feeder is cut in, is
is supplied from at least two synchronized feeders which are
less than 100ms.
independent from one another and which are equipped with
SUE3000 High Speed Transfer Devices.
In doing so, the SUE3000 High Speed Transfer Device has
the task of ensuring uninterrupted continuous operation of
the connected devices in case of a power supply breakdown,
taking into account different physical factors; by way of the
fastest possible transfer to a standby feeder.
Corresponding to its multifaceted areas of application, the
SUE 3000 is set up for different switchgear arrangements.

Figure 56: SUE 3000 High Speed Transfer Device Figure 57: An example of switchgear

57
1. UniGear ZS1
Typical units

Single-line diagram of typical units

Withdrawable

Withdrawable
IF - Incoming/outgoing feeder BT - Bus-tie R - Riser RM - Riser with measurements
Withdrawable
Withdrawable

Withdrawable

M - Measurements IFD - Direct incoming/outgoing IFDM - Direct incoming/ outgoing DF - Switch-disconnector unit
feeder feeder with measurements

58
Single-line diagram of the busbar applications

Current transformers Voltage transformers Duct entry Earthing switch

Graphical symbols

Circuit-breaker Contactor Switch-disconnector Disconnector Isolating bar Socket and plug

Voltage transformers Current transformers Fuse Earth Cable entry Busbar entry

Key to components Standard components Accessories Alternative solutions

59
1. UniGear ZS1 - Single Busbar System
Technical data
Units: ... 12 kV - 17.5 kV - ... 31.5 kA
Width (mm) 650 800 1000
Height (mm) 2200/2595 (1)
2200/2595 (1)
2200/2595 (1)

Height with gas exhaust duct (mm) 2675 (4)

2675 (4)
2675 (4)

Depth (mm) 1340 1340 1390 1340 1390 1405

Rated current (A) 630 1250 1600 2000 2500 630 1250 1600 2000 2500 3150 3600 4000 1600 2000 2500 3150 3600 4000
IF Incoming/outgoing (2) (2) (2)

BT Bus-tie
R Riser
RM Riser with measurements
M Measurements
IFD Direct incoming/outgoing
Direct incoming/outgoing with
IFDM
measurement
DF Switch-disconnector unit (3)

IFC Contactor panel (2), (6)

Units: ... 12 kV - 17.5 kV - 40 / 50 kA

Width (mm) 650 800 1000
Height (mm) 2200/2595 (1)
2200/2595 (1)
2200/2595 (1)

Height with gas exhaust duct (mm) 2700 (4)

2700 (4)
2700 (4)

40 kA 1340 1390 1340 1390 1405

Depth (mm) 1390
50 kA 1390 1455 1390 1455
Rated current (A) 630 630 1250 1600 2000 2500 3150 3600 4000 2000 2500 3150 3600 4000
IF Incoming/outgoing
BT Bus-tie
R Riser
RM Riser with measurements
M Measurements
IFD Direct incoming/outgoing
Direct incoming/outgoing
IFDM
with measurement
IFC Contactor panel (2), (6)

Units: ... 24 kV - ... 31.5 kA

Width (mm) 800 1000
Height (mm) 2325/2720 (1)
2325/2720 (1)

Height with gas exhaust duct (mm) 2733 (4)

2733 (4)

Depth (mm) 1700 (5)

1700 (5)

Rated current (A) 630 1250 1600 2000 2500 630 1250 1600 2000 2500 3150
IF Incoming/outgoing
BT Bus-tie
R Riser
RM Riser with measurements
M Measurements
IFD Direct incoming/outgoing
Direct incoming/outgoing
IFDM
with measurement
(1) The height of the unit is a function of the height of the low voltage compartment, available in the 705 and 1100 mm versions.
(2) For the characteristics of the unit equipped with contactor refer to page 25.
(3) For the characteristics of the unit equipped with switch-disconnector refer to page 26.
(4) Others solutions are available, please contact ABB representative.
(5) For short-time current up to 25 kA a 1560 mm depth version is available.
(6) Rated current, short current and internal arc are restricted by coordinated fuses.

60
 Height with gas exhaust duct
Height Unit compartments
A Circuit-breaker compartment
B Busbar compartment
C Cable compartment
D Low voltage compartment
E Gas duct channel

Width Depth

Figure 58: Example of switchgear with gas duct Figure 59: Example of switchgear with gas duct Figure 60: Example of UniGear ZS1 with higher
with top chimneys (total height of the with outlet (total height of the LV compartment (1100 mm)
switch-gear is 2530 mm for 12-17,5 kV switchgear is 2675 mm for 12-17,5 kV
up to 40 kA) up to 40 kA)

61
62
63
2. UniGear ZS1 - Double Busbar System
Description

When ABB developed UniGear ZS1, the double busbar

system was included since the beginning.
The users of UniGear ZS1 double busbar system are
mainly power utility companies, main substations and
heavy industries. In any case the using of this product
is highly recommended where there is the request to
increase the service continuity.

The use of UniGear ZS1 double busbar switchgear is

necessary when some of the following features are required:
• Load shedding of outgoing feeders with a different level of
importance during emergency conditions;
• Isolation of particular outgoing feeders from the normal
network;
• Outgoing feeders balancing on two busbar systems during
normal operating condition;
• Flexibility during inspection and maintenance procedures
without switchgear load interruption;
• Extension of switchgear without shutdown.
• Motor operated line-disconnector that permit fast switching
between the two busbar systems during emergency
situations (only possible with Bus-tie transversal closed).
• Free access to one busbar system during maintenance
operations while the other is in operation and the
considered unit is out of operation. • Circuit-breaker maintenance and testing without feeder
• Incoming feeders and the most important outgoing feeders shutdown.
can be equipped with two circuit-breakers in order to allow • Fewer number of components and less switching
apparatus redundancy. apparatus.

< 2500 A < 2500 A < 4000 A < 4000 A < 4000 A < 2500 A

Figure 61: Example of one section of UniGear ZS1 double busbar system

64
The UniGear ZS1 double busbar systems are based on two IEC electrical characteristics
different panel types:
Rated voltage kV 12 17.5 24
• Two busbar systems, two busbar-disconnectors and one
Test voltage kV 1 min 28* 38* 50
circuit-breaker (up to 2500 A-12-17.5 and 2000 A-24 kV);
Impulse withstand voltage kV 75 95 125
• Two busbar systems, two circuit-breakers compartments
Rated frequency Hz 50/60 50/60 50/60
with one or two circuit breakers, this version is called duplex
Rated short-time
system (up to 4000 A-12-17.5 kV and 2500 A-24 kV). withstand current
kA 3 s up to 31.5 31.5 25
Both types provide full busbar system redundancy Peak withstand current kA up to 80 80 63
(physical isolation between source busbar systems) and allow
Internal arc withstand current kA 1 s up to 31.5 31.5 25
uninterrupted and reliable service conditions.
Thanks to the numerous standard units available, the Rated current of the
A up to 4000 4000 2500
main busbars
switchgear can be suitably configured to satisfy all
Rated circuit-breaker
A up to 4000 4000 2500
configuration requirements. thermal current
Each switchgear panel can be equipped with circuit-breakers. 630 630 630
All the significant components and accessories are identical 1250 1250 1250
Double busbar-disconnector
to those used for UniGear ZS1 single level and double level feeders rated current
A 1600 1600 1600
units and therefore the same operation and maintenance 2000 2000 2000
procedures are guaranteed. 2500 2500 -
ABB double busbar system can be provided with single Duplex feeder rated current A 3150 3150 -
section or two or more sections in order to satisfy the most Duplex feeders rated current 3600 3600 2500
A
demanding customer request. with forced ventilation 4000 4000 -
For examples refer to the two sections: 1) For other versions, please refer to the chapters nr.1 (Single Level) and chapter nr.3 (Double
level).
• One section of double busbar (please refer to figure 61). 2) The values indicated are valid for both vacuum and SF6 circuit-breaker.
• Two sections of double busbar (please refer to figure 62). 3) For panel with contactor the rated current value is 400 A.
* 42 kV (GB/DL)

< 2500 A < 4000 A < 2500 A < 4000 A < 4000 A < 2500 A < 4000 A < 2500 A

Figure 62: Example of two sections of UniGear ZS1 double busbar system

65
2. UniGear ZS1 - Double Busbar System
Characteristics

Compartments Busbar disconnectors

Each panel is made up of four independent power IF unit busbar-disconnectors are designed to act as two
compartments: apparatus (A), busbar 1 (B1), busbar 2 (B2) position switches - open and closed positions - and operation
and cable (C), please refer to page 69. is manual (e.g. without springs assistance).
There is a metallic segregation between all the compartments. The opening and closing operation of the busbar-disconnector
In its front/top part the panel is fitted with a compartment to is operated from the front of the panel.
take the auxiliary instruments (D). The position of the busbar-disconnector is indicated on the
front of the panel with mechanical coupled indicators.
UniGear ZS1 double busbar system is arc-proof version and
supplied with a duct for the evacuation of the gases produced The busbar-disconnectors are clearly separated and the
by an arc (E). relevant busbar compartments are segregated from each
other in order to achieve the following:
Each compartment of the unit is fitted with a flap on the top • It should be possible to carry out maintenance and also
surface. The pressure generated by the fault makes this open, extend the switchgear with additional units, keeping one
allowing the gas to pass into the duct. of the two busbars systems energised.
The apparatus compartment is accessible from the front. Door • A fault generated in one compartment (e.g. insulation
closing of these compartments is available in two versions, discharge) will not generate any damage to the others or
with screws or central handle. require the shutdown of the unit.
Removal of the apparatus from the switchgear (circuit-
breakers and contactors) and from its relative compartments Busbar-disconnectors are provided with limit switches for
takes place by means of a single dedicated truck. the detection of operating position and they can be operated
manually or, as an option, motor operated.
The busbar and cable compartment are accessible from the
rear of the switchgear by means of removable panels. The busbar-disconnectors are provided with the necessary
All the normal service operations are carried out from the interlocking facilities.
front, whereas maintenance and start-up operations also The interlocks between the two line disconnectors and the
require access from the rear of the switchgear. circuit breaker are implemented by means of locking magnets.

Figure 63: Closed position of busbar-disconnector Figure 64: Open position of busbar-disconnector

66
The busbar-disconnector consists of a moveable copper
tube housed inside an epoxy insulator. Electrical contact is 7
guaranteed by two or four connection springs (depending on
the rating of the disconnector).
Additional protective insulating caps are mounted on both 2
sides of the insulator, thus providing the device with a high
level of reliability.

1 Door of the apparatus compartment

2 Low voltage compartment
3 Racking-in/racking-out operation (apparatus)
4 Earthing switch operation
5 Open/closed busbar-disconnector B1
6 Open/closed busbar-disconnector B2
7 Gas duct channel

Figure 65: Front panel with operating slots of busbar-disconnector Figure 66: Double busbar system with two busbar-disconnector

Figure 67: The two busbar compartments

67
2. UniGear ZS1 - Double Busbar System
Typical units

Single-line diagram of typical units

IF - Incoming/Outgoing IF and IFM - Busbar A Duplex IF and IFM - Busbar B Duplex BTT - Transv. Bus Tie

M - Measurements BTL - Longitudinal Bus Tie RL - Bus Riser Longi- RLM - Bus Riser Longitudinal with
tudinal Metering

68
Busbar applications

Top-mounted VTs Top-mounted earthing switch Top entry duct

Key to components Standard components Accessories Alternative solutions

69
2. UniGear ZS1 - Double Busbar System
Technical data

Units ... 12 - 17.5 kV - ... 31.5 kA

Depth (mm) 2021 2021 2021
Height (mm) 2200/2595 (1) 2200/2595 (1) 2200/2595 (1)
Height with gas exhaust duct (mm) 2700 (2)
2700 (2)
2700 (2)
Width (mm) 650 800 1000
Rated current (A) 630 1250 1600 2000 2500 1600 2000 2500 3150 3500 4000 2500 3150 3500 4000
IF Incoming/outgoing
Incoming/outgoing
IF
duplex feeder
Incoming/outgoing duplex
IFM
feeder with measurements
BTT Transverse bus-tie
M Measurements
BTL Longitudinal bus-tie
RL Longitudinal riser
Longitudinal riser
RML
with measurements

Units ... 24 kV - ... 25 kA

Depth (mm) 2570 2570
Height (mm) 2400/2720 (1) 2400/2720 (1)
Height with gas exhaust duct (mm) 3000 (2) 3000 (2)
Width (mm) 800 1000
Rated current (A) 630 1250 1600 2000 2500 1600 2000 2500
IF Incoming/outgoing
IF Incoming/outgoing duplex feeder
IFM Incoming/outgoing duplex feeder with measurements
BTT Transverse bus-tie
M Measurements
BTL Longitudinal bus-tie
RL Longitudinal riser
RLM Longitudinal riser with measurements

IF and IFM duplex feeder, M, BTL, RL and RLM are available for both A and B busbar system connections.
1) The height of the unit ia a function of the height of the low voltage compartment, available in the 705 and 1100 mm versions.
2) Others solutions are available, please contact ABB representative.

70
 Height with gas exhaust duct

Height

Width Depth

Unit compartments
A Apparatus compartment
B Busbar compartment
C Cable compartment
D Low voltage compartment
E Gas duct channel

71
72
73
3. Marine applications
Description

The Marine Market is divided into four different segments:

• Passenger vessels (cruise ships and ferries).
• Industrial vessels (shuttle tankers, drill ships, oil carriers,
cargo vessels, etc.).
• Rigs (drill and oil rigs).
• Navy.
In this type of application the temperature range, vibrations
and variable inclination are particularly severe conditions that
impact the functional requirements of on-board components
such as the switchgear.

ABB is the leading manufacturer of air-insulated switchgear

for marine applications, installed by all main shipyards (Brazil,
China, Denmark, Finland, France, Germany, Japan, Korea,
Italy, Norway, Singapore, Spain, UK and USA).
The switchgear suitable for marine applications is UniGear
ZS1 in single and double level arrangement up to 7.2-12 kV
rated voltage (with the option for 17.5 kV), with the need for
many dedicated features and some special typical units.
Over 10,000 ABB panels are in service in the world on board
all kind of ships.
Registers and end-customers (shipyards or ship owners)
require switchgear manufactured to comply with Shipping
Register test requirements for on-board apparatus. Figure 68: UniGear ZS1 single level for marine application
For this purpose, tests have been performed in compliance
with the main Shipping Register regulations; DNV, LR, RINA,
BV, GL, ABS, KR and Russian regulations.
In order to guarantee the necessary comfort and facilities,
high power generation plants and control systems must be
concentrated in significantly reduced overall dimensions.
UniGear ZS1 can be offered in single level with the possibility
to be coupled with double level; it offers a wide range of
apparatus and control units to satisfy marine installation
requirements.
UniGear ZS1 switchgear provides the ideal technical solutions
for marine applications:
• Arc-proof construction, mechanical safety interlocks,
automatic segregation shutters and apparatus control
with the door closed guarantee personnel safety during
installation, operation and maintenance;
• High degree of protection (up to IP43) on the external
enclosure;
• Metallic partitions between each compartment and earthing
of all components accessible to personnel: apparatus,
shutters, doors and the whole switchgear frame;
• High fire resistance thanks to minimal use of plastic and resins:
the auxiliary equipment and wiring are highly self-extinguishing.

74
Shore connection
Ships generate emissions while docked in port by running their auxiliary engines to
create onboard electric power.
In ports with heavy ship traffic, this practice creates emissions and negative health
and environmental impact to the local surrounding communities.
As global trade steadily expands, ship emissions represent an ever-increasing
environmental concern.
Sustainability is today a key area of focus in the shipping industry, where strong
measures are being taken on several fronts to dramatically reduce ship emissions.
One such measure is shore-to-ship electric power supply, which eliminates pollution
problems and particle discharge as well as noise and vibration from ships in port.
UniGear ZS1 Shore Connection panel is delivered as a finished cabinet solution with
both a power module and a control module.
Depending on the system configuration and onboard requirements, the cabinet
may be supplied with cable connectors located in the front of the cabinet or with
openings for cable entry through the cabinet floor.
All equipment is constructed and factory tested according to international standards
and classification society rules.

Ambient conditions for classification of on-board apparatus

•  Ambient temperature from 0 °C to + 45 °C
•  Inclination up to 25° permanent

Vibration in the frequency range of 2 … 100 Hz at the following motion width

•  1mm amplitude in the frequency range of 2…13.2 Hz
•  0.7g acceleration amplitude in the frequency range of 13.2…100 Hz

Fully type tested

The UniGear ZS1 switchgear has undergone all the tests required by the
international (IEC), in addition, the tests required by the main shipping registers
(LR, DNV, RINA, BV, GL, KR and Russian) have been carried out for use of the
switchgear in marine installations.
For more information about dedicated tests required by main shipping registers,
please refer to page 13.

IEC electrical characteristics

Rated voltage kV 7.2 12
Rated insulation voltage kV 7.2 12
Rated power frequency withstand voltage kV 1 min 20 28
Rated lightning impulse withstand voltage kV 60 75
Rated frequency Hz 50 / 60 50 / 60
Rated short-time withstand current kA 3 s ...50 ...50
Peak current kA ...125 ...125
kA 1 s ...40 ...40
Internal arc withstand current
kA 0.5 s ...50 ...50
Main busbar rated current A 1250...4000 1250...4000
Circuit-breaker rated current A 630...3150 630...3150
Circuit-breaker rated current with forced ventilation A 3600...4000 3600...4000
1) The values indicated are valid for both vacuum and SF6 circuit-breaker.
2) For panel with contactor the rated current value is 400 A.

75
3. Marine applications
Characteristics

The features required for marine application, which are not Doors
part of the standard design, are described here below.
The door of the apparatus compartment and the rear panel is
always supplied with handrails.
Degree of Protection In addition, all the doors (low voltage, apparatus and cable
On request, the external housing of UniGear ZS1 can be compartments) are equipped with an appropriate stop to fix
supplied with different degrees of protection, the standard them in the open position.
one requested for marine application is IP42 or IP43; where:
• IP42: protection against foreign bodies with diameter 1mm Cables
and against water ingress at 15° maximum inclination;
UniGear ZS1 single level
• IP43: protection against foreign bodies with diameter 1mm
Single level IF and IFM units are usually delivered in the
and against water ingress at 60° maximum inclination.
deeper version (1650-1700 mm). This design will allow the
following targets to be achieved:
Duct for secondary wirings • bottom and top cable entry;
On the top of the switchgear and exactly above the low • appropriate cable terminal distance (minimum
voltage compartment as an option can be supplied the wiring requirements):
duct. - 700 mm in case of bottom entry;
Into this duct there are positioned the terminal boards related - 1000 mm in case of top entry.
to the interpanel wiring between panels. Standard depth IF units (1340-1390 mm) are also used as an
alternative in case of problems with space.
Gas duct This feeder version will only allow bottom cable entry and
a cable terminal distance in the range of 440…535 mm,
UniGear ZS1 is arc-proof version and supplied with a duct for
depending on the rated current.
the evacuation of the gases produced by an arc.
The duct is fixed on the top of the auxiliary compartment.
UniGear ZS1 double level
In marine plants, the exhaust gases cannot normally be
All the described recommendations for single level units must
evacuated out of the room and therefore the gas duct must
be applied to double level units.
always be closed on both the end-sides and equipped with
The cable terminal distance of IF units is 600 mm for all the
top chimneys.
following configurations:
If there are cases where it is possible to evacuate hot gases
• Bottom entry (both feeders);
out of the room, the gas duct with outlet can be supplied.
• Top entry (both feeders);
• Bottom and top entry (one feeder from top, one feeder from
bottom).

1 Gas exhaust duct

2 Flaps
3 Top chimneys

Figure 69: UniGear ZS1 with compact gas duct with top chimneys

76
Mixed configuration with single level, double level and motor control center

Outgoing Metering unit Incoming Slim Bus tie Bus riser Slim Incoming Metering unit Outgoing
feeders with feeder contactor contactor feeder feeders with
circuit- breakers Outgoing feeder feeder feeder Outgoing feeder circuit- breakers

Thermo-graphic inspection
Thermographic inspection is normally required on power cable
terminations and sometimes on main busbar systems.
Customers are normally much more sensitive to the former,
because cable termination faults represent a considerable
percentage of all the faults in switchgear, whereas faults in
main busbar systems are quite rare.
Thermo-graphic inspection and supervision can be done in
two ways:
• Temporary inspection by means of an IR camera through an
appropriate inspection window;
• Continuous supervision by means of IR sensors located
inside the switchgear.

The first system (temporary inspection) requires an IR camera

and an inspection window for each compartment to be
supervised.
The second system (continuous supervision) requires the
continuous thermal monitoring.
This is a non-touch temperature monitoring system based on
IR temperature probes connected to a central unit (up to 8
sensors can be plugged in to each central unit).
Due to the switchgear design constraints, the main busbar
Thermo-graphic inspection can only be carried out using
the continuous thermal monitoring system.
The power cables can be supervised with both solutions.
With regard to UniGear ZS1 double Level, we can point out Figure 70: Example of Thermo-graphic senso in UniGear ZS1 single level

that due to the switchgear design constraints, both the main

busbar and the power cables thermo-graphic inspection can
only be carried out using the continuous thermal monitoring
system.

77
3. Marine Applications
Typical units

For the typical units used in marine application please refer Additional features of Measurement and
to page 58 for UniGear ZS1 single level and page 86/87 for
UniGear ZS1 double level.The required units, which are not
Riser units
part of the standard design, are described here below. Out of choice, M and R units should be equipped with fixed
Voltage Transformers instead of withdrawable VT’s with fuses.
In this configuration the “apparatus compartment”, where
Earthing transformer units is placed the VT’s truck, will be used as an additional
From the electrical point of view, marine plants are based on auxiliary compartment. It is fully segregated from the power
isolated networks (isolated neutral point). compartments with metallic partitions and designed as a low
The main consequences are as follows: voltage compartment with respect to the safety rules.
•  the network can be operated with single-phase earth fault; The inside rear and side walls of the compartment is fitted
•  earth fault detection is very difficult, due to the very low with the grid plate for fixing the auxiliary equipment.
earth fault current. This will be equipped with the relevant left-hand side duct for
wiring entry from the bottom and exit to the top-mounted Low
In order to increase this and therefore allow releases to voltage compartment.
operate on single-phase earth faults, two solutions can be
used:
•  connecting the secondary winding of the generator to
ground by means of a resistor;
•  installing an earthing transformer in the network.

For this reason, the UniGear ZS1 range must be enhanced

with two addition typical units:
•  ME: Busbar metering unit with earthing transformer feeder;
•  RE: Rise with earthing transformer feeder.
In the case of switchgear with a single busbar section, ME
can be used for this purpose; in the case of switchgear
equipped with two busbar sections, both ME and RE units
must be used, in order to cover all the schemes.

78
ME – Metering with earthing transformer RE – Bus Riser with metering and earthing
transformer

79
3. Marine Applications
Technical data

7.2 - 12 kV - ... 31.5 kA

Unit width (mm) 650
Unit depth (mm) 1650
Rated current (A) 630 1250 1600 2000 2500
IF Incoming/outgoing duplex feeder (1) ( 3)
IFM Incoming/outgoing duplex feeder with measurements ( 1) ( 3)

Unit width (mm) 650

Unit depth (mm) 1340
Rated current (A) 630 1250 1600 2000 2500
IF Incoming/outgoing feeder (2) ( 3)
BT Bus-tie
R Riser
RE Riser with earthing transformer
RM Riser with measurements
M Measurement
ME Measurement with earthing transformer

(1) Bottom and top cable entry

(2) Bottom cable entry
(3) Up to 50 kA with vacuum contactor

80
7.2 - 12 kV - ... 40-50 kA
Unit width (mm) 650 1000
Unit depth (mm) 1650 1700 1650 1700
Rated current (A) 400 1250 1600 2000 2500 3150 4000 630 1250 1600 2000 2500 3150 4000
IF Incoming/outgoing feeder (1) ( 3)
IFM Incoming/outgoing with measurements ( 1) ( 3)

Unit width (mm) 650 1000

Unit depth (mm) 1340 1390 1340 1390
Rated current (A) 400 1250 1600 2000 2500 3150 4000 630 1250 1600 2000 2500 3150 4000
IF Incoming/outgoing feeder (2) ( 3)
BT Bus-tie
R Riser
RE Riser with earthing transformer
RM Riser with measurements
M Measurement
ME Measurement with earthing transformer
(1) Bottom and top cable entry
(2) Bottom cable entry
(3) Up to 50 kA with vacuum contactor

81
3. Marine Applications
UniGear ZS1 Double Level
Description
UniGear ZS1 is also available as single busbar system
in the double level configuration. Each panel consists of
two completely independent superimposed units and is
functionally identical to two single-level units placed side
by side.

Thanks to the numerous standard units available, the

switchgear can be suitably configured to satisfy all installation
requirements. Each unit can be equipped with circuit-breakers
or contactors, as well as with all the accessories available for
UniGear ZS1 single level units.
All the significant components are identical to those used
for the single-level units and therefore the same service and
maintenance procedures are guaranteed.
The UniGear ZS1 double level switchgear is mainly distinguished
by its efficient use of space. All the configurations allow a
drastic reduction in the space occupied, with special regard
to the width of the switchgear (30...40% less in typical
configurations).
Its use is recommended in installations with a high number of units, with the possibility of extension on both sides of the
feeders, fitted with either circuit-breakers or contactors. switchgear.
It can be used as a motor control center for applications up to The switchgear requires access from the rear for the
12 kV. installation and maintenance procedures, while all the service
All the electrical characteristics of the double and single level operations are carried out from the front.
units are identical. The UniGear ZS1 double level switchgear can be used in two
The overall rated current of the busbar system is given by the typical configurations:
sum of the currents of the two top and bottom half-busbars. • Complete with double-level.
The double-level units can be coupled directly to single-level • Compound with simple and double-level.

Figure 71: Example of complete UniGear ZS1 double level configuration

82
The complete solution only uses double level panels to realise and can be used for relatively limited rated currents (1600
all the standard units: incoming feeders, bus-tie, riser, busbar A maximum current of the incoming feeders). It is normally
measurement and outgoing units. used to construct local distribution switchgear, with a limited
The compound solution in contrast, uses both the simple and number of outgoing feeders.
double level solution: the former for the incoming feeders, The field of application of the compound solution is aimed at
bus-tie and riser compartments, the latter for the busbar main distribution switchgear, with high rated currents (3150
measurement and outgoing units. A maximum current of the incoming feeders) and numerous
The complete double level solution makes it possible to outgoing feeders.
achieve the maximum reduction in installed dimensions

IEC electrical characteristics

Rated voltage kV 7.2 12 17.5
Rated insulation voltage kV 7.2 12 17.5
Rated power frequency withstand voltage kV 1 min 20 28 38
Rated lightning impulse withstand voltage kV 60 75 95
Rated frequency Hz 50 / 60 50 / 60 50 / 60
Rated short-time withstand current kA 3 s ...50 ...50 ...40
Peak current kA ...125 ...125 ...105
kA 1 s ...40 ...40 ...40
Internal arc withstand current
kA 0.5 s ...50 ...50 –
Main busbar rated current A ...1600 ...1600 ...1600
630 630 630
1000 1000 1000
Circuit-breaker rated current
1250 1250 1250
1600 1600 1600
1) GB/DL version is available with higher request in dielectric characteristics (42 kV) and short time withstand current (4 s).
2) The values indicated are valid for both vacuum and SF6 circuit-breaker.
3) For panel with contactor the rated current value is 400 A.

Figure 72: Example of UniGear ZS1 single and double level configuration

83
3. Marine Applications
UniGear ZS1 Double Level
Characteristics
Compartments duct placed laterally to the switchgear [e]. Each compartment
of the switchgear panel placed on the 1st level is fitted with
Each panel consists of two superimposed units [1st level
a flap positioned on the side of the switchgear. The pressure
and 2nd level] and each unit is therefore made up of three
generated by the fault makes this open, allowing the gas to
independent power compartments: apparatus [A], busbar [B]
pass into the duct. This solution means the units placed on
and cable [C] (please refer to page 89).
the 2nd level are not affected by this fault.
There is metallic segregation between all the compartments.
The apparatus compartments are accessible from the front.
In its middle part, the panel is fitted with a compartment to
Door closing of these compartments is available in two
accomodate the auxiliary instruments of both the units [D].
versions, with screws or central handle. Removal of the
This solution means the apparatus interfacing with the user
apparatus from the switchgear (circuit-breakers, contactors
is at a convenient height. In the top part of the panel, an
and measurement truck) placed on the two levels and from
additional compartment is available to house any further
its relative compartments, takes place by means of a single
instruments provided [d].
dedicated fork-lift truck. This truck can also be used for the
The arc-proof switchgear is normally fitted with a duct for
same procedures for the single level units.
evacuation of the gases produced by an arc [E].
The busbar and cable compartments are accessible from the
Each compartment of the unit placed on the 2nd level is
rear of the switchgear by means of removable panels.
fitted with a flap on the top surface. The pressure generated
All the normal service operations are carried out from the
by the fault makes this open, allowing the gas to pass into
front, whereas maintenance and start-up operations also
the duct. The gases produced by faults generated in the
require access from the rear of the switchgear.
power compartments of the unit placed on the 1st level are
evacuated towards the main duct by means of a dedicated

2
3

2° Level 4

1° Level 4

2
3

1 Door of the apparatus compartment

2 Apparatus racking-in/racking-out operation
3 Earthing switch operation
4 LV compartment
5 Additional LV compartment

84
The characteristics of the busbar system, branch connections, The bus-tie units can be fitted with current transformers on
earthing busbar, earthing switch, insulator bushings and the load side of the circuit-breaker for busbar measurement.
shutters are the same as those for the single level units. Installation of the current transformers on the supply side is
A maximum of six single or three-core cables per phase can also possible to realise special protection schemes. The riser
be used depending on the rated voltage, on the switchgear compartment is also available in the version with withdrawable
panel dimensions and on the cross-section of the cables. instrument truck with voltage transformers with fuses [RM].
The mixed configuration with single and double level requires
Configurations connection between the two sections of switchgear by means
of the connection unit. This unit makes all the connections
The typical switchgear panels available allow the most suitable
between the two types of switchgear (busbars, earthing
configurations for the installation requirements.
busbar, gas exhaust duct, ducts for connection of the auxiliary
The incoming/outgoing feeder panel [IF] is the most widely
circuits) and can integrate the earthing switch of the busbars
used: both switchgear levels consist of units of this type and
[J] and also the withdrawable instrument truck with voltage
can be used both as incoming and outgoing feeders.
transformers with fuses [JM]. These units are positioned on
The bus-tie [BT] and riser [R] units are used to arrange
the 2nd level, whereas the incoming/outgoing feeder units are
complete double-level switchgear configuration.
included on the first level.
These units are positioned on the 2nd level, whereas the
incoming/outgoing feeder units are included in the 1st level.

Figure 73: Mixed configuration of UniGear ZS1 single and double level

85
3. Marine Applications
UniGear ZS1 Double Level
Typical units

IF BT R
Incoming/outgoing feeder Bus-tie Riser
2° Level
1° Level

IF IF IF
Incoming/outgoing feeder Incoming/outgoing feeder Incoming/outgoing feeder

86
RM J JM
Riser with measurements Connection unit Connection unit with

Withdrawable
Withdrawable

IF IF IF
Incoming/outgoing feeder Incoming/outgoing feeder Incoming/outgoing feeder

Key to components Standard components Accessories Alternative solutions Standard components

87
3. Marine Applications
UniGear ZS1 Double Level
Technical data
... 12 kV - ... 50 kA
Depth (mm) 1976
Height (mm) 2700 (1)

Height with gas exhaust duct (mm) 2700 (1)

Width (mm) 750 750 900 900

Rated short-time current (kA) ... 31.5 ... 31.5 ... 50 ... 50
Rated current (A) 630 1000 1250 1600
2nd IF Incoming/outgoing (2)

1st IF Incoming/outgoing (2)

2nd BT Bus-tie
1st IF Incoming/outgoing

2nd R Riser
1st IF Incoming/outgoing

2nd RM Riser with measurements

1st IF Incoming/outgoing

2nd J Connection 1250 A

1st IF Incoming/outgoing ( 2)

2 nd JM Connection with measurements 1250 A

1 st
IF Incoming/outgoing ()
2

.... 17.5 kV - ... 40 kA

Depth (mm) 1976
Height (mm) 2700 ( 1)
Height with gas exhaust duct (mm) 2700 ( 1)
Width (mm) 750 750 900 900
Rated short-time current (kA) ... 31.5 ... 31.5 ... 40 ... 40
Rated current (A) 630 1000 1250 1600
2 nd IF Incoming/outgoing
1 st IF Incoming/outgoing

2 nd BT Bus-tie
1st IF Incoming/outgoing

2nd R Riser
1st IF Incoming/outgoing

2nd RM Riser with measurements

1st IF Incoming/outgoing

2nd J Connection 1250 A

1st IF Incoming/outgoing

2 nd JM Connection with measurements 1250 A

1 st
IF Incoming/outgoing
(1) The height of the switchgear in the mixed configuration with single and double level is the same as that of the double level unit
(2) For the characteristics of these units equipped with contactor refer to page 24.

88
 Height
Width Depth

Unit compartments
A Apparatus compartment
B Busbar compartment
C Cable compartment
D Low voltage compartment
E Gas duct channel

89
Notes

90
91
Contact us

1VCP000138 - Rev. F, en - Technical catalogue - 2012.09 - (UniGear ZS1) (gs)

Your sales contact: www.abb.com/contacts
More product information: www.abb.com/productguide

The data and illustrations are not binding. We reserve the right to make changes
without notice in the course of technical development of the product.

© Copyright 2012 ABB.

All rights reserved.