ZX2. Gas-insulated medium voltage switchgear Instruction manual BA 435/02 E. ABB Power Distribution

ZX Gas-insulated medium voltage switchgear Instruction manual BA 435/0 E ABB Power Distribution

Your safety first always! That's why our instruction manual begins with these recommendations: Only install switchgear and/or switchboards in enclosed rooms suitable for electrical equipment. Ensure that installation, operation and maintenance are carried out by specialist electricians only. Comply in full with the legally recognized standards (DIN VDE / IEC), the connection conditions of the local electrical utility and the applicable safety at work regulations. Observe the relevant information in the instruction manual for all actions involving switchgear and switchboards. Danger! Pay special attention to the hazard notes in the instruction manual marked with this warning symbol. Make sure that under operation condition of the switchgear or switchboard the specified data are not exceeded. Keep the instruction manual accessible to all persons concerned with installation, operation and maintenance. The user s personnel are to act responsibly in all matters affecting safety at work and the correct handling of the switchgear. WARNUNG Anerkannte Regeln der Technik und Betriebsanleitungen beachten! Gefährliche Spannung kann elektrischen Schock und Verbrennungen verursachen. Vor Aufnahme von Arbeiten jeder Art dieses Gerät unbedingt freischalten, erden und kurzschließen. WARNING Always observe the instruction manual and follow the rules of good engineering practice! Hazardous voltage can cause electrical shock and burns. Disconnect power, then earth and short-circuit before proceeding with any work on this equipment. If you have any further questions on this instruction manual, the members of our field organization will be pleased to provide the required information.

Contents Page Contents Page 1 Summary 6 1.1 General 6 1. Standards and specifications 6 1..1 Switchgear manufacture 6 1.. Installation and operation 6 1.3 Operating conditions 6 1.3.1 Normal operating conditions 6 1.3. Special operating conditions 7 Technical data 8.1 Panel type ZX 8. Disconnector/earthing switch type UXTE, and disconnector type UXT 9.3 Dimensions and weights 10.4 Resistance to internal arc faults 11 3 Design and function of the switchgear system and its equipment 1 3.1 Design and equipment of the panels 17 3. Gas system in the panels/switchgear 17 3.3 Vacuum circuit-breakers, type VD4 X 17 3.4 Disconnector/earthing switch, type UXTE 18 3.5 Disconnector, type UXT 18 3.6 Sensor systems 18 3.7 High voltage connections 18 3.8 Bay control and protection unit REF54 (SCU) 19 3.9 Protection against maloperation/interlock dependencies/earthing of tee-off 19 3.9.1 Interlock dependencies 19 3.9. Earthing a tee-off in a single busbar system 19 3.9.3 Earthing the busbar in a single busbar system 0 3.9.4 Earthing a tee-off in a double busbar system 0 3.9.5 Earthing the busbar in a double busbar system 1 3.10 Test facilities 4 Despatch and storage 8 4.1 Condition on delivery 8 4. Packaging 8 4.3 Transport 8 4.4 Delivery 8 4.5 Intermediate storage 8 5 Erection of the switchgear at site 30 5.1 General site requirements 30 5. Construction data 30 5.3 Fundamental notes on erection work 31 5.4 Foundation frame 31 5.5 Laying of the foundation frame 31 5.6 Raised false floor 33 5.7 Erection and connection of the panels 38 5.7.1 Preparatory work 38 5.7. Erection of the switchgear 38 5.8 Connection of cables and wiring 44 5.8.1 High voltage plastic-insulated cable with plug connectors 44 5.8. Control cables and wiring 44 5.9 Preparing the insulating gas system for operation 44 5.10 Final erection work 44 6 Commissioning/operation 45 6.1 Commissioning 45 6.1.1 Preparatory work 45 6.1. Initial start-up 45 6. Switching operations 45 6..1 Circuit-breaker 45 6.. Three-position switch and disconnector 46 6..3 Undervoltage release 46 6.3 Observation of the display and monitoring facilities 46 6.3.1 Gas monitoring 46 6.3. Electrical/mechanical display/monitoring 46 4 ABB Power Distribution

Contents Page 6.4 Test procedures 46 6.4.1 Testing for the off-circuit condition 46 6.4. Testing for the in-phase condition 47 6.4.3 High voltage tests 47 6.4.4 Current tests 48 6.4.5 Maintenance earthing 48 6.5 Application of the X-ray regulations 49 7 Maintenance 53 7.1 General 53 7. Inspection/servicing 53 7..1 Vacuum circuit-breaker 54 7.. Three-position switch and disconnector 54 7..3 Gas system and gas servicing 54 7..4 Outlet filter 54 7.3 Repair 54 7.4 Working and auxiliary materials 55 7.4.1 Working materials 55 7.4. Auxiliary materials 55 We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual - or extracts to third parties is prohibited. The information supplied is without liability. Subject to alteration. ABB Calor Emag Mittelspannung GmbH, 000 ABB Power Distribution 5

1 Summary 1.1 General Fundamental features of the ZX panels: rated voltage up to 36 kv three-phase metal-enclosed gas-insulated gas-tight metal-clad busbar compartment gas-tight metal-clad circuit-breaker compartment computerised switchbay control system sensor technology for adapted measured value acquisition indoor installation factory-assembled type-tested. Basic panel variants: incoming and outgoing feeders bus sectionalisers in single and double busbar systems bus coupler panels in single and double busbar systems bus riser panels in single and double busbar systems metering panels in double busbar systems supplementary equipment: busbar metering system in single busbar systems Panel equipment, variants: vacuum circuit-breaker single or double busbar systems: busbar system 1 with disconnector/earthing switch (three-position switch) with functions of: busbar connection, disconnection, earthing. busbar system with disconnector with functions of: busbar connection, disconnection. Details on the technical design and equipment of a switchgear, such as technical data, detailed list of equipment fitted, detailed circuit diagrams, etc. can be found in the order documents. 1. Standards and specifications 1..1 Switchgear manufacture The panels comply with the following VDE standards and the corresponding IEC publications: VDE 0670 and IEC 60056, 6019, 6098 and 60694 VDE 0373 and IEC 60376 and 60480. 1.. Installation and operation The relevant standards are to be observed during installation and operation, in particular: DIN VDE 0101, Power installations exceeding AC 1 kv, VDE 0105, Operation of electrical installations DIN VDE 0141, Earthing systems for special power installations with rated voltages above 1 kv, the accident prevention regulations issued by the appropriate professional bodies, the safety guidelines for production materials, the order-related details provided by the switchgear manufacturer. 1.3 Operating conditions 1.3.1 Normal operating conditions Designed in accordance with VDE 0670 Part 1000, Common specifications for high-voltage and controlgear standards and IEC Publication 60694, with the following limit values: Ambient temperature: Maximum +40 C Maximum 4 hour average +35 C Minimum (corresponding to minus 5 indoor class) 5 C Site altitude: 1000 m above sea level Ambient air: The ambient air is not to be significantly contaminated by dust, smoke, corrosive or flammable gases, or salt. 6 ABB Power Distribution

1.3. Special operating conditions Special operating conditions are to be agreed by the manufacturer and operator. The manufacturer is to be consulted in advance about each special operating condition: Site altitude above 1000 m: Adjustment of the gas monitoring system is required for greater altitudes. Increased ambient temperature: The current carrying capacity is reduced, Additional cooling facilities for heat dissipation are to be provided. Climate: The risk of corrosion or other impairment, e.g. in the control cabinets, is to be avoided in areas: with high humidity and/or with major, rapid temperature fluctuations. Take countermeasures to prevent condensation phenomena (e.g. provide electric heaters). ABB Power Distribution 7

Technical data.1 Panel type ZX Electrical data Rated voltage kv 1 17.5 4 36 Rated power frequency withstand voltage kv 8 38 50 70 Rated lightning impulse withstand voltage kv 75 95 15 170 All voltages quoted apply to an insulating gas pressure, absolute, at 0 C, of bar ) 1.0 1.0 1.0 1.0 Rated frequency Hz 50/60 Rated current of busbars A 150/500 Rated current of tee-offs 3) A...000/500 4) Rated peak withstand current 3) ka...100...100...100...100 Rated short time current, 3 s 3) ka...40...40...40...40 Rated short-circuit breaking current of the circuit-breaker ka...40...40...40...40 Rated short-circuit making current of the circuit-breaker ka...100...100...100...100 Rated operating sequence O-0.3 s CO-3 min CO 5) Break time: manual tripping ms 45 90 45 90 45 90 45 90 protection tripping ms 40 55 40 55 40 55 40 55 Closing time: manual tripping ms 65 95 65 95 65 95 65 95 protection tripping ms 60 60 60 60 Insulating gas system )6) Insulating gas N 7) SF 6 8) SF 6 8) SF 6 8) Design pressure, absolute bar 1.36 1.36 1.36 1.36 Operating pressure, absolute, 0 C (equals filling pressure) bar 1.3 1.3 1.3 1.3 Rated pressure, absolute, 0 C (minimum operating pressure) bar 1. 1. 1. 1. Motor and release data Charging motor W <00 <00 <00 <00 Closing coil W 50 50 50 50 Opening coil W 50 50 50 50 Rated supply voltage DC voltage V 60, 110, 0 9) Degree of protection (IEC 6059, DIN VDE 0470- Gas-tight enclosure IP 65 IP 65 IP 65 IP 65 Control cabinet IP 4X 10) IP 4X 10) IP 4X 10) IP 4X 10) Higher values in accordance with international standards on request ) 1 bar = 100 kpa 3) For details refer to table: "Panel width-classification" section.4 4) Cooling included 5) Other operating sequences on request 6) For further details see BA 47 - insulating gas system for ZX switchgear 7) Insulating gas: nitrogen 8) Insulating gas: sulphur hexafluoride 9) Other voltages on request 10) IP 5X on request 8 ABB Power Distribution

. Disconnector/earthing switch type UXTE, and disconnector type UXT Test voltages Rated voltage kv 1 17.5 4 36 Rated power frequency withstand voltage across the isolating distance kv 3 45 60 80 Rated lightning impulse withstand voltage across the isolating distance kv 85 110 145 195 Insulating gas system ) Insulating gas N 3) SF 6 4) SF 6 4) SF 6 4) Operating pressure, absolute, 0 C ( equals filling pressure ) bar 1.3 1.3 1.3 1.3 Rated pressure, absolute,0 C ( minimum operating pressure ) bar 1. 1. 1. 1. 1 bar = 100 kpa ) For further details see BA 47 - insulating gas system for ZX switchgear 3) Insulating gas: nitrogen 4) Insulating gas: sulphur hexafluoride Rated voltage kv 1/17.5/4/36 Test currents Rated current A 630 5) 150 500 ) Rated peak withstand current ka 63 80...100 Rated short time current, 3 s ka 5 31.5...40 Motor data Motor power, max 3). W 180 180 180 Motor running times, max 3).: Centre position to BB s 18 18 0 Centre position to earth s 18 18 0 Rated supply voltage DC 4) V 60,110,0 Panel width: 600 mm ) Panel width: 800 mm 3) At rated supply voltage 4) Other voltages on request 5) Panel width: 400 mm ABB Power Distribution 9

.3 Dimensions and weights View X ZX A C D A B B ZX X 895 100 300 600 13 n panels ) 800 600 0 30 1710 Figure /1: Dimensions, double busbar system Figure shows panels with rated currents 000 A. A Pressure relief duct with absorber B Pressure relief duct, top C Pressure relief duct, side D End cover E Pressure relief duct, rear Panels with rated currents greater than 000 A are also fitted with a cooling fan. The panel height is then increased by 00 mm to 500 mm or 800 mm. ) n 1 View X ZX A C D B ZX A B X E 1105 775 100 300 600 n panels ) 800 600 0 30 1710 Figure /: Dimensions, single busbar system Figure shows panels with rated currents 000 A. A Pressure relief duct with absorber B Pressure relief duct, top C Pressure relief duct, side Optionally also with voltage sensors for busbar metering D End cover E Pressure relief duct, rear Panels with rated currents greater than 000 A are also fitted with a cooling fan. The panel height is then increased by 00 mm to 500 mm or 800 mm. ) n 1 10 ABB Power Distribution

Weights: Weight of a standard panel, double busbar, panel width 400 mm, rated current 630 A: Weight of a standard panel, double busbar, panel width 600 mm, rated current 150 A: Weight of a standard panel, double busbar panel width 800 mm, rated current 000 A: approx. 650 kg approx. 100 kg approx. 1700 kg See section 5. for dimensions of the switchroom (construction data)..4 Resistance to internal arc faults Panel width 400 mm 600 mm 800 mm Core modul/bb-compartment 5 ka, 1s 31.5 ka, 1s 40 ka, 1s Cable compartment 0 ka, 1s, three-pole 5 ka, 1s, three-pole 5 ka, 1s, three-pole Resistance to internal arc faults: Criteria 1-6 of PEHLA directive no. 4 (in conjunction with VDE 0670 Part 6 and IEC 6098) are fulfilled. The panels have integrated pressure relief ducts with the opportunity for: channelling out of the switchroom in a manner suitable for the building dimensions, or channelling through an absorber on the last two panels (when the ceiling height is sufficient). Table: Panel width-classification Rated voltage kv 1 17.5 I K, 3s ka 5 31.5 31.5 40 40 0 5 31.5 40 I P ka 63 80 80 100 100 50 63 80 100 I tee-off A 630 150 000/ 150 000/ 630 150 000/ 150/ 500 500 500 000/ 500 Panel width mm 400 600 800 600 800 400 600 800 800 Rated voltage kv 4 36 I K, 3s ka 0 5 5 31.5 40 5 31.5 40 I P ka 63 63 80 100 63 80 100 I tee-off A 630 150 000/ 150/ 150/ 150 150/ 150/ 500 000/ 000/ 000/ 000/ 500 500 500 500 Panel width mm 400 600 800 800 800 600 800 800 ABB Power Distribution 11

3 Design and function of the switchgear system and its equipment 3 0 8 1.1 Figure 3/1: Panel, front view Figure 3/: Panel type ZX with control cabinet open 1.1 Control cabinet door 3 Three-position switch operating mechanism 8 Circuit-breaker operating mechanism 0 Disconnector operating mechanism 5 5.1 5. 6 Figure 3/3: Bay control and protection unit REF54 5 Bay control and protection unit 5.1 LCD display (example) 5. LEDs 6 Measuring sockets for capacitive voltage indicator system 1 ABB Power Distribution

B 3.5 G 19 0 E H Figure 3/4: Panel, double busbar, with pressure relief ducts at top and rear The side walls of busbar compartments 1 and, of the circuit-breaker compartment and the cable termination compartment have been cut open to provide a better view. I B E G H I Pressure relief duct, top Pressure relief duct, rear Control cabinet Circuit-breaker compartment Cable compartment Disconnector/earthing switch (three-position switch) in busbar compartment 1 19 Disconnector -Q in busbar compartment 0 Operating mechanism for item 19 3.5 Bushing for plug-in busbar connection Figure 3/5: Pressure relief disk for a busbar compartment in the upper pressure relief duct Figure 3/6: Vacuum circuit-breaker type VD4 X (before installation in the works) ABB Power Distribution 13

-Q5 -Q1 -Q5 -Q1 -Q16 -Q11 -Q15 -Q1 -Q0 -Q0 Feeder Cable connection Coupler Riser Busbar metering Figure 3/7a: Examples of panels type ZX, with single busbars -Q5 -Q1 -Q -Q5 -Q1 -Q15 -Q -Q16 -Q11 -Q15 -Q1 -Q6 -Q1-Q5 -Q -Q0 -Q0 -Q0 -Q0 Feeder Bus coupler Bus sectionaliser -Q16 -Q11 -Q6 -Q1 -Q15 -Q1 -Q5 -Q -Q51 -Q1 -Q5 -Q Bus sectionaliser (without C.B.) Trunking bar connection Busbar metering Figure 3/7b: Examples of panels type ZX, with double busbars 14 ABB Power Distribution

Figure 3/8: ZX panel, single busbar, 150 A Figure 3/9: ZX panel, single busbar, 000 A Figure 3/10: ZX panel, double busbar, 000 A ABB Power Distribution 15

6 5 4 B B G 1 3 ( 0 SS SS1 3 (4) 5 19 18 17 16 15 K H 7 8 9 10 -Q5 -Q1 -Q -Q0 -T1 14 13 I 11 1 -R1 -C1 Figure 3/11: ZX panel, double busbar, 150 A, fundamental structure SS1 Busbar system 1 SS Busbar system B Pressure relief duct, top E Pressure relief duct, rear G Control cabinet H Circuit-breaker compartment I Cable termination compartment -Q0 Circuit-breaker -Q1 Tee-off disconnector -Q Tee-off disconnector -Q5 Tee-off earthing switch -T1 Current sensor -R1 Voltage sensor -C1 Capacitive voltage divider 1 Panel enclosure Disconnector/earthing switch -Q1/-Q5 (three-position switch) 3 Three-position switch operating mechanism (4) Pressure sensor for busbar compartment 1 5 Bay control and protection unit REF54 6 Measuring sockets for capacitive voltage indicator system 7 Pressure sensor for circuit-breaker compartment 8 Circuit-breaker operating mechanism 9 Cable or test plug socket 10 Cable socket 11 Cable plug 1 Surge arrester 13 Floor plate, split 14 Connecting link panel/panel for item 15 15 Main earthing bar 16 Combined current and voltage sensor 17 Pressure relief disk 18 Circuit-breaker 19 Disconnector -Q 0 Disconnector operating mechanism ( Pressure sensor for busbar compartment Tee-off conductor 3 Busbar connection, plug-in type 4 Busbar 5 Drying agent bag 6 Pressure relief disk Inert gas 16 ABB Power Distribution

3.1 Design and equipment of the panels (Figures /1, /, 3/1 to 3/1 The metal-enclosed ZX panels are laser cut and welded panel enclosures, completely earthed and thus protected against accidental contact. The stainless steel encapsulation and the insulating gas protect all live parts in the high voltage area permanently from soiling, humidity, foreign bodies and other injurious influences. The modular structure provides the conditions necessary for all panel variants normally required in a relatively simple manner. Facilities are also provided, for instance, for: one or two busbar systems, three-position switch or disconnector, different connection methods, such as multiple cables. Relieved pressure is guided into pressure relief ducts (A), (B), (C) and (E): In the case of internal arcing fault, the following pressure relief disks open: Pressure relief disk 17 on circuit-breaker compartment (H) into pressure relief duct (E). The gases are channelled out via ducts (C) and (A). Pressure relief disk 6 on the busbar compartment into pressure relief duct (B). In the case of an arc in the cable compartment (I), a pressure relief flap in pressure relief duct (E) opens. The gases are channelled out via ducts (C) and (A). Each panel is a unit, They are linked together by plug-in busbar connections 3. Basic equipment in the panels: Circuit-breaker VD4 X Three-position switch UXTE Disconnector UXT Sensor system Control cabinet with the bay control and protection unit REF54 Cable and test plug sockets. The insulation test criteria of VDE and IEC list are fulfilled by the ZX standard series up to and including 36 kv even when the gas filling is at atmospheric pressure. 3. Gas system in the panels/switchgear (Figures 3/11 and 3/15) A permanently protected climate for the entire live primary area is ensured by the gas-tight encapsulation of the panels and their filling with dry insulating gas. The circuit-breaker compartment and the busbar compartments in each panel are separate gas compartments with their own filling connectors. The gas compartments in the individual panels set up side by side are not connected together. The operating pressure (p e ) (equals filling pressure) in the individual compartments is monitored by temperature compensated pressure sensors: Pressure sensor 7 for the circuit-breaker compartment, Pressure sensors 4 and 1 for busbar compartments 1 and. When the pressure drops below the minimum operating pressure, a pressure loss signal is output. With a rapidly rising pressure as a consequence of an internal arc fault and a correspondingly high current, the bay control and protection unit REF54 shuts the incoming feeders or couplers down. Details on the gas system and gas servicing of the ZX switchgear can be found in instruction manual BA 47 Insulating gas system for ZX switchgear. The gas compartments contain drying agent bags 5. Further details on the drying agent material can be found in instruction manual BA 47. 3.3 Vacuum circuit-breakers, type VD4 X (Figures 3/, 3/6 and 3/11, and separate manual BA 436/E) Functions of the vacuum circuit-breaker 18: opening and closing on rated currents, short-circuit breaking operations, earthing function in conjunction with three-position switch. The earthing function of the three-position switch prepares - under no current - for the connection to earth. Earthing proper is performed by the circuitbreaker. This integration of functions is advantageous, as a circuit-breaker is of higher quality in the earthing function than any other earthing switch. The circuit-breaker poles are installed horizontally in the circuit-breaker compartment (H). The circuitbreaker operating mechanism is located outside the gas compartment and is therefore easily accessible. It is connected to the breaker poles by a gastight thrust bushing. ABB Power Distribution 17

3.4 Disconnector/earthing switch, type UXTE (Three-position switch) (Figures 3/, 3/4 and 3/1 The ZX panels are fitted with specially designed three-position disconnectors and earthing switches -Q1/-Q5. These switches are motor-operated rodtype switches whose live switching components are located in busbar compartment 1 (insulating gas compartment), while the operating mechanism block is easily accessible from the control cabinet (G). The operating mechanism block contains the drive motor, the position indicators (sensors and mechanical indicators) and the emergency manual operating system. The three-position switch performs the functions of: connecting, disconnecting, and earthing. The three switch positions are unequivocally specified by the operating mechanism. The switch has its disconnecting position at the centre. In the limit positions, disconnector ON and earthing switch ON, the moving contact (sliding part) driven by an insulating spindle, reaches the isolating contacts, which are fitted with one or two spiral contacts respectively. 3.5 Disconnector, type UXT (Figures 3/, 3/4 and 3/1 Disconnector -Q is a motor-operated rod-type switch. Its live switching components are located in busbar compartment (insulating gas compartment). The operating mechanism block is split and located outside the gas compartment. The drive motor is located at the rear of the panel behind a removable cover. The position indicators (sensors and mechanical indicators) and the emergency manual operating system are accessible from control cabinet (G). Disconnector -Q is structured similarly to the three-position switch, but without the earthing switch assembly. 3.6 Sensor systems (Figures 3/3, 3/11, 3/1 to 3/15, 6/3 and 6/7) In comparison with conventional inductive instrument transformers, sensors require much less space. They facilitate measured value acquisition suitable for the control and automation system REF54. The following sensors are used in ZX panels: Sensors for current measurement 16 Sensors for voltage measurement 16 Capacitive pick off for voltage display Sensors 4, 7 and 1 for insulating gas pressure monitoring Sensors to detect the switch positions of the circuit-breaker, disconnector/earthing switch and disconnector Sensor to detect the charging condition of the circuit-breaker spring energy store. Arrangement of the sensors: Current and voltage sensors are located in the rear part of the circuit-breaker compartment. The external connections allow wiring to be fed through the cable compartment (I) to the REF54. Sensors for pressure monitoring: B0G for the circuit-breaker compartment: on the circuit-breaker base plate in control cabinet (G). B1G for busbar compartment 1: beside the operating mechanism for the disconnector/earthing switch -Q1/-Q5 in the control cabinet (G). BG for busbar compartment : beside the base plate for the drive motor of disconnector -Q at the rear of the panel. Sensors for detection of the switch positions: B0E and B0A for the circuit-breaker: on its mechanism shaft. B1E, B1A, B5E and B5A for the disconnector/earthing switch: on its operating mechanism in the control cabinet. BE and BA for the disconnector: beside its emergency manual operating mechanism in the control cabinet. Sensor B0S for detection of the charging condition of the spring energy storage mechanism: above the spring drum in the circuit-breaker operating mechanism. 3.7 High voltage connections (Figures 3/4, 3/8 to 3/11, 5/15 and 5/16) Cable plug connector systems: high voltage plastic-insulated cable with internal cone cable plug connector system and sockets to DIN 47 637. Plug-in cable sockets 9 and 10 mounted in a gastight manner in the floor plate of the circuit-breaker compartment maintain the partitioning between the insulating gas compartment and the cable termination compartment. 18 ABB Power Distribution

3.8 Bay control and protection unit REF54 (Figures 3/3 and 3/15) The following functions are integrated in the bay control and protection unit REF54: Busbar protection Tee-off protection Control Measurement Position indication Hazard and fault signalling Connection to control systems. Panel interlocks and the sequence of switching operations (e.g. isolation, testing of the off-circuit condition and earthing) are controlled by the REF54 panel unit. The single-line diagram providing information on switching device positions is made visible on LC display 5.1. Measured values such as conductor currents, phase voltages, energy metering and active and reactive power, number of operating cycles and number of operating hours appear numerically and/or as a bar diagram on the display. Further information, such as alarm and fault signals, is displayed with text by LEDs 5.. The bay control and protection unit REF54 can be connected to a control system via optical fibre cables. Electromagnetic interference is avoided by the use of optical fibre cables. Please consult the REF54 instruction manual no. BA 453 for details on handling of the bay control and protection unit and the detailed technical description. 3.9 Protection against maloperation/interlock dependencies/earthing of tee-off In order to prevent dangerous situations and maloperation, a series of interlocks are provided to protect the operators and the switchgear itself. In ZX panels with digital control systems, protection against maloperation is fundamentally effected by the software in the panel unit. The circuit-breaker, three-position switch and disconnector can be controlled directly at the panel or from the control room using the local/remote lock-switch. Operation at the panel is by selection on the REF54. 3.9.1 Interlock dependencies 1. Limit position blocking of the switching devices.. Dependence of the disconnectors -Q1 or -Q on the earthing switch -Q5 and vice versa. 3. Dependence of the disconnectors -Q1 or -Q on the circuit-breaker -Q0. 4. Dependence of the circuit-breaker -Q0 on the earthing switch -Q5. 5. Interdependence of the disconnectors -Q1 and -Q. 6. Dependence of the disconnectors -Q1 and -Q on bus coupler circuit-breakers and vice versa. 7. Dependence of the bus section disconnector on the busbar tee-off disconnectors and vice versa (for bus sectionalising without circuit-breaker only). Details of interlocks/dependencies over and above those listed in points 1 to 7 (e.g. with neighbouring systems) can be found in the individual order documents. The interlock polling between panels is effected by loop lines from panel to panel. Operation on failure of the auxiliary power supply: On failure of the auxiliary power supply, the devices can be operated manually. No provision is however made for interlocked emergency manual operation of the three-position switches and disconnectors. Emergency manual operation: Intervention in the interlock concept is possible by opening the control cabinet door. Emergency manual operation without maloperation prevention is possible by means of a hand crank and mechanical push-button. 3.9. Earthing a tee-off in a single busbar system (Figure 3/7) 1. Manual earthing Operating sequence for tee-off earthing: Circuit-breaker -Q0 OFF. Disconnector -Q1 OFF. Earthing switch -Q5 ON. Test for off-circuit condition (display on REF54 or capacitive voltage indicator system (see section 6.4.). Circuit-breaker -Q0 ON (only possible when the REF54 has detected the off-circuit condition and enabled the switching operation). Secure panel to prevent reconnection (m.c.b. F101 and F106 OFF). Label the panel to indicate that earthing has been effected. ABB Power Distribution 19

. Automatic earthing by selecting the earthing sequence on the REF54 display (this facility depends on the order placed) Condition: circuit-breaker -Q0 OFF. Select and start the automatic earthing sequence: Disconnector -Q1 OFF. Earthing switch -Q5 ON. Check on off-circuit condition by REF54. Circuit-breaker -Q0 ON. M.c.b. F101 and F106 OFF. Feedback message Earthed and secured. Label the panel to indicate that earthing has been effected. 3. Cancelling the earthing of a tee-off Open the control cabinet door and switch on the m.c.b. F101 and F106 manually. Circuit-breaker -Q0 OFF. 3.9.3 Earthing the busbar in a single busbar system (Figures 3/7 and 6/7) Earthing of the busbar or a busbar section is dependent on the switchgear configuration. Systems with bus ties / risers permit the earthing of a single busbar section. 1. Manual earthing of a busbar section using the bus tie / riser Operating sequence: Circuit-breaker -Q0 in the bus tie (tie breaker) OFF. All disconnectors -Q1 in the busbar section to be earthed OFF. Disconnectors (-Q11 or -Q1) between the busbar section to be earthed and the tie breaker ON. Earthing switch (-Q15 or -Q16) on the opposite side of the tie breaker ON. Tie breaker -Q0 ON. M.c.b. F101 and F106 OFF. Label the busbar section to indicate that earthing has been effected. The busbar section is then earthed. All disconnectors in the earthed busbar section are blocked.. Automatic earthing of a busbar section by selecting the earthing sequence on the REF54 display (this facility depends on the order placed) Condition: Circuit-breaker -Q0 in the bus tie (tie breaker) OFF. All disconnectors -Q1 in the busbar section to be earthed OFF. Select and start the automatic earthing sequence: Disconnectors (-Q11 or -Q1) between the busbar section to be earthed and the tie breaker -Q0 ON. Earthing switch (-Q15 or -Q16) on the opposite side of the tie breaker -Q0 ON. Tie breaker -Q0 ON. M.c.b. F101, F10 and F106 OFF. Feedback message Earthed and secured. Label the busbar section to indicate that earthing has been effected. The selected busbar section is then earthed. All disconnectors in the earthed busbar section are blocked. 3. Cancelling the earthing of a busbar section Open the control cabinet door and switch on the m.c.b. F101, F10 and F106 manually. Circuit-breaker -Q0 in the bus tie OFF. 4. Maintenance earthing of a busbar via free sockets in a tee-off Condition: The tee-off is earthed. All disconnectors in the busbar to be earthed OFF. Operating sequence: Fit a short-circuiting bridge to the free sockets and connect to main earthing bar 14. Circuit-breaker OFF. Earthing switch OFF. Disconnector ON. Circuit-breaker ON. M.c.b. F101 and F106 OFF. Label the busbar to indicate that earthing has been effected. All relevant panels are to be secured to prevent switching operations, e.g. tripping m.c.b. 3.9.4 Earthing a tee-off in a double busbar system (Figures 3/7 and 3/1 1. Manual earthing Operating sequence for tee-off earthing: Circuit-breaker -Q0 OFF. Disconnectors -Q1 and -Q OFF. Earthing switch -Q5 ON. 0 ABB Power Distribution

Test for off-circuit condition (display on REF54 or capacitive voltage indicator system (see section 6.4.). Circuit-breaker -Q0 ON (only possible when the REF54 has detected the off-circuit condition and enabled the switching operation). Secure panel to prevent reconnection (m.c.b. F101, F10 and F106 OFF). Label the panel to indicate that earthing has been effected.. Automatic earthing by selecting the earthing sequence on the REF54 display (this facility depends on the order placed) Condition: circuit-breaker -Q0 OFF. Select and start the automatic earthing sequence: Disconnectors -Q1 and -Q OFF. Earthing switch -Q5 ON. Check on off-circuit condition (by REF54). Circuit-breaker -Q0 ON. M.c.b. F101, F10 and F106 OFF. Feedback message Earthed and secured. Label the panel to indicate that earthing has been effected. 3. Cancelling the earthing of a tee-off Open the control cabinet door and switch on the m.c.b. F101, F10 and F106 manually. Circuit-breaker -Q0 OFF. 3.9.5 Earthing the busbar in a double busbar system (Figures 3/7 and 3/1 Earthing of the busbar or a busbar section is dependent on the switchgear configuration. Systems with bus couplers permit the earthing of a single busbar section. 1. Manual earthing of a busbar section Operating sequence: a) Busbar 1: Circuit-breaker in the bus coupler OFF. Disconnector -Q in the bus coupler OFF. All disconnectors -Q1 in the busbar section to be earthed OFF. Disconnector -Q1 in the bus coupler ON. Earthing switch -Q15 in the bus coupler ON. Circuit-breaker in the bus coupler ON. M.c.b. F101, F10 and F106 OFF. Label the busbar section to indicate that earthing has been effected. The busbar section of busbar 1 is then earthed. All disconnectors in the earthed busbar section are blocked. b) Busbar : Circuit-breaker in the bus coupler OFF. Disconnector -Q1 in the bus coupler OFF. All disconnectors -Q in the busbar section to be earthed OFF. Disconnector -Q in the bus coupler ON. Earthing switch -Q5 in the bus coupler ON. Circuit-breaker in the bus coupler ON. M.c.b. F101, F10 and F106 OFF. Label the busbar section to indicate that earthing has been effected. The busbar section of busbar is then earthed. All disconnectors in the earthed busbar section are blocked.. Automatic earthing by selecting the earthing sequence on the REF54 display (this facility depends on the order placed) Condition: Circuit-breaker -Q0 in the bus coupler OFF. All disconnectors in the relevant busbar section OFF. Select the operating sequence: a) Busbar 1: Disconnector -Q in the bus coupler OFF. Disconnector -Q1 in the bus coupler ON. Earthing switch -Q15 in the bus coupler ON. Circuit-breaker in the bus coupler ON. M.c.b. F101, F10 and F106 OFF. Feedback message BB1 earthed and secured. Label the busbar section to indicate that earthing has been effected. The busbar section of busbar 1 is then earthed. All disconnectors in the earthed busbar section are blocked. b) Busbar : Disconnector -Q1 in the bus coupler OFF. Disconnector -Q in the bus coupler ON. Earthing switch -Q5 in the bus coupler ON. Circuit-breaker in the bus coupler ON. M.c.b. F101, F10 and F106 OFF. Feedback message BB earthed and secured. ABB Power Distribution 1

Label the busbar section to indicate that earthing has been effected. The busbar section of busbar is then earthed. All disconnectors in the earthed busbar section are blocked. 3. Cancelling the earthing of a busbar section Open the control cabinet door and switch on the m.c.b. F101, F10 and F106 manually. Circuit-breaker -Q0 in the bus coupler OFF. 3.10 Test facilities The panels are properly filled with insulating gas at the works and tested to the VDE or IEC standards. Testing on completion of switchgear installation is therefore unnecessary. Should there be any need to perform tests, the tests are to be performed as follows: For voltage and current tests, direct access to the conductors in the connection area is possible without removing the cable connection or extracting the insulating gas. Access is effected via free cable connecting sockets or via the cable sockets for the surge arresters. The surge arresters must be removed during voltage tests. Voltage tests: cable tests with DC voltage, cable fault location measurements with impulse voltage and system tests (without cables) with a AC voltage can be performed with a test plug as shown in Figure 6/8. A test plug for current tests as shown in figure 6/9 can be used to test the protection devices by primary current injection (see also the note in section 6.4.4). This configuration is short-circuit proof and can also be used as an additional maintenance earth. The possible testing processes are described in the following sections: testing for the off-circuit condition: Section 6.4.1 testing for the in-phase condition: Section 6.4. high voltage tests: Section 6.4.3 current tests: Section 6.4.4. ABB Power Distribution

ABB Power Distribution 3

-XI..,-XU.. Terminal designation 1 Front view - 1 80A /40A /640A /150mV Class 1 without correction factor 3 -XI.. 640A/150mV 40A/150mV 80A/ 150mV S1 S S3 S4 P1 Primary conductor In = 150 A Ip = 100 ka Ith 3sec = 40 ka Capacitance C1 35pF max 55pF 0kV/ V3 V/ V3 Class 1 Working area S1 - S: 30...180A S1 - S3: 10... 480A S1 - S4: 40... 160A -XU.. 1 Pick-off: 10 000 :1 a n CK Leakage capacitance 5pF P Figure 3/1: Combined current and voltage sensor with capacitive pick-off KEVCI 4 AE1, for rated voltages up to 4 kv and panel width 600 mm -XI..,-XU.. Terminal designation 1 Front view The following changes apply to rated voltage 36kV: Sensor: KEVCI 36 AE1 Pick-off: 0 000:1 bzw. 30 kv / 3 1,5 V / 3 Capacitance: C1 18 pf, max. pf - 1 -XI.. 1600A/150mV S1 S P1 Primary conductor In = 500 A Ip = 100 ka Ith 3sec = 40 ka 1600A/150mV Class 1 without correction factor 3 Capacitance C1 35pF max 55pF 0kV/ V3 V/ V3 Klasse 1 -XU.. 1 Pick-off: 10 000 :1 a n CK Leakage capacitance 5pF Working area S1 - S: 800...300A P Figure 3/13: Combined current and voltage sensor with capacitive pick-off KEVCA 4 BE1, for rated voltages up to 4 kv and panel width 800 mm The following changes apply to rated voltage 36kV: Sensor: KEVCI 36 BE1 Pick-off: 0 000:1 bzw. 30 kv / 3 1,5 V / 3 Capacitance: C1 18 pf, max. pf 4 ABB Power Distribution

L1 L L3 I II -Q1/Q5 -Q0 -T1L1..L3 -R1L1..L3 0kV/ V 3 V/ V 3 150mV 3 P1 P 3 -Q -XI..,-XU.. Terminal designation Front view 1 -C1L1..L3 -A00 Tee-off protection; measurement, metering IL1 IL IL3 UL1 UL UL3 -X3 d8 z8 d4 z4 d0 z0 d16 z16 d1 z1 d8 z8 1 -XIL1 1 -XItL1 1 -XIL 1 -XItL 1 -XIL3 1 -XItL3 -XUL1 1 1 -XUtL1 -XUL 1 -XUtL 1 -XUL3 1 1 -XUtL3 T1L1 S1 S. a n T1L S1 a n S. R1L1 P P1 P1 P1 R1L T1L3 S1 S. P R1L3 a n P Current and voltage sensors 3 single core cables GND IL0 d4 z4 1 -XIL0 1 -XItL0 Figure 3/14: Current and voltage sensors in an outgoing cable feeder panel, up to 4 kv, double busbar The circuit diagram is identical for the single busbar system, but without tee-off disconnector -Q. -Q0 Circuit-breaker -Q1 Busbar tee-off disconnector -Q Busbar tee-off disconnector -Q5 Tee-off earthing switch -T1... Current sensors -R1... Voltage sensors -C1... Capacitive voltage divider Inputs and interfaces of the bay control and protection unit REF54: IL... Measurement inputs for current UL... Measurement inputs for voltage -XI... Interfaces of the current sensors -XU... Interfaces of the voltage sensors -XIt... Test interfaces of the current sensors and the inputs -XUt... Test interfaces of the voltage sensors and the inputs -A00 Bay control and protection unit REF54 ABB Power Distribution 5

+ - - F116 4 1 3 SPA - BUS () - F101 -F100 4 3 4 1 3 4 1 3 3 -F106 4 1 4 3 ( 3 4 -F10: 4 -B5E Figure 3/15a: BK BN BU -B5A ( + - 11 11 11 11 + - () - F100 - F101 - F10 - F106 1 1 1 1 -F106:4 -F10 1 4 3 3 -A00 A15 X4: d10 X4: z10 X4: d18 X4: z18 X5: d6 X5: z6 X5: d4 X5: z4 X5: d X5: z X7: d X7: d0 X7: z0 X7: z X1: 1 X1: 3 X6: d18 X6: z18 X6: d10 X6: z10 X6: d6 X6: z6 X6: d X6: z -A00 MMK A5 A6 A7 A A1 A3 A4 E3 E1 E4 E7 E E1 E6 E8 X4: d6 X4: z6 BK BN BU X4: d4 X4: z4 X4: d8 BK BN BU X4: z8 -B1E X4: d14 X4: z14 BK BN BU -B1A X4: d4 BK X4: z4 BN BU -B0E X4: d X4: z BK BN BU -B0A X4: d1 X4: z1 BK BN BU -B0S X4: d16 X4: z16 4 -B5E3 3 -B5E -B5E1 1 X6: d X6: d0 X6: z0 X6: z M -M1 X6: d1 B X6: z1 M -M0 F X6: d8 X6: z8 X6: d4 X6: z4 -V3 -V C1 C C1 C -Y3 -Y X4: z0 X4: d0 X4: z8 X4: d8 X7: d18 X7: z18 4 E10 E14 A14 A13 A1 E5 E9 E17 E16 E15 5 6 3 110 kpa 140 kpa 140 kpa 4 110 kpa 5 6 3 110 kpa 140 kpa 140 kpa 4 110 kpa 3 5 110 kpa 140 kpa 4 6 110 kpa 140 kpa BK BN BU -BA BK BN BU -BE M -M -B0G -B1G -BG Figure 3/15b:Continued from figure 3/15a 6 ABB Power Distribution

Figure 3/15: Circuit diagram of the panel controller for a double busbar system The circuit diagram is identical for the single busbar system, but without M, BG, BE, BA and F10. Inputs E15, E16 and E17 and outputs A1 to A15 on the REF54 are not then used. -B0A Sensor, Circuit-breaker -Q0 OFF signal -B0E Sensor, Circuit-breaker -Q0 ON signal -B0S Sensor, spring energy store charged signal -B5E Sensor, Earthing switch -Q5 ON signal -B5A Sensor, Earthing switch -Q5 OFF signal -B5E1 3 Reed contacts, Earthing switch -Q5 ON signal -B1E Sensor, Disconnector -Q1 ON signal -B1A Sensor, Disconnector -Q1 OFF signal -BE Sensor, Disconnector -Q ON signal -BA Sensor, Disconnector -Q OFF signal -B0G Pressure sensor for circuit-breaker compartment -B1G Pressure sensor for busbar compartment 1 -BG Pressure sensor for busbar compartment -M0 Charging motor for spring energy store, circuit-breaker -M1 Drive motor for disconnector/earthing switch -Q1/Q5 -M Drive motor for disconnector -Q -MMK Man/machine communications -Y and -V Shunt release off with series rectifier for -Q0 -Y3 and -V3 Shunt release on with series rectifier for -Q0 -A00 Bay control and protection unit REF54 -F100 M.c.b. for charging motor, circuit-breaker -F101 M.c.b. for drive motor, disconnector/earthing switch -Q1/-Q5 -F10 M.c.b. for drive motor, disconnector -Q -F106 M.c.b. for controller, circuit-breaker ON/OFF -F116 M.c.b. for auxiliary power supply to the REF54 ABB Power Distribution 7

4 Despatch and storage 4.1 Condition on delivery The factory-assembled panels are checked for proper assembly and function. Condition on delivery: Compliance of the equipment with the order checked. Routine testing to VDE 0670 Part 6 or ICE 6098 performed. Installation material and accessories packaged separately. Bushings for the busbars closed off with transport covers. Condition of the gas compartments: Filled with insulating gas at rated operating pressure, Fitted with drying agent bags. Note: Air freight is to be discussed and agreed in individual cases. 4. Packaging Panels with basic packaging or without packaging. Panels with seaworthy or similar packaging (also containerised for overseas transport): sealed in polythene sheeting, transport drying agent bags inserted, moisture indicators inserted, sight window fitted for checking of the indicator when AL composite sheeting is used. Observe the directions for the drying agent bags to DIN 55 473. The following applies: Coloured indicator blue: contents dry. Coloured indicator pink: contents moist (e.g. relative humidity over 40%). 4.3 Transport (Figures 4/1 to 4/3) Note: Do not walk on the tops of the panels (rupture point for the pressure relief system!). The transport units are normally individual panels. Take account of the weights of the transport units. Take account of the high centre of gravity. Handle the panels in the upright position. Only perform loading operations taking account of all safety precautions to protect personnel and the material transported with: a crane, and/or fork-lift truck. Handling by crane: Attach suspension ropes of a sufficient loadbearing capacity with shackles (opening angle 30 mm). Fit these to the four lifting lugs. Attach rope guide harness to the top of the panel. Handling in the switchgear room can be effected by a trolley with steerable wheels. Take account of the high centre of gravity of the panels. Danger of tipping! 4.4 Delivery The responsibilities of the consignee include but are not limited to: Checking the delivery for completeness and freedom from damage (e.g. also for moisture and its injurious effects). Any deficiencies/transport damage noted are to be documented on the waybill, reported to the shipper/carrier in accordance with the ADSP or KVO liability conditions for German insurance. Note: Always document major damage with photographs. 4.5 Intermediate storage Conditions for optimum intermediate storage: 1. Panels with basic packaging or without packaging. Dry and well ventilated storage room. Climate in accordance with VDE 0670 Part 1000/ IEC 60694. Room temperature not falling below -5 C. No other injurious environmental influences. Store the panels upright. Do not stack panels. Panels with basic packaging: open the packaging at least partially. Panels without packaging: loosely cover with protective sheeting. sufficient air circulation must be preserved. Check regularly for any condensation.. Panels with seaworthy or similar packaging with internal protective sheeting: Store the transport units: protected from the weather, in a dry place, protected from damage. Check the packaging for damage. Check the drying agent (see section 4.): on delivery, later at appropriate intervals. When the service life from the date of packaging has been exceeded: the protective effect of the packaging is no longer ensured, take action for further intermediate storage. 8 ABB Power Distribution

min.45 o ZX 75 530 895 Figure 4/1: Preparation for handling by crane, double busbar system 565 530 775 1105 13 115 (for panel width 800) 95 (for panel width 600) 75 (for panel width 400) ZX (170) 1464 (64) Figure 4/: Preparation for handling by crane, single busbar system Figure 4/3: Preparation for handling by fork-lift truck Note: The forks must support the full section length. ABB Power Distribution 9

5 Erection of the switchgear at site In the interests of the best possible erection sequence, and in order to ensure a high quality standard of the panels, local installation of the switchgear should only be carried out, or at least responsibly managed and supervised, by specially trained skilled personnel. 5.1 General site requirements At the start of erection, the switchgear room at site must be complete, fitted with lighting and power for the erection work, lockable, dry, and with good ventilation facilities. All necessary provisions for laying of the power and control cables such as openings, ducts, etc. must already be in place. Compliance with the conditions for indoor switchgear to VDE 0670 Part 1000 etc., including those for the minus 5 indoor temperature class, must be ensured. 5. Construction data (Figures 5/4 to 5/7) Panel width mm 400 600 800 800 Rated current A 630 150 000 > 000 Ceiling height ) : without additional absorber mm 500 500 500 with additional absorber mm 800 800 800 with additional cooling fan and without absorber mm 800 with additional cooling fan and with absorber mm 3100 Assembly opening : in ceilings: width mm 500 700 900 900 length mm 1810 1810 1810 1810 in doors: width mm 900 1100 1300 1300 height mm 300 300 300 300 Aisle width 3) : Inspection aisle mm 800 800 800 800 Operator aisle mm 1100 1300 1500 1500 Panel weight kg ca. 650 ca. 100 ca. 1700 ca. 1800 (outgoing feeder, double busbar) Floor load kg/m ca. 100 ca. 1400 ca. 1500 ca. 1600 Minimum dimensions ) Panel including top pressure relief duct 3) Governed by DIN VDE 0101 and the data on maximum panel width. The ZX switchgear installations are mounted on a foundation frame set into the screed, or on a raised false floor. The openings shown in figure 5/4 are intended as an aid to planning. Instead of the large openings shown, drill holes can also be used, depending on the number of high voltage cables. Openings (drill holes) for power cables in the station floor are to be constructed so as to be eddy-current free. Note: The following is to be taken into account in determining the foundation data: Single busbar systems: Any additional frame available for the voltage sensors in the busbar metering system. The distance from the additional frame including end coffer to the side wall of the room should be 500 mm to ensure sufficient room for movement (see also section.3). Double busbar systems: From 5 panels onwards, a pressure relief duct is required at both ends of the switchgear installation. 30 ABB Power Distribution

5.3 Fundamental notes on erection work DIN-bolts of tensile class 8.8 are to be used. Recommended tightening torque Nm Lubricant ) Thread Without Oil or grease M 6 10,5 4,5 M 8 6 10 M8 3) 1 4,5 M10 50 0 M1 86 40 M 16 00 80 The rated tightening torques for fasteners without lubrication are based on a coefficient of friction for the thread of 0.14 (the actual values are subject to an unavoidable, partly not inconsiderable, spread). Rated tightening torques for fasteners with lubrication in accordance with DIN 43 673. ) Thread and head contact surface lubricated. 3) These values apply to welded on studbolts only. Any tightening torques which deviate from those in the general table (e.g. for contact systems or device terminals) are to be taken into account as stated in the detailed technical documentation. It is recommended that the threads and head contact surfaces of bolts should be lightly oiled or greased, so as to achieve a precise rated tightening torque. Remove any dirt from the surfaces in general and from insulating material surfaces. Observe the cleaning instructions in Section 7.. When handling SF 6, avoid any escape of gas into the switchroom: as incorrect readings may be caused during leakage testing. ventilate well if leakage occurs. 5.4 Foundation frame (Figures 5/1 to 5/3) Switchgear on a foundation frame: The relevant data for the order in hand can be found in the ABB documentation. The single or multiple panel foundation frame can be supplied with the switchgear. It is as a rule laid by site personnel and should be aligned and inspected under the supervision of a responsible specialist. The specifications of DIN 43 661 are also to be maintained when laying the foundation frame, in particular the evenness and straightness tolerances as a condition for perfect switchgear assembly. Tolerance conditions for laying of the frame to DIN 43 661, version A: Evenness tolerance: +/- 1 mm per metre. Straightness tolerance: max. 1 mm per metre, but max. mm for the entire length of the frame. 5.5 Laying of the foundation frame (Figures 5/1 to 5/3) Bolt the individual parts of foundation frame elements 7 together. Bolt the individual sections composed of foundation frame elements 7 (where the switchgear has several panels) together using connecting links 7.1 and bolts 7.5. Set up the complete foundation frame on the concrete floor precisely at the specified position. Fasten the foundation frame to the concrete floor sufficiently firmly with the bolts and dished washers 7., checking the correct dimensional position continuously. Enter jacking screws 7.3 into the relevant threaded bores (different lengths to correspond to the height of the screed), inserting a steel shim 7.8 below each screw. Loosen the compensation bolts 7.4 and carefully align the entire surface of foundation frame 7 in the horizontal plane and at the correct height, using a levelling instrument and screwing in jacking screws 7.3 to the appropriate depth. The top edge of the foundation frame must be 1 to 3 mm above the screed (take account additionally of the material thickness of any additional floor covering). Tighten the compensation bolts 7.4, performing a final check on the dimensions and horizontal position of the frame. Weld jacking screws 7.3 firm to prevent inadvertent changes to their settings. Perform the necessary work for proper earthing of the foundation frame with 30 x 4 mm galvanised steel strip. Two connections are necessary in switchgear with more than 6 panels. Carefully backfill the foundation frame when applying the screed. Note: Before applying the screed, insert auxiliary bolts 7.9. These prevent the screed from penetrating into the rivet nuts. Remove auxiliary bolts 7.9 when the screed has hardened. The foundation frame must not be subjected to any undue impacts or pressures, particularly, during the installation phase. ABB Power Distribution 31

7.4 Figure 5/1: 7.1 Individual parts of a foundation frame element, -panel example version 7.1 Connecting link 7.4 Compensation bolt n x FT = a Panel width FT 7 (143) 1333 7.3 7.1 7.9 Panel width FT Foundation frame width a Number of panels n 1 3 4 7. 7.6 400 400 800 100 1600 600 600 100 1800 400 800 800 1600 400 _ Figure 5/: Foundation frame 7 Foundation frame element, individual parts bolted together 7.1 Connecting link 7. Bolt and dished washer for foundation frame fastening to concrete floor 7.3 Jacking screw for foundation frame 7.6 Plug 7.9 Auxiliary bolt for frame mounting and panel fastening bolt 1.4 3 ABB Power Distribution

Section A-A (without item (143) 1.5 1 1333 1.4 1 3 mm 7.3 7.5 7.9 7.4 A h A 7 7.8 7.,7.6 Figure 5/3: Foundation frame on concrete floor (showing the panel) 1 Panel 1.4 Panel fastening bolt 7 Foundation frame element 7. Bolt and dished washer for fastening of the foundation frame to the concrete floor 7.3 Jacking screw for foundation frame 7.4 Compensation bolt 7.5 Bolt for the connecting link 7.6 Plug 7.8 Steel shim 7.9 Auxiliary bolt for frame installation h Screed height 40 to 50 mm 5.6 Raised false floor (Figures 5/6 and 5/7) When a raised false floor is used, the manufacturer s installation instructions are to be observed. The false floor must satisfy all requirements specific to the switchgear installation. ABB Power Distribution 33

) A B C D 3 5 6 150 (143) 665 150 150 150 8x150 1 190 10 10 190 30 150 160 160 30 815 8 660 580 110 430 500 3x160 85 870 85 65 660 180 1710 800 4 400 50 600 600 800 800 800 600 600 50 800 a 7 b c d 60 50 000 A B C D (155) ( 7 Figure 5/4: Guideline construction data for a foundation frame on a concrete floor See figure 5/5 for sections Minimum 1 Inspection aisle Operator aisle 3 Basement entrance 4 Platform, approx. 5 kn 5 Pressure relief duct at side, including end cover 6 Instead of individual openings, continuous openings or drilled holes are possible 7 Earthing bar 8 Panel without cable connection, e.g. bus coupler panel 9 Door 10 Waste air opening 11 Intake air opening 1 Intake air opening, if required 13 Waste air opening 14 Or as shown in figure 5/7 15 Height of cable basement as required 16 To earthing bar 17 Opening for control cable 18 Opening for power cable, plug size 19 Opening for power cable, plug size 3 0 Instrument transformer for billing purposes 1 Screed, see also figure 5/3 Panel width a b c d in switchgear mm mm mm mm 600 mm 137 1455 1300 1100 800 mm or 600 mixed with 800 mm 157 1655 1500 1300 Room height : Rated Absorber Room height current A mm 000 with 800 000 without 500 > 000 with 3100 > 000 without 800 34 ABB Power Distribution

Section A - A 800 1710 c Section B - B 800 1710 c 1 00 11 1 00 11 10 16 150 ZX 150 665 (155) 100 600 (7) 9 d 300 800 10 16 30 ZX 150 815 (155) 100 600 (7) 9 d 300 800 1 0 1 1 660 b 65 180 18 17 13 14 15 1 660 b 65 180 18 17 13 14 15 (143) a (143) a a) Panel width 600 mm, without instrument transformer b) Panel width 600 mm, with instrument transformer Section C - C 800 1710 c Section D - D 800 1710 c 00 00 1 00 11 1 11 00 10 16 30 ZX 160 160 660 (155) 100 600 (7) 9 d 300 10 16 ZX 160 160 160 500 100 600 9 d 300 0 1 (155) (7) 1 1 870 b 85 180 19 17 13 14 15 870 b 85 180 1 19 17 13 14 15 (143) a (143) a c) Panel width 800 mm, with instrument transformer d) Panel width 800 mm, without instrument transformer Figure 5/5: Sections for figure 5/4 See figure 5/4 for legends and dimensional table Minimum ABB Power Distribution 35

A B 5 150 8x150 150 1 190 10 10 190 800 6 815 30 150 160 160 30 1333 150 150 665 8 660 3x160 500 1710 4 400 50 600 600 800 800 800 600 600 50 800 3 a 7 b c 000 A B 100 M 10 M 10 M 10 600 400 100 100 100 Figure 5/6: Guideline construction data for a raised false floor See figure 5/7 for sections Minimum 1 Inspection aisle Operator aisle 3 Basement entrance 4 Platform, approx. 5 kn 5 Pressure relief duct at side, including end cover 6 False floor structure, only shown in the area of the switchgear 7 Earthing bar 8 Panel without cable connection, e.g. bus coupler panel 9 Door 10 Waste air opening 11 Intake air opening 1 Intake air opening, if required 13 Waste air opening 14 Or as shown in figure 5/5 15 Height of cable basement as required 16 To earthing bar 17 False floor structure, supplied by others 18 Power cable, plug size 19 Power cable, plug size 3 0 Instrument transformer for billing purposes Panel width a b c in switchgear mm mm mm 600 mm 137 1300 1100 800 mm or 600 mixed with 800 mm 157 1500 1300 Room height 1 : Rated Absorber Room height current A mm 000 with 800 000 without 500 > 000 with 3100 > 000 without 800 36 ABB Power Distribution

Section A - A Section B - B 800 1710 b 800 1710 b 13 1 00 11 13 00 00 1 11 14 10 16 150 ZX 150 665 (7) 100 600 9 c 300 800 14 10 16 ZX 30 160 160 660 100 600 9 c 0 300 1 1 17 18 1333 X a 15 1 17 19 X 1333 (7) a 15 a) Panel width 600 mm, without instrument transformer b) Panel width 800 mm, with instrument transformer Detail X (7) 3 Figure 5/7: Sections for figure 5/6 See figure 5/6 for legends and dimensional table Minimum ABB Power Distribution 37

5.7 Erection and connection of the panels (Figures 5/3 and 5/8 to 5/14) Note: Do not walk on the top of the panels (rupture point for pressure relief system!). 5.7.1 Preparatory work Grease the upper surfaces of the foundation frame (this facilitates erection and alignment of the individual panels). Enter the two or four guide pins 35 at the sides of the panels into the relevant bores (see figure 5/10, section A-A). 5.7. Erection of the switchgear Erect the end panel of the switchgear at the precise position specified on the foundation frame. Lightly enter panel fastening bolts 1.4 into the relevant threaded bores in the foundation frame. Align the panel if necessary. Perform a final check on the aligned position of the panel and fasten it to the foundation frame by tightening the panel fastening bolts 1.4. Remove the protective caps from the busbar sockets 3.1. Carefully check insulating parts 3. and contact tubes 3.3 for any dirt, and clean if necessary (see also section 7.). Note: Only prepare insulating parts and contact tubes for the panel currently being erected. Protect them from further contamination! Evenly apply a thin coating of assembly paste AP to the conical surfaces A of insulating parts 3.. Note: Leave no ungreased areas on conical surface A. Carefully insert contact tubes 3.3 and insulating parts 3. into the busbar sockets 3.1. Slide the adjacent panel carefully and evenly (without tipping) against the erected panel in such a way that the contact tubes, insulating parts and guide pins slide into the corresponding bores without the use of force. If necessary, align the panel appropriately with the panel height adjustment bolts 1.5. As soon as the distance between the two panels is so small that bolts 36 and 37 can be entered in the bores in the erected panel, insert these, each with nuts and dished washers respectively. Spacer 38 is also to be fitted on socket head bolt 37 (see figure 5/9, section B-B). Then join the two panels together by tightening bolts 36 and 37 step by step. Completely bolt the panels together with bolts 40, each with dished washers (see figure 5/8). When the panels have been completely joined, check the second panel again for correct alignment and fasten it to the foundation frame with the panel fastening bolts 1.4. Dismantle connecting link 14 for the main earthing bar 15 in the cable compartment and lead it through to the adjacent panel. Bolt the connecting link to the main earthing bar with bolts 39 and one dished washer at each of the bolt head and nut ends. Check the bolted connection between main earthing bar 15 and the connecting link 14 in the previously erected panel and tighten bolt 39 if necessary. Erect the further panels by following the same procedure. Assembly of the top pressure relief duct, the absorber and the cooler if fitted can be effected during installation of the individual panels or when all panels have been joined together. 38 ABB Power Distribution

View X 40 37. 40 37.1 37. A A B 40 37. 3 35 3.1 3. 3.3 B 40 37.1 37. 40 37. X 40 37. C 40 37. C 40 37. a) Double busbar 40 37. A 40 37. 40 37.1 37. B A B 40 37. 40 37.1 37. 40 37. 40 37. C C 40 37. b) Single busbar Figure 5/8: Switchgear erection (See figure 5/9 for sections and details) 3 Busbar connection, plug-in type 3.1 Busbar socket 3. Insulating part 3.3 Contact tube 35 Guide pin 37.1 M8 hexagon nut 37. Dished washer 8 40 Socket head bolt M8 x 5 ABB Power Distribution 39

Section A-A 3.4 3.1 3. 3 10 Panel division ca. 50 Evenly greased with assembly paste AP A Busbar connection Insulating part Section B-B Section C-C Panel division 10 Panel division 38 37. 37 15 39 35. 14 35. 35.1 Panel/panel connection Earthing bar connection Figure 5/9: Switchgear erection (section for figure 5/8) 14 Panel/panel connecting link 15 Main earthing bar 3 Busbar connection, plug-in type 3.1 Busbar socket 3. Insulating part 3.4 O-ring 35.1 M10 hexagon nut 35. Dished washer 10 37 Socket head bolt M8 x 40 37. Dished washer 8 38 Spacer 39 Socket head bolt M10 x 35 40 ABB Power Distribution

A B 35 36 A B 35. 35.1 Section A-A 35 35. Section B-B 35. 35.1 36 a) Panel joined up from the right 36 35 b) Panel joined up from the left Figure 5/10: Switchgear erection panel/panel connection, view from top (without pressure relief duct) 35 Guide pin 35.1 M10 hexagon nut 35. Dished washer 10 36 Socket head bolt M10 x 50 ABB Power Distribution 41

35. Detail X 35. X 43 35.1 4 41 37. 40 Detail Y Evenly greased, assembly paste AP 4 Y Figure 5/11: Busbar end in an end panel 35.1 M10 hexagon nut 35. Dished washer 10 37. Dished washer 8 40 Socket head bolt M8 x 5 41 Plate for blanking plug 4 Blanking plug 43 Socket head bolt M10 x 30 44 45 1330 665 A 50 0 B F C D 600 Figure 5/1: Pressure relief duct, side, double busbar, right-hand side mounting shown A B C D F Pressure relief duct with absorber Pressure relief duct, top Pressure relief duct, side End cover Panel 44 Fastening material, packed in bag group Screw fasteners for side pressure relief duct 45 Plug 4 ABB Power Distribution

3.1 3. 3.3 L3 L L1 Figure 5/13: Busbar connection 3.1 Busbar socket 3. Insulating part 3.3 Contact tube Figure 5/14: Assembly of the busbar connection, shown for 150 A L1: Protective cap removed L: Contact tube 3.3 fitted L3: Insulating part 3. and contact tube 3.3 fitted 1 7 10 11 13 13.1 13. 13.3 13.4 Figure 5/15: Plug connector for single-core plastic-insulated cable 10 Socket 11 Cable plug K Cable earthing conductor to be connected to switchgear earth, do not establish cable earthing via the plug Figure 5/16: Cable compartment (panel side wall cut out) 1 Surge arrester 13 Floor plate, split 13.1 Reducer ring 13. Cable mounting 13.3 Supporting section, at earth potential 13.4 Insulated earthing point for cable jacket (nonstandard) 7 High voltage cable ABB Power Distribution 43

5.8 Connection of cables and wiring The cable compartments (I) in the panels are fitted with cable connection fittings in accordance with the cable types and sizes specified in the project planning for the switchgear as a whole. 5.8.1 High voltage plastic-insulated cable with plug connectors (Figures 3/4, 3/11, 5/15 and 5/16) Lay the single-core plastic-insulated cables as specified in the project planning to the individual panels. Remove the transport covers fitted to protect the sockets. Expose the cable cores, check the correct phase assignment, and secure. 5.10 Final erection work Clean the external surfaces of the enclosure and control cabinets in the switchgear where necessary and check for any damage to the paintwork, touching up with a suitable paint if necessary (see Section 7.3). Properly refit any cladding and covers of operating mechanisms, cable ducts, etc. removed during the erection work. Remove all tools and other foreign bodies from the switchgear. Check the general condition of the switchgear. Check that the areas adjacent to the switchgear are in the proper condition. Fit cable plug 11 in accordance with the manufacturer s instructions. Fit the plugs to the sockets 10 mounted in the circuit-breaker compartment floor (without opening the insulating gas compartment) and secure them with bolts. Align the cables and fasten them at mountings 13. Close off any unused sockets, e.g. in spare panels, with suitable cable blanking plugs to ensure the necessary insulation. 5.8. Control cables and wiring (Figures 3/ and 5/1 Establish the necessary connections for incoming and outgoing cables and wiring, and cross connections. The control cables and wiring are to be laid in cable ducts at the right of the cable compartment (for external wiring). The connections from panel to panel are to be made by plug connectors in the control cabinets. 5.9 Preparing the insulating gas system for operation Observe the relevant data in instruction manual BA 47/E Insulating gas system for ZX switchgear. 44 ABB Power Distribution

6 Commissioning/operation Note on safety at work Operation by trained specialists familiar with the particular switchgear only. 6.1 Commissioning 6.1.1 Preparatory work In preparation for commissioning, the following work is to be performed prior to connection with the high voltage power supply: Connect the auxiliary and control voltage and check the correct polarity. Check mechanical and electrical interlocks for compliance with the specified conditions. Perform a functional test on the protective devices (observe DIN VDE 014. Check the general condition of the switchgear and external conditions for detrimental factors of any kind. Display the instructions for handling SF 6 in the switchroom. The handling specifications for SF 6 also apply accordingly to nitrogen. Display the ABB instruction manual on the handling of insulating gas and behaviour during faults in the switchroom. Instruct the local operators on the fundamental details of operating the switchgear in normal service. Check the readiness for operation and the switching condition of the upstream and downstream electrical equipment. Perform further checks where necessary on the following equipment from the areas adjacent to the switchgear: power cables control wiring auxiliary voltage and its polarity remote controls external earth with connection to main earthing bar 15 switchroom equipment switchroom condition. 6.1. Initial start-up Comply with all relevant safety regulations Ensure that the switchgear circuit-breakers are in the OFF position. Close the disconnector for the relevant busbar system. Cancel any existing short-circuiting and earthing connections in the critical switching area. Energise the switchgear step by step, observing the displays on the REF54. Check that corresponding conductor sections are in phase where relevant with several incoming feeders and switchgear sections. Check measurements and functions dependant on high voltage. Look out for irregularities of any kind. 6. Switching operations 6..1 Circuit-breaker (Figures 3/, 6/1, 6/ and 6/4) The circuit-breaker is fitted with a charging motor. Charging of the spring energy storage mechanism takes place automatically. Opening and closing the circuit-breaker: Opening and closing are effected by selection on the bay control and protection unit REF54. ON-OFF switching operations may only be performed with the control cabinet door closed. Opening the control cabinet door constitutes intervention in the interlock system. Observe the position indicator. Emergency manual operation: 1. On failure of the charging motor, the charging process can be performed or completed by hand: Open control cabinet door 1.1. Insert charging lever 8.9 into recess 8.8 and pump for approx. 5 strokes until the charged condition is displayed. When the charged condition is reached, the charging mechanism automatically disengages and further strokes of the charging lever have no effect. Key to the charging condition displays: Discharged Charged. If the control voltage fails with the circuit-breaker closed, it is possible to open it using the mechanical OFF push-button 8.3. Note: On failure of the control voltage, there is no maloperation protection for the circuit-breaker, three-position switch and disconnector during emergency manual operation. ABB Power Distribution 45

6.. Three-position switch and disconnector (Figures 3/, 3/11, 6/3, 6/5 and 6/6) The three-position switch and the disconnector 19 are fitted with motor-operated mechanisms. Opening and closing are effected by selection on the bay control and protection unit. ON-OFF switching operations may only be performed with the control cabinet door closed. Opening the control cabinet door constitutes intervention in the interlock system. Observe the position indicator on LCD display 5.1 or on the control unit. Sensors 9 to 3 on the three-position switch operating mechanism 3 detect the following switch positions: Disconnector -Q1 ON and OFF, and earthing switch -Q5 ON and OFF. Sensors 33 and 34 on disconnector operating mechanism 0 detect the following switch positions: Disconnector -Q ON and OFF. Emergency manual operation: In place of motorised operation, the switching process can also be initiated and completed manually. Caution! The interlock is ineffective on emergency manual operation. Open control cabinet door 1.1 Prior to emergency manual operation, switch the relevant m.c.b. (F101 or F10) off. Insert the crank in the hollow shaft. Three-position switch -Q1/-Q5: If the three-position switch is in the central position (i.e. disconnector and earthing switch OFF), the disconnector can be closed with approx. 4 clockwise turns, and the earthing switch with approx. 4 anti-clockwise turns. If the earthing switch ON position is to be reached from the disconnector ON position, or vice versa, the crank is to be removed in the self-inhibiting central position (disconnector and earthing switch OFF) and refitted. When the crank is refitted, the further switching operation is automatically enabled. Disconnector -Q: Close the disconnector with approx. 4 clockwise turns and open it with approx. 4 anticlockwise turns. Note: Always perform every switching operation right up to the stop in the relevant limit position. Observe the mechanical and electrical position indicators. 6..3 Undervoltage release Undervoltage releases may be fitted as an option. In order to prevent the circuit-breaker being opened by the undervoltage release on power failure with teeoff earthing, an interlock rod or wire is provided. 6.3 Observation of the display and monitoring facilities 6.3.1 Gas monitoring (Figures 3/11 and 6/ All high voltage compartments in the switchgear must have a sufficient insulating gas pressure during operation. The minimum operating gauge pressure (p e ) is listed in section.1. This is monitored by sensors 4, 7 and 1. If the gas pressure falls below the minimum operating gauge pressure, an LED on the bay control and protection unit signals that the gas should be topped up. Note: If a panel is isolated for a relatively long period (several weeks), m.c.b. F116 for the auxiliary voltage supply to the REF54 must remain on. Only in this way is monitoring of the insulating gas ensured. Details on the gas system of the ZX switchgear can be found in instruction manual BA 47. 6.3. Electrical/mechanical display/monitoring During operation of the switchgear, observe all visible operating data and condition displays in the secondary system and watch out for irregularities of any kind, including the external conditions of the switchgear. 6.4 Test procedures 6.4.1 Testing for the off-circuit condition (Figure 6/ The panels are fitted with the low impedance, capacitive voltage indicator system LRM, including corresponding (hand-held) display units with connecting plugs for testing of the off-circuit condition. For details, see draft DIN VDE 068 Part 415, or IEC 6143 Part 5. 46 ABB Power Distribution

Note: Only display units which comply with the IEC or VDE standards and the technical design of the indicator system in the relevant switchgear may be used! Note: The measuring sockets must on no account be short-circuited, except during voltage testing of the system (e.g. with power frequency withstand voltage or impulse withstand voltage)! Testing for the off-circuit condition is performed with a plug in display unit at corresponding pairs of measuring sockets 6 in the vicinity of the panel controls. Use of the display unit: Perform a functional test on the display unit immediately before and after use, e.g. with interface tester KSP. The display must be clearly visible. The presence of operating voltage is indicated by a signal. Observe the individual operating instructions for the display unit for the relevant switchgear! Interface testing: Perform interface testing as a functional test on all coupling components, e.g. with interface tester KSP. The interface test is a repeat test to IEC 6143 Part 5 or draft DIN VDE 068 Part 415. 6.4. Testing for the in-phase condition Testing for the in-phase condition, e.g. when there is more than one incoming feeder, can be performed with a suitable phase comparator at measuring sockets 6 on the capacitive voltage indication system. Test procedure: Only use phase comparators which comply with the IEC or VDE specifications and the technical design of the display system in the relevant switchgear! Perform a functional test on the equipment at the start of testing. Do not exceed the maximum permissible length of measuring leads per phase. Connect the measuring leads precisely assigned to the corresponding main conductor sections. Always follow the details in the operating instructions for the phase comparator! 6.4.3 High voltage tests (Figures 6/1 and 6/8) The test plugs available for high voltage tests, shown in figure 6/8, are suitable for the following applications up to and including 4 kv rated voltage. For high voltage tests on the 36 kv rated voltage level, separate test facilities are required. Information on these can be obtained from the switchgear manufacturer. Taking account of the sensor systems used and the bay control and protection unit, the test voltages must not exceed the following values: Cable tests with DC voltage: 1 kv switchgear: 48 kv 4/36 kv switchgear: 70 kv up to 1 hour. Higher values on request. Insulation testing of the switchgear at the relevant power frequency withstand voltage: 1 kv switchgear: 8 kv 4 kv switchgear: 50 kv 36 kv switchgear: 70 kv. Performance of voltage tests: Isolate the switchgear area in accordance with the safety rules of VDE 0105 and secure it to prevent reconnection. Verify the off-circuit condition with a suitable hand-held display unit at measuring sockets 6 on the capacitive voltage indicator system. Unscrew surge arresters where fitted, or unscrew the cable blanking plugs from the free cable sockets. Check the test plug to ensure that the surface is clean and dry, and clean it if necessary. Grease the silicone part of the test plugs in accordance with the directions. Insert the test plug into the prepared cable socket and screw it tight. Notes: Only fit the test plugs for voltage tests for the duration of those tests. Short-circuit the measuring sockets 6 in the panels concerned for the duration of the testing process at test voltages up to rated power frequency withstand voltage. Applies to integrated voltage sensors. With plug-in voltage sensors/instrument transformers, the cable test voltages permissible to DIN standards may be used if the sensors are withdrawn. ABB Power Distribution 47

For performance of cable tests, in the switching condition tee-off disconnected and earthed, earthing of the cable has to be cancelled by opening the circuit-breaker. This is accomplished by using the mechanical OFF button to open the circuit-breaker (see also Section 3.9). 6.4.4 Current tests (Figures 6/1 and 6/9) The test plugs available for current test are suitable for the following applications: Testing of the protection functions in the bay control and protection unit REF54 by means of primary current injection. Test instruction: The following is to be observed when testing the protection system of the REF54: In order to prevent damage to the OFF-release coil during testing, either the OFF-release coil has to be disconnected or the protection test equipment must be deactivated by the trip command. This ensures that the opening release is not energised in the meantime by the trip command, which could lead to the coil burning out. Establishment of maintenance earthing in conjunction with an earthing and short-circuiting set. The short-circuit resistance of the current test plugs for the switchgear must correspond to the condition of the individual switchgear. Handling of the plugs for current tests: Isolate the switchgear area in accordance with the safety rules of VDE 0105 and secure it to prevent reconnection. Verify the off-circuit condition with a suitable (hand-held) display unit at measuring sockets 6 on the capacitive voltage indicator system. Unscrew surge arresters where fitted, or unscrew the cable blanking plugs on the free cable sockets. Check the test plug to verify that the surface is clean and dry, and clean it if necessary. 6.4.5 Maintenance earthing a) Double busbar systems: In the double busbar system, there is an opportunity to earth the busbar via the bus coupler. b) Single busbar systems: Earthing of the busbar with the bus tie / riser, as described in section 3.9.3. Earthing with an earthing and short-circuiting set. Handling during earthing with an earthing and short-circuiting set: (Figures 6/1 and 6/9) The plugs for current tests described under 6.4.4 are used in conjunction with corresponding cable sets for short-circuiting and earthing to establish maintenance earths. The short-circuit resistance of the cable set must correspond to the conditions of the switchgear. Caution! Observe the notes in Section 3.9 on the interlock dependencies for all work with earthing and shortcircuiting sets! Isolate the switchgear area in accordance with the safety rules of VDE 0105 and secure it to prevent reconnection. Verify the off-circuit condition with a suitable (hand-held) display unit at measuring sockets 6 on the capacitive voltage indicator system. Unscrew surge arresters if fitted, or unscrew the cable blanking plugs on the free cable sockets. Check the test plugs to ensure that the surface is clean and dry, and clean them if necessary. Carefully screw the short-circuiting and earthing cable set to the test plug. Connect the common earthing connector of the cable set to the earthing terminal of the panel. Insert the test plugs into the prepared cable sockets and screw them tight. Insert the test plug into the prepared cable socket and screw it tight. Only fit the test plugs for the duration of the tests. 48 ABB Power Distribution

6.5 Application of the X-ray regulations One of the physical properties of vacuum insulation is the possibility of x-ray emissions when the contact gap is open. The specified type test performed by the Physikalisch-Technische Bundesanstalt (PTB) in Brunswick demonstrates that the local dosage output of 1 µsv/h at a distance of 10 cm from the touchable surface is not exceeded. The results are as follows: The use of the vacuum interrupters at rated voltage is completely safe. Application of the rated power frequency withstand voltage specified for the switching device by VDE 0670 and IEC 60056 or a DC voltage of 48 kv or 70 kv during cable tests is also safe. Higher voltages than the rated power frequency withstand voltage specified in DIN VDE or IEC standards or the DC voltage must not be applied! Fulfilment of the above requirement with the vacuum interrupter in the open position is dependent on maintenance of the specified distance between the contacts (which is automatically ensured with correct mechanism function and force transmission). ABB Power Distribution 49

1.1 5 5.1 1.1 8 8.4 8.1 (8.) 5. 8.3 6 Figure 6/1: Display area on the panel Figure 6/: Handling of the door-lock 1.1 Control cabinet door 5 Bay control and protection unit REF54 5.1 LCD display (example) 5. Light-emitting diode (LED) 6 Measuring sockets for capacitive voltage indicator system Opening the control cabinet door: - Open the safety lock (if fitted) - Release the catch with the double bit key - Draw the closing lever out to an angle of 45 and then swing it upwards to the left through approx. 135 until the stop is reached Closing the control cabinet door: - reverse the procedure for opening 1.1 Control cabinet door 8 Door-lock 8.1 Catch (8.) Safety lock (if ordered) 8.3 Double bit key 8.4 Closing lever 31 30 9 3 3 3.1 34 33 3. 3.3 3.4 0 0.1 0. Figure 6/3: Operating mechanisms for the three-position switch and disconnector 3 Three-position switch mechanism 3.1 Hollow shaft (emergency manual operation shaft) 3. Mechanical position indicator 3.3 Cam for OFF position of the three-position switch 3.4 Drive motor for three-position switch 0 Disconnector mechanism 0.1 Hollow shaft (emergency manual operation shaft) 0. Mechanical position indicator 9 Sensor, disconnector -Q1 ON 30 Sensor, disconnector -Q1 OFF 31 Sensor, earthing switch ON 3 Sensor, earthing switch OFF 33 Sensor, disconnector -Q ON 34 Sensor, disconnector -Q OFF 50 ABB Power Distribution

8 8.1 8. 8.3 8.4 8.5 8.9 8.8 8.7 8.6 Figure 6/4: Emergency manual operation, circuit-breaker type VD4 X Figure 6/5: Emergency manual operation, three-position switch UXTE 8 Circuit-breaker operating mechanism 8.1 Front plate 8. ON push-button 8.3 OFF push-button 8.4 Operating cycle counter 8.5 Mechanical position indicator 8.6 Rating plate 8.7 Charging condition indicator 8.8 Recess for charging lever 8.9 8.9 Charging lever for emergency manual operation Figure 6/6: Emergency manual operation, disconnector UXT Figure 6/7: View of the stored-energy spring mechanism for the circuit-breaker, front plate removed ABB Power Distribution 51

Figure 6/8: Test plug for high voltage tests up to 4 kv rated voltage Figure 6/9: Test plug for current tests Also usable as a maintenance earth in conjunction with an earthing and short-circuiting set 5 ABB Power Distribution

7 Maintenance Maintenance serves to preserve trouble-free operation and achieve the longest possible working life of the switchgear. In accordance with DIN 31 051 and IEC 6108, it comprises the following closely related activities: Inspection: Determination of the actual condition Servicing: Repairs: Measures to maintain the specified condition Measures to re-establish the specified condition 7.1 General It is essential to observe the following during all maintenance work: The relevant regulations in section 1.. The notes on safety at work in section 6 Standards and specifications in the country where the switchgear is erected. It is recommended that ABB after sales service personnel be called in to perform servicing and repair work. Follow/observe the instructions on SF 6 systems and the ABB instruction manual on the handling of insulating gases and procedures for fault conditions. The handling regulations for SF 6 also apply accordingly to nitrogen. Keep these instructions and manual permanently on display and available in the switchroom. The inspection and servicing intervals for the switching devices are determined by fixed criteria such as switching frequency and number of shortcircuit breaking operations. The length of the intervals for inspection and servicing of the control cabinet and its equipment is influenced by ambient conditions (for instance pollution and aggressive atmosphere). In addition to this instruction manual, the following instruction manuals must be observed: Insulating gas system BA 47/E Bay control and protection unit REF54 BA 453/E Circuit-breaker VD4 X BA 436/E Further details can be found in the technical documentation for the switchgear installation (including, for example, any agreed special operating conditions). 7. Inspection/servicing Under normal operating conditions (see section 1.3), checking of the operating mechanisms is to be carried out by a suitably qualified electrician after 10 years at the latest or after 10,000 operating cycles of the circuit-breaker and,000 operating cycles of the three-position switch or disconnector. In exceptional operating conditions (including adverse climatic conditions) and/or particularly adverse environments (including heavy contamination and aggressive atmosphere) inspection at shorter intervals may be required. Inspection is first and foremost to be visual examination for contamination, corrosion and moisture. The inspection should however also include checking of the mechanical and electrical functions of the following devices: Switching devices Bay control and protection unit REF54. If an incorrect condition is found, the corresponding repair work is to be initiated immediately. Cleaning If the necessity of cleaning is established during inspections, the following procedure is to be adopted: Prior to cleaning, isolate and secure the working area if necessary in accordance with the safety rules of DIN VDE and IEC. Cleaning of surfaces in general: Remove weakly adhering dry dust deposits with a soft dry cloth. Remove more strongly adhering contamination with slightly alkaline household cleanser, or with Rivolta BWR 10. Cleaning of insulating material surfaces and conductive parts (outside the gas compartments): Minor contamination with Rivolta BWR 10. Strongly adhering contamination with Cold cleanser 716 Cleaning of busbar insulating parts, cable sockets and busbar sockets with cable cleanser MAB. Observe the manufacturer s instructions and the special ABB instruction manuals BA 100/E and BA 1006/E on safety at work. Wipe down after cleaning, using clean water, and dry properly. ABB Power Distribution 53

7..1 Vacuum circuit-breaker (Figure 6/7) The vacuum circuit-breaker has a long service life. It has a low maintenance operating mechanism and the breaker poles are maintenancefree. Consult the relevant sections of instruction manual BA 436/E for further information. 7.. Three-position switch and disconnector The three-position switch and disconnector are maintenance-free for 000 operating cycles. 7..3 Gas system and gas servicing Consult the relevant sections of instruction manual BA 47/E for further information. 7..4 Outlet filter The filter mats in the outlet filter are to be changed as required. Note the information on inspection and servicing in section 7.. Replacement procedure: Draw off the grille. This is done by prising off with the fingertips in the recesses at the bottom end of the filter. Change the filter mat. Replace the grille. Spare filter mats: Part no. (order ref.) Filter mat for fan system: GCE0995403P0100 7.3 Repair Remove all rust from damaged paintwork areas on sheet steel and other steel parts mechanically, e.g. with a wire brush. Lightly grind the surrounding paint coat and carefully degrease the entire area. Then immediately apply an anti-rust primer and, after an appropriate hardening period, apply the top coat. Only use suitable and compatible paint products. Use top coat paint in the standard colour RAL 703, or the relevant special colour. Carefully remove any white rust from galvanised and chromium plated functional parts and rust on phosphated parts with a wire brush or a cleaning pad, e.g. Scotch-Brite, and clean with a dry cloth. Then grease evenly with Isoflex Topas NB 5. Notes: It is essential to observe the section on safety at work in instruction manual BA 47/E for all work on gas compartments. Caution when working in gas compartments! High gas concentrations may result in a danger of asphyxiation! Filter mat for control cabinet: GCE0995404P0100 54 ABB Power Distribution

7.4 Working and auxiliary materials 7.4.1 Working materials Part no. (Order ref.) Insulating gas system: Nitrogen (N ) GCE099067P0100 Degree of purity 4.6 Delivery form: liquid gas in steel cylinders Observe the relevant ABB instruction manual BA 1007/E on safety at work! GCEA901007P010 Sulphur hexafluoride (SF 6 ) GCE099053P0103 Delivery form: liquid gas in steel cylinders Observe the quality requirements to IEC 60376/ VDE 0373! Observe the relevant ABB instruction manual GCEA901004P010 BA 1004/E, pp. 1 to 3, on safety at work! Note: If extreme temperatures 50 C cannot be ruled out where gas cylinders are stored, transported or temporarily stored in the open air in direct sunlight, a reduced filling factor of 0.75 kg/l cylinder contents is to be required when ordering for safety reasons! Drying agent material: Drying agent bag to DIN 55 473, capacity per bag 10 g GCE0990443P0100 7.4. Auxiliary materials Lubricants: Isoflex Topas NB 5, GCE000749P0100 Assembly paste AP, for insulating part/cast resin plug connections GCE0009098P0100 Cleaning agents for general cleaning: Rivolta BWR 10, GCE0007707P0100 Observe the relevant ABB instruction manual BA 100/E GCEA90100P010 Cleaning agent for conductive parts, parts in insulating material, and all parts with heavy contamination: Cold cleaner 716, GCE0007706P0100 Observe the relevant ABB instruction manual BA 1006/E GCEA901006P010 Cleaning agent for busbar insulating parts, busbar sockets and cable sockets: Cable cleaner MAB GCE0009100P0100 Paintwork: Paint in standard colour RAL 7035 1 kg-box GCE9014060R0103 Spray tin GCE0007895P0100 ABB Power Distribution 55

Instruction manual no. GCEA 68 0435 P010 Printed in Germany (1.00-500-PPI) We reserve the right to make changes in the course of technical development. ABB Calor Emag Mittelspannung GmbH ABB Sace T.M.S. S.p.A Oberhausener Strasse 33 Petzower Strasse 8 Via Friuli, 4 D-4047 Ratingen D-1454 Glindow I-4044 Dalmine Phone: +49(0)1 0/1-1 30, Fax: +49(0)1 0/1-19 16 Phone: +39 035/395111, Fax: +39 035/395874 E-mail: calor.info@de.abb.com E-mail: sacetms.tipm@it.abb.com Internet: http://www.abb.de/calor Internet: http://www.abb.com