UniGear type ZVC Medium voltage, arc-proof, air-insulated, fused vacuum contactor switchgear

Transcription

1 UniGear type ZVC Medium voltage, arc-proof, air-insulated, fused vacuum contactor switchgear Power IT Installation, Operation and Maintenance Manual

2 1 TABLE OF CONTENTS 1) INTRODUCTION...2 2) STANDARDS AND SPECIFICATIONS...3 3) TYPE TEST REPORTS...3 4) TECHNICAL SPECIFICATION...5 A) ELECTRICAL DATA...5 B) INTERNAL ARC WITHSTAND...5 C) ENVIRONMENTAL DATA...6 5) DIMENSIONS & WEIGHTS...7 6) RECEIPT AND INSPECTION...8 7) STORAGE AND INSPECTION...9 A) SHORT TERM STORAGE (MAX FOUR WEEKS ONLY)...9 B) LONG TERM STORAGE (ONE MONTH TO SIX MONTHS)...9 8) BASIC STRUCTURE...9 A) COMPARTMENTS AND PARTITIONS...9 B) INTERLOCKS AND LOCKING FACILITIES ) INSTALLATION...13 A) FOUNDATION...13 B) BOLTING PANELS TOGETHER...13 C) BUSBARS...13 D) POWER CABLE CONNECTION...14 E) CONTROL CABLE CONNECTION...15 F) EARTHING...15 G) CONNECTING TO UNIGEAR TYPE ZS ) OPERATION...16 A) EARTH SWITCH...16 B) CONTACTOR...16 C) RACKING...17 D) REMOVAL OF CONTACTOR TRUCK...18 E) INSERTION OF CONTACTOR TRUCK...18 F) FUSE OPERATION ) MAINTENANCE...19 A) GENERAL...19 B) INSPECTION AND SERVICING...19 C) REPAIRS/REPLACEMENT...21 i) Recommended Spare parts...21 ii) Corrosion Repair...21 iii) Trip Coil Replacement...21 iv) Feeder Unit Replacement...22 v) Fuse Replacement ) TROUBLESHOOTING...23 We reserve all rights to this publication. Misuse, particularly including duplication and the making available of this manual or extracts to third parties is prohibited. The information supplied is without liability. Subject to alteration ABB Australia Pty Limited

3 1) INTRODUCTION 2 UniGear type ZVC is three-phase, air-insulated indoor switchgear designed for the operation, control and protection of motors and transformers at rated voltages up to 7.2kV and rated current up to 400A. Other applications are possible and should be referred to the manufacturer. UniGear type ZVC s combination of maximum accessibility at minimum dimension and innovative integration of components offers a lightweight cubicle with small footprint providing greater utilisation of switchroom space. The UniGear type ZVC enclosure is constructed from 2mm thick zinc coated steel sheet. The indoor, metalclad, IP4X design using vacuum switching technology and epoxy resin enclosed conductors ensure long service life is possible. An integral fault-making cable earthing switch is included and ALL operations, ON-OFF-ISOLATION-EARTHING, are conducted with the front door closed to ensure maximum personnel protection in the event of an internal arcing fault and to avoid contamination and electrical deterioration of the switchgear. UniGear type ZVC comprises a fixed portion for the connection of the main busbars and the outgoing cables. It houses fixed isolating contacts, current transformers and earthing switch. The low voltage control and protection equipment is housed in a separate compartment mounted on top of the cubicle. A withdrawable truck mounted fused vacuum contactor with primary and secondary isolating contacts is located in the fixed portion and is moved between the isolated and service positions by rotation of a racking screw by a special handle provided with the switchboard. Widely available tag type fuses are used as the short circuit protection device and two parallel fuses per phase can be accommodated. Figure 1 Illustrates the main features of a typical UniGear type ZVC cubicle. A B Busbar compartment Contactor and HRC fuses compartment 1 2 Busbars Withdrawable fused contactor s contacts C Cable compartment 3 Vacuum contactor D Low voltage compartment 4 5 HRC fuses Instrument current transformer 6 Earthing switch 7 Auxiliary voltage transformer 8 Cable connection terminals Figure 1

4 3 2) STANDARDS AND SPECIFICATIONS UniGear type ZVC switchgear cubicles comply with standards and specifications for factory assembled high voltage switchgear to IEC (AS ). Other relevant standards for components include: IEC (AS ) Motor Starter & Contactor IEC and (AS ) Isolators (HV Fuses) IEC (AS ) Earthing Switch IEC (AS ) Degree of Protection IP4X external closure IP2X internal shutters & partitions IEC (AS ) Arc fault containment IEC (AS ) Current transformers Special requirements in compliance with regulations issued by local authorities should be checked with the manufacturers. 3) TYPE TEST REPORTS TYPE TEST STANDARD CLAUSE TEST VALUE AUTHORITY REPORT NO. RESULT SHORT TIME & PEAK WITHSTAND CURRENT TEST - Main Bus System IEC kA/3 sec Pehla 0047Ra OK - Earthswitch IEC kA/1 sec Pehla 0049Ra OK - Earthing circuit IEC kA/1 sec Pehla 0049Ra OK OVERLOAD CURRENT IEC kA/1 sec Pehla 0048Ra OK WITHSTAND TEST IEC kA/30 sec Pehla 0048Ra OK VERIFICATION OF MAKING & BREAKING CAPACITIES - Earthswitch making IEC kA Peak Pehla 0051Ra OK - Fused contactor making IEC kA - C x100 Pehla 0001Ma OK - Vacuum contactor breaking (max) IEC kA SACE LBRP5158 OK - Fused contactor breaking (max) IEC kA - O x25 Pehla 0001Ma OK - Fused contactor breaking (min) IEC A - O x25 Pehla 0001Ma OK VERIFICATION OF CO-ORDINATION TEST WITH

5 4 TYPE TEST STANDARD CLAUSE TEST VALUE AUTHORITY REPORT NO. RESULT SCPD'S - CLASS 'a' ASSESSMENT - Test duty A - 100% break IEC kA Pehla 0052Ra OK - Test duty B - 100% make IEC kA/125kAp Pehla 0134Ra OK - Test duty C - take over point IEC kA / 7.2kV Pehla 0052Ra OK VERIFICATION OF INTERNAL ARCING FAULT - Load side IEC60298 Appx AA 50kA Pehla 0135Ra OK - Line side IEC60298 Appx AA 50kA Pehla 0135Ra OK - Main bus IEC60298 Appx AA 50kA/0.5 sec Pehla 0135Ra OK DIELECTRIC TESTS - Partial discharge IEC < 100 pc ABB T & D TR-168 UNDER PREPARATION - Lightning and switching IEC /60kV ABB TPT C1144 OK impulse voltage test - Power frequency withstand IEC kV/1 min ABB T & D TR-169 OK voltage test - 10kV - Power frequency withstand IEC kV/1 min ABB T & D TR-170 OK voltage test - 20kV - Power frequency withstand IEC kV/1 min ABB T & D TR-179 OK voltage test - Special POWER FREQUENCY WITHSTAND VOLTAGE TEST - Aux Circuit IEC kV/1 min ABB T & D TR-170 OK TEMPERATURE RISE TEST IEC TABLE 3 ABB T & D TR-175 OK - Starter IEC (1/2/4/7AA) OK TEMPERATURE RISE IEC TABLE 3 Pehla - Main busbars IEC MECHANICAL TESTS - Earthswitch mechanical endurance IEC CO OPS. ABB T & D TR-176 OK - Earthswitch & starter operation IEC CO ABB T & D TR-181 OK - Interlocks E/Sw/Starter IEC Attempts ABB T & D TR-181 OK - Fuse Striker Mechanism IEC min/max energ ABB T & D TR-180 UNDER PREPARATION DEGREE OF PROTECTION - External surface IEC IP4X ABB T & D TR-177 OK - Internal barriers & partitions IEC IP2X ABB T & D TR-178 UNDER PREPARATION

6 4) TECHNICAL SPECIFICATION 5 a) Electrical Data Rated Voltage kv Rated Frequency kv 50/60 50/60 Rated Insulation Level kv 3.6/10/40 7.2/32/60 Maximum Busbar Current A 4000 Rated Current of Tee-Off A 400 Rated Peak Withstand Current 3 sec ka 130 Rated Short Time Current 3 sec ka 50 Auxiliary Voltage: - Fused Contactor Feeder Unit V - Mechanically Latched Trip Coil V V AC/DC 48-60V DC V DC V AC V AC Earthing Switch Rated Making ka 31.5 Current Earthing Switch Short Time ka 12.5 current 1 sec HV Fuse type Tag type to BS type II 454mm centres maximum CT rated secondary current A 1 Main Circuit Resistance: - Bus risers to top spout bushing - Cable tags to bottom spout bushing µω µω 40 ± ± 15 b) Internal Arc Withstand Accessibility type A restricted to authorised personnel only. Minimum ceiling height m Internal Arc Fault rating is 40 ka/1 sec, and 50 ka/0.5 sec. 1 To use a lower ceiling height contact ABB for a solution

7 6 c) Environmental Data UniGear type ZVC is suitable for clean, dry indoor environments complying with IEC (AS 1939) rated values. Max ambient temperature +40 C Max 24 hour average ambient temp +35 C Minimum ambient temperature -5 C Maximum average relative humidity Over 24 hour period 95% Over 1 month period 90% The ambient air must not be significantly contaminated by dust, smoke, corrosive or combustible gases, vapour or salt. Altitude category does not exceed 1000m Special performance and operating conditions to meet customer needs can sometimes be provided. Refer to the manufacturer for details if equipment is to be installed or operated in conditions exceeding the ratings above. For technical data of individual components included as part of the switchgear refer to the ABB Equipment list for the project, together with the associated operating instructions.

8 7 5) DIMENSIONS & WEIGHTS Maximum Weight of Panel without Truck Maximum Weight of Contactor Truck Weight of Palette and Both End Covers : : : 275 kg 95 kg 90 kg Total Maximum Weight of Panel and Truck : 460 kg A Busbar compartment B Contactor and HRC fuses compartment C Cable compartment D Low voltage compartment E Gas exhaust duct Width (mm) 325 Height (mm) LV Box Height (mm) Height with Arc duct (mm) 2670 Depth (mm) Power Cable Entry Bottom Entry Front Access Bottom Entry Front Access Bottom Entry Rear Access Top Entry Rear Access Top Entry Rear Access Control Cable Entry Bottom Entry Front Access Bottom Entry Front Access Bottom Entry Front Access Top Entry Front Access Top Entry Front Access No Yes Yes/No No Yes Arc Duct Floor plan Power cable: Bottom entry Top entry 1304 Bottom entry 1124 Control Cable: 1304 Top entry

9 8 6) RECEIPT AND INSPECTION UniGear type ZVC is shipped in groups of one, two or three cubicles. The withdrawable vacuum contactor is shipped inside the cubicle locked in the service position. Loose items, usually comprising items such as service trolley (for removal of contactor from cubicle), door key, operating handles, connecting busbars, connecting hardware and inter-cubicle wiring, accessories, spare parts, HV fuses are packed separately. Each package in the shipment is secured to a pallet base and is clad to suit airfreight, sea freight, road freights or to customer requirements as appropriate.! Always lift from base using forks or slings. Check all packages on the consignment note have been received. Check the consignment for signs of rough handling and damage to packaging, particularly to dessicant. Check the contents of each package against the packing list and notify the manufacturer within seven days of any damage or discrepancies. Equipment should be left on a pallet until it is delivered to the switchroom and is ready for placing in its final position.

10 9 7) STORAGE AND INSPECTION If storage is required after ex-works delivery the consignee has responsibility to ensure the receipt and inspection procedures outlined in section 6 above are completed. a) Short term storage (max four weeks only) Return the equipment to its original packaging and store in dry conditions complying with manual section 4c. Make sure fresh packs of desiccant drying agent are included in the packaging. Conduct weekly inspections to ensure packing and storage conditions are unchanged.! DO NOT STACK PACKAGES; STORE IN THE UPRIGHT POSITION. b) Long term storage (one month to six months) Unpack the equipment (Do NOT remove from pallet) and store in a dry, well ventilated room with conditions complying to manual section 4c. Store the cubicles in an upright position! DO NOT STACK PACKAGES; STORE IN THE UPRIGHT POSITION. Loosely cover cubicles with plastic sheeting to prevent contamination. Adequate air circulation must be maintained to prevent corrosion. Perform regular (weekly) check for any condensation. 8) BASIC STRUCTURE The enclosure and partitions are manufactured from zinc coated sheet steel to provide the highest degree of protection against corrosion. In addition, the front doors and the rear cover have a powder coat stoving enamel finish ABB standard colour RAL 7035 light grey 50% gloss. Other colours are available as special order options. a) Compartments and Partitions (Refer figure 3) UniGear type ZVC component layout is categorised as metal clad compartmented switchgear according to the definitions of IEC The external enclosure and the internal partitions between compartments are earthed metal barriers providing absolute protection of personnel against contact with high voltage conductors.

11 10 The cubicle comprises three high voltage compartments. On top of each compartment a pressure relief flap (1) is fitted to release internal overpressure in the event of an arcing fault. A separate compartment for low voltage equipment (2) is fitted on top of the cubicle at the front. External wiring to this compartment is housed inside the front of the cubicle in earthed metal wiring ducts (3). Flat copper busbars are supported on the epoxy resin encapsulated riser conductors (4). These are located in the busbar compartment (5). No additional support is necessary to withstand the rated short circuit current of the busbar system. Unit busbar lengths are factory installed between cubicles in a shipping suite and are joined at the riser conductors. The cable compartment (6) is arranged for front access terminating cables entering through the glandplates in the bottom of the panel in the basic version. Current transformers are installed on spout bushings (7) which are integrated into the bus riser moulding. Cable connection tags (8) and earthing switch contacts (9) are segregated by epoxy resin phase barriers. The earthing switch (10) is manually operated using its handle inserted in its mechanism (11) at the front of the cubicle. The contactor compartment (12) includes guide rails for the withdrawable fused contactor (13). The withdrawable contactor truck is locked to the cubicle with bar operated by a bit key (14) and moves between isolated and service position on racking screw (15). Automatic metal shutters (16) cover the bus-side spout bushings (17) when the truck is in the isolated position (optional cable side shutters can be provided). Self-aligning tulip contacts in the spout bushings connect with disconnecting contacts (18) when the truck is in the service position. Secondary contacts (19) are automatically connected, via the plug on the rear of the truck, when the truck is installed in the cubicle. Contactor operating mechanism (20) is mounted on the truck chassis and is connected to the vacuum interrupters (21) by a lever and pushrod assembly. The fixed contact of the interrupter is rigidly connected to resin encapsulated conductors in fuse module (22) while, the moving contact is connected by flexible conductor (23). Tag type HRC fuses (24) complete the primary circuit. Control VT (25) (optional) with primary fuses is mounted to the chassis and connect to terminals on the load side of the main power fuses. A mechanical latched operating mechanism (optional), is resettable by energising the trip coil (26) or a manual pushbutton (27) fitted to the front of the panel. A hinged, screw fixed steel door (28) provides access to the contactor and cable compartments. All operations, ON-OFF, isolation, earthing and emergency manual trip must be conducted with the door closed. All indicators, such as ON-OFF, isolated or in-service, earthed and fuse blown can be seen with the door closed through viewing windows (29).

12 Figure 3 Legend: 1. Pressure Relief Flap 2. Low Voltage Equipment Compartment 3. Metal Wiring Ducts 4. Riser Conductors 5. Busbar Compartment 6. Cable Compartment 7. Current Transformers 8. Cable Connection Tags 9. Earth Switch Contacts 10. Earth Switch 11. Earth Switch Operating Mechanism 12. Contactor Compartment 13. Truck Guide Rails 14. Withdrawable Fused Contactor Truck 15. Racking Screw 16. Shutters 17. Spout Bushings 18. Disconnect Contacts 19. Truck Secondary Contacts 20. Contactor Operating Mechanism 21. Vacuum Interrupters 22. Flexible Conductor Connecting Items 21& Fuse Module 24. HRC HV Fuses 25. Control VT (optional) 26. Trip coil (optional - latched) 27. Contactor Manual Trip Operator (where trip coil fitted) 28. Contactor and Cable Compartment Door 29. Contactor and Earth Switch Viewing Windows

13 12 b) Interlocks and Locking Facilities A series of interlocks is provided to protect personnel, the switchgear itself and, to prevent dangerous situations and maloperation that may otherwise lead to serious consequences. The individual effective interlocks are as follows: The truck can only be moved from the test/isolated position into the service position (and vice versa) when the fused contactor and earthing switch are open and the door is closed. The fused contactor can only be closed when the truck is fully engaged in the test or service position. The door cannot be opened when the truck is in the service position. For a mechanically latched fused contactor, with the truck in the test position, and without control voltage, it is only possible to open (not close) it manually. With the truck in the test/isolated position the voltage transformer secondary is isolated. The earthing switch can only be closed when the truck is in the test/isolated position. With the earthing switch closed, the truck cannot be moved from the test/isolated position into the service position. Details of any additional interlocks, e.g. in connection with a blocking magnet on the truck and/or earthing switch operating mechanism, can be found in the project specific documents. Interlock plates (optional), can be fitted so that only trucks of a certain type (eg. fuse rating or contactor type) are able to be inserted into matching panels. The switchgear is also provided with facilities for padlocking the contactor/cable compartment door, the contactor truck racking shaft and the earth-switch operating shaft.

14 13 9) INSTALLATION a) Foundation Lay switchroom floor with a tolerance of ±1mm per metre in all directions under the switchboard including a metre in front of the switchboard with a maximum ±3mm over the entire switchboard length. To achieve these tight tolerances or to meet seismic requirements (if applicable) we recommend using foundation frames. ABB can provide foundation frames if required. b) Bolting Panels Together Precisely lineup shipping sections as per the project specific General Arrangement drawing so that each section is not more than 2mm off in all planes. Bolt together using M8x16 (7 off), M10x16 (12 off) and M10x20 (6 off) hex-head bolts (tensile 8.8) and Belleville washers to a tightening torque of 25 Nm for M8 and 50 Nm for M10. Quantities and lengths of bolts may vary for non-standard designs. c) Busbars Clean any greasy or sticky substance off the risers and busbars with a soft dry cloth. Access to the buswork is gained by removing the pressure relief flaps above the busbar compartment. Install busbars supplied loose across each shipping section starting at bottom bar and then continue to work upwards (figure 4). Remember to fit the joining boots (if provided). Use M10 socket head bolts (tensile 8.8), nuts, spacers (when required) and two Belleville washers per bolt to a tightening torque of 50 Nm. Joining boot (optional) Busbar insulation (optional) Busbar connection (left side) Busbar connection (right side) Bus riser module Typical Busbar and Riser module connections (3150A) Spacer Figure 4

15 14 Replace pressure relief flaps ensuring the nylon bolts are used for fixing the rear of the pressure relief flap only. d) Power Cable Connection Remove the contactor truck from the panel and remove the partition plate between the contactor and cable compartments for easier access by unscrewing the four socket head bolts (indicated by the red circles on figure 5). Remove the cable gland plates from the bottom of the cubicle and terminate the cables on the cable module using an appropriate HV cable termination kit. Cut gland plates to fit around the cable and refit to cubicle base. Connect the cable earth and seal any remaining gaps with elastic sealing compound to prevent ingress of dirt or vermin. Cable Termination Module Partition plate Cable Screen Gland plate Earth bar With partition plate fitted Without partition plate fitted Figure 5

16 15 e) Control Cable Connection Feed control cables through the small entry gland (figure 6), which is in the front left hand side of the cubicle base plate. Run the cables up the vertical duct, through the grommets in the base of the instrument compartment into the terminals nominated by the control schematic. Provision for top control cable entry into the instrument compartment is optional. f) Earthing Join the inter-panel earthing bar located in the front of the cable compartment (figure 6) between each shipping section with the connecting link supplied loose. Connect one point of this interpanel earthing bar with the substation earth. g) Connecting to UniGear type ZS1 Where a UniGear type ZS1 panel is bolted to a UniGear type ZVC panel, special transition busbars and earthing bars will be supplied loose. Bolt panels together as described previously. Quantities and lengths of bolts may vary for designs other than this basic one. Three additional cover plates (figure 7) required to seal the UniGear type ZS1 bus compartment are supplied for each UniGear type ZS1 to UniGear type ZVC transition. For bolting alongside other designs of switchgear, contact ABB for the feasibility of preparing the design. Control Cable Duct UniGear type ZS1 cover plates Figure 6 Earthing Bar Figure 7

17 16 10) OPERATION a) Earth switch Ensure the withdrawable contactor truck is in the test position or removed from the panel. Remove the padlock from the blocking plate covering the earth switch operating screw. To operate the earth switch, ensure that the contactor/cable compartment door is closed, insert the operation handle in the earth switch operating hole and turn in the direction indicated on the label (figure 8). The earth switch status is shown in the label window. b) Contactor Switching of the contactor is carried out via the control features fitted to the instrument compartment. The contactor status is indicated on the front of the contactor (figure 9) and can be viewed through the top viewing window. Switching operations can only be carried out with the withdrawable contactor in service or in the test position. We highly recommend that all switching be done with the front door closed. For a mechanically latched contactor (optional), manual emergency tripping is achieved by using the special rod provided to operate the emergency manual trip operator (figure 10) fitted on the withdrawable contactor. Figures 8, 9 & 10

18 17 c) Racking To rack the contactor truck from test position into service ensure the following: The contactor truck is locked using the bit key provided. The contactor compartment door is closed The earth switch is off The contactor is off The padlock is removed from the blocking plate covering the racking hole. Insert the racking handle in the racking hole and rotate the handle 14 revolutions clockwise (figure 11). While in service the contactor compartment door cannot be opened and the earth switch cannot be closed. To rack the contactor truck out of service into its test position please ensure the contactor is off. Insert the racking handle in the racking hole and rotate the handle 14 revolutions anti-clockwise (figure 11). Figure 11 Where a voltage transformer (installed on the contactor truck) powers the control circuit, please note that this supply is active only when the contactor truck is in service. If supply is required to this circuit under other conditions we recommend connecting a temporary test supply via terminals in the instrument compartment A truck position indication label (figure 12) is visible through the top viewing glass. Please note that the contactor cannot be closed while the truck is in an intermediate position indicated by the yellow position indication. Figure 12

19 18 d) Removal of Contactor Truck Ensure that the contactor truck is in test position, and the earth switch is closed. Open the contactor compartment door and move a contactor trolley in front of the panel ensuring that its hinged part is locked into the holes in the partition plate under the contactor truck. Unlock the contactor truck using a bit key (figure 13) and pull the contactor truck onto the trolley using the handle on the front of the contactor truck. Lock the contactor truck onto the trolley and unhinge the trolley from the partition plate. The trolley and the contactor truck can now be moved away from the panel. Figure 13 e) Insertion of Contactor Truck Open the contactor compartment door and move a contactor truck and trolley in front of the panel ensuring that its hinged part is locked into the holes in the partition plate under the contactor truck. Unlock the contactor truck using a bit key (figure 13) and push the contactor off the trolley into the panel. Lock the contactor truck into the panel, unhinge the trolley from the partition plate and remove the trolley. f) Fuse Operation When any fuses are healthy the fuse condition indication label (figure 14) is green. On fuse operation this label changes to BLOWN on a red background. An adjacent label (figure 15 typical fuse rating) fitted on the truck shows the fuse rating. Figures 14 & 15

20 19 11) MAINTENANCE a) General Maintenance serves to preserve trouble-free operation and achieve the longest possible working life of the switchgear. It comprises the following closely related activities: Inspection: Servicing: Repairs/Replacement: condition. Determination of the actual condition Measures to preserve the specified condition Measures to re-establish the specified Note: Maintenance work must be carried out in a careful manner by trained personnel familiar with the characteristics of the individual switchgear installation, in accordance with all relevant safety regulations to AS/IEC and of other technical and statutory authorities, together with other overriding instructions. It is recommended that ABB service personnel are called in to perform servicing and repair work, and for some of the work described in greater detail, this is essential. The inspection and servicing intervals for some of the equipment/components (e.g. parts subject to wear) are determined by fixed criteria such as switching frequency, length of service and number of short-circuit breaking operations. For other parts, the length of the intervals may depend, for example, on the different modes of operation in individual cases, the degree of loading, and also environmental influences (including pollution and corrosive atmosphere). The equipment operating instructions must also be observed together with this instruction manual in the individual cases concerned. Further details can be taken from the technical documentation for the switchgear installation (including, for example any agreed special operating conditions). b) Inspection and servicing Inspection and servicing of the switchboard should be carried out approximately every one to five years, depending on the operating conditions and local environment. We recommend logging all switchgear maintenance. The inspection should include but not be limited to the following: Electrically isolate the area where work is to be carried out and secure it against reconnection. Check the installation for abnormalities of any kind, dirt and the effects of other environmental influences. Check the function of the switch equipment, the controls, interlocks, protection, indicators and other devices. Check the surface condition of the isolating contact system for any damage and retighten the fixing screws. The tulip contacts are

21 20 fixed with hexagon socket head cap screws M10. After cleaning, lightly grease the contact faces. Contact parts which are corroded or show signs of other damage or overheating should be removed and replaced. Check all switchgear accessories and the auxiliary equipment such as indicating lamps and the anti-condensation heaters. No external discharge may occur on the insulating material surfaces of equipment at operating voltage. This can, for example, be detected by characteristic noises, a clearly perceptible smell of ozone, or visible glowing in the dark. Basic servicing activities, and those which may be found necessary during inspections, including the following: Carefully clean the unit, and in particular the insulating material surfaces, when they are found to be dirty. Remove dry dust deposits using a soft dry cloth. For more strongly adhering deposits, e.g. sticky/greasy dust, use a cloth soaked in slightly alkaline household cleaner. Wipe off with clean water and dry carefully. Alternatively, use a safety cleaner with a fluoride hydrocarbon base (check for compatibility with plastics and elastomers) Do not use either trichlorethane, trichlorethylene, or carbon tetrachloride. Should external discharges occur as a result of condensation, application of a thin silicone film on the surface concerned is often effective as a temporary remedy. It is advisable to seek advice from ABB on permanent solutions to such unusual problems. Close the contactor and measure the distance between the nut and the washer on the moving end of the vacuum bottle. For new vacuum bottles this gap is 1mm. When this gap is reduced to zero please contact ABB to arrange refurbishing of the truck. Check that the bolt connections at the contact points in the busbar system and the earth connections are tight, and that the racking operation functions correctly. Replenish the grease on the contact points and mechanism of the truck racking system. When lubrication is inadequate or missing, thoroughly clean the areas concerned and regrease with Isoflex Topas NB52. Replenish the grease on the sliding and bearing surfaces in the cubicles including the shutters, the interlock and guide systems, the spindle mechanisms and the switch truck wheels. Where necessary, thoroughly clean and regrease with Isoflex Topas NB52 lubricant.

22 21 c) Repairs/Replacement UniGear type ZVC is maintenance free switchgear. Please contact ABB in the event of an equipment failure for replacements. i) Recommended Spare parts Complete truck Trip coil Feeder unit Fuses ii) Corrosion Repair Repair work is to be carried out immediately after a defect has been discovered. All rust is to be removed from damaged paintwork areas on steel sheet and other steel parts mechanically. Lightly grind the surrounding paint coat and carefully degrease the entire area. Then immediately apply an anti-rust primer and, after an appropriate hardening period, apply the topcoat. The total dry film thickness should be approx. 60 um. Only use suitable and compatible paint products. Topcoat is standard colour light grey RAL 7035 or the relevant special colour. iii) Trip Coil Replacement (figure 16) Undo the three screws (1) attaching the microswitches mounting plate to the truck traverse (on the left-hand side of the truck looking from the front). Slide trip coil out of the trip operating mechanism (2), disconnect its wires and remove the two screws holding it to the mounting plate (3). Fit the new trip coil reversing the steps taken in the removal process. (2) Slide trip coil out of operating mech. Mounting Plate Trip Coil (3) Remove these two screws (1) Remove these three screws Figure 16

23 22 iv) Feeder Unit Replacement (figure 17) Undo the two screws holding the feeder unit to the truck (on the righthand side of the truck looking from the front). Remove feeder unit from the truck and disconnect its wires. Fit the new feeder unit reversing the steps taken in the removal process. Remove these two screws Feeder Unit Figure 17 v) Fuse Replacement (figure 18) If a fuse is blown we recommend that all fuses on the truck are replaced. Unbolt the four screws connecting each fuse to the moulding and remove each fuse. Replace with new fuses ensuring that the fuse s striker pin is nearest the front of the truck and the majority of the fuse is facing into the moulding. Where two fuses per phase are used, the fuses are fitted, in the same way, back-to-back. Fuse striker to this end (front) Remove these four screws (for each fuse) Fuses 25NM PARALLEL FUSE SINGLE FUSE Figure 18

24 23 12) TROUBLESHOOTING a) Truck cannot enter cubicle. i) Inhibited by current interlock Select contactor truck of correct current rating. ii) Racking mechanism not closed against the front of the truck. Rotate racking handle to the anti-clockwise stop. b) Truck cannot be locked in cubicle. i) Earth switch open. Close earth switch. c) Truck cannot be racked in. i) Handle not fully engaging the racking screw shaft. Push firmly on the handle. Maintain positive forward pressure on the handle during rotation. ii) Truck locking bars not fully extended. Rattle the truck in position and make sure the key spindle pops out at the clockwise stop. iii) Shutters padlocked. Remove padlocks. iv) Front door not completely closed. Tighten door screws. v) Earth switch is closed. Open earth switch. vi) Racking hole padlocked Remove padlock. d) Truck cannot be removed from cubicle. i) Truck not fully in isolated/test position Rotate racking handle to anti-clockwise stop. ii) Truck locked in cubicle Unlock truck.

25 24 e) Vacuum contactor cannot be closed. i) Racking operation not completed. (mechanical and electrical block) Rotate handle fully to stop. ii) Secondary control plug damaged. Check secondary control plug for damage. iii) No control supply available. Check control fuses. iv) Fuse blown auxiliary switch not reset. v) Vacuum contactor auxiliary switches inoperative. Check operation of auxiliary switches. Replace if necessary. vi) Open circuit close coil. Contact ABB to replace close coil. f) Earth switch cannot be closed i) Earth switch operating hole cover is padlocked. Truck is not fully in isolated/test position.

26 25 The data and illustrations are not binding. We reserve the right to make changes in the course of technical development of the product. UniGear type ZVC Installation, Operation and Maintenance Manual 1VGA Rev. B Sep, 2003 ABB Australia Pty Limited Bapaume Road Moorebank 2170 NSW Australia Locked Bag 7315 Liverpool BC NSW 1871 Phone +61 (0) Fax + 61 (0) Internet address: