Transportation and storage.. 3 General. 3 Unpacking at installation site....... 3 Transfer of cubicles at installation site... 3 Weight.. 4 Temporary storage. 4 Erection at site 5 General. 5 The switchgear bed 5 Fastening of the switchgear to the floor. 5 Cubicle dimensions 6 Bottom dimension drawings. 7 Connecting cubicles.. 9 The busbar compartment. 10 The busbar connections 11 Connecting the switchgear to the earth electrode 14 Cable arrangement 15 Preparation for cable installation. 15 Installation of the cables 16 Finishing of the cable installation. 17 Examples. 17 Mounting of equipment.. 19 Mounting of circuit-breakers.. 19 Mounting of motor operating device UEMC 40 K8_ for UES-K3/2. 22 Mounting of auxiliary switches for UES-K3/2. 23 Mounting of position indication and operation set. 24 Mounting of motor operating device for UES-A3M/2 24 Mounting of auxiliary switches for UES-A3(M)/2.. 25 Mounting of shunt trip-coil. 25 Installing of indicating system for current transformers afterwards 25 2
UniSwitch is delivered either as single cubicles or switchgear units with a length of no more than 2,0 m. The size of the package depends upon the number of cubicles and has to be defined separately for each case. The package of the switchgear is made according to ABB Transmit instruction 353 PAK 1A1. The switchgear can be transferred by a manual forklift or a forklift truck. The packages should be placed on a smooth base. The UniSwitch switchgear should only be installed indoors. Therefore it is important to store the switchgear cubicles in their transportation packages as long as possible. The packages should be opened only for inspection of possible transportation damages. After the inspection the package should be restored to original condition. Possible transportation damages should be reported immediately to the carrier/forwarder. If the installation of the switchgear is made right after the delivery, the transportation packages can be removed except the plastic film of the cubicles, which is to be removed at the final switchgear installation site. The cubicles can be transferred in a horizontal plane by a manual forklift or a forklift truck, exceptionally by means of rolling tubes (using at least four tubes). The switchgear cubicles are usually transferred in upright position. Leaning or overturning should be avoided. If necessary single cubicles can be leaned to horizontal plane e.g. because of low door height. In such a case the cubicle has to be supported from a wide area. If a crane is available lifting of a single cubicle is made with two lifting wire cables from the lifting lugs situated on the roof of the cubicle. When lifting several cubicles or a whole switchgear unit (4 cubicles at the most or a maximum length of 2 m) four lifting wires, long enough, should be used. Circuit-breaker cubicles must not be lifted with circuit-breaker installed in the cubicle. 3
Table 1a. The weight of different cubicles without packing. Approximate weight/kg Cubicle type Height = 1635mm Depth = 900 mm Width mm Height = 1885mm Depth = 900 mm Width mm 375 500 750 375 500 750 SDC 1) 130 140 140 150 SDF 2) 140 150 150 160 CBC 3) 4 440 DBC 110 1 1 130 SEC 140 150 150 160 SBC 3) 4 440 BRC 1) 140 150 150 160 SMC 3) 440 460 1) without instrument transformers 2) without fuses 3) without circuit-breaker Table 1b. The weight of different devices. Device Approximate weight/kg Instrument transformer 12/17,5 kv 25 Instrument transformer 24 kv 30 Circuit-breaker HAD-US 100 Circuit-breaker VD4S 75 The package should immediately be taken indoors after having arrived. The conditions have to meet the environmental demands of the IEC 60721-3-1 standard, classification 1K3 (table 2). The maximum temporary storage time of the cubicles is 12 months. Inhibitors, placed in the cubicles for protection against humidity during temporary storage and transport, should not be removed before the end of the installation. Table 2. Climatic conditions according to IEC 60721-3-1, classification 1K3. Low air temperature - 5 C High air temperature + 40 C Low relative humidity 5 % High relative humidity 95 % Rate of change of temperature 0,5 C/min 4
The switchgear is to be erected on a metal frame casted in the floor of the switchgear room or on a raised floor. When preparing the floor, the demands of the DIN 43661 standard should be applied. Particularly the straightness and uniformity of the base are important for a successful installation and should therefore be paid special attention to. The straightness of the floor should be ± 1 mm on the switchgear area. The load capacity of the floor should also be sufficient. If the switchgear consists of only a few cubicles, and there are no heavy cubicles included, it can be installed on the concrete floor. The metal frame is made of one or several parts depending of the size of the switchgear. The frame is casted in the floor when casting the surface of the floor. There is no height adjustment of the cubicles. Adjustment is made by installing steel plates under the cubicles. When designing cable ducts in the concrete floor the dimensioning drawings in chapter 2.5 should be applied. The switchgear can be fastened to the metal frame by welding through the holes of the bottom of the cubicle (2 welding seams/cubicle) or by two spline bolts/cubicle (M12) straight to the concrete floor. Fastening of a switchgear consisting of several cubicles can be done by fastening every second cubicle. The end cubicles of the switchgear should always be fastened according to the enclosed figure. The left-hand end cubicle is fastened from the left-hand front and the right-hand back corners of the cubicle floor. The right-hand end cubicle is fastened from the right-hand front and left-hand back corners. 5
The following drawings illustrate the main dimensions and the need of space of different cubicle types. 1000 C 40 H = 1635 Alt H = 1885 A D 250 940 35 250 940 B 1190 1190 Cubicle types: SDC Cubicle types: CBC SDF SMC DBC SBC BRC SEC Table 3. Dimensions of CBC, SMC and SBC cubicles. Circuit breaker A B C D HAD-US 652 mm 215 mm 1155 mm 230 mm by H = 1635 480 mm by H = 1885 VD4S 652 mm 195 mm 1135 mm 130 mm by H = 1635 380 mm by H = 1885 There should be at least 250 mm pressure release space between the back of the switchgear and the switchgear room wall. This space should be closed by fastening a metalsheet (thickness at least 2 mm) between the back of the switchgear and the wall of the switchgear room (depth 250 mm and height 1865 mm). If the switchgear is situated in the middle of the switchgear room it has to be equipped with pressure relief channels. 6
W = 375 W = 500 W = 750 188 288 288 769 210 210 500 85 600 D = 940 210 769 500 600 D = 940 769 210 500 600 D = 940 Ø17 60 33 85 Ø17 60 33 85 Ø17 60 33 W = 375 W = 500 W = 750 228 148 328 248 328 248 769 210 210 500 85 600 D = 940 210 769 210 500 600 D = 940 769 210 210 500 600 D = 940 210 210 Ø17 60 33 85 Ø17 60 33 85 Ø17 60 33 7
W = 375 W = 500 W = 750 188 288 288 85 469 469 469 769 600 D = 940 769 600 D = 940 769 600 D = 940 Ø17 60 33 85 Ø17 60 33 85 Ø17 60 33 8
There are four 11x mm holes for 1635 mm high cubicles (five holes for 1885 mm high cubicles) in the front and back of the sidewalls for connecting the cubicles to each other in the cable compartment. The holes are vertical on the righthand sidewalls and horizontal on the lefthand sidewalls thus a small tolerance for erection is acceptable. The connection is made by a 10,5 washer, a M10x bolt and a M10 nut. The torque of the fastening bolts should be 10 Nm. In the secondary compartment the cubicles are connecting to each other through three 8 holes nearest the front of the secondary compartment. The connection is made with a 6,5 washer, a M6x slotheaded screw and a M6 nut. The torque of the fastening screws should be 5 Nm. To ensure the connection of the back upper part of the cubicles a back up strip of approximately cm length is mounted from above. The back up strip is pushed into the seam of the back upper part of the cubicles as down as possible. 9
As a final step in connecting the cubicles to each other the roof seams between the cubicles are secured. This is made by mounting a back up strip of the same length as the cubicle depth into the seams. The strip should be pushed so deep that the bending on the end of it touches the bottom edge of the seam. The strip must be fixed with a screw from its middle point. The busbar compartment is covered with the top plate. The top plate is fixed to the cubicle by screws from its front and back. There are 6 screws in the 375 mm wide and 8 screws in the 500 mm wide cubicle. The busbar compartment can be accessed by loosening the screws and removing the top plate. Note that the top plates of the end cubicles of the switchgear can not be removed. A warning sign is placed on the top plate indicating highvoltage beneath the roof. 10
The top plate of the cubicle is removed according section 2.7 before making busbar connections. The busbar connections in the end cubicles are made through the top openings of adjacent cubicles. The busbars are mounted with their bended end always to the right. In the left-hand end cubicle the busbar end is mounted to the terminal of the SFG switch-disconnector. A busbar shim made of copper and with the same thickness as busbar, is mounted on the busbar. In the right-hand end cubicle of the switchgear the busbar shim is mounted between the bended end of the busbar and the upper terminal of the SFG switch-disconnector. The busbar joints are made with a 10,5 spring washer and a M10x40 hexagon head bolt. The torque of the joint is 35 Nm. a,b c d d a,b d d a,b c Lefthand end cubicle Middle cubicle Righthand end cubicle a: Hexagon head bolt M10x40 b: Spring washer, hole 10,5 c: Copper busbar shim, outer diameter 30, height 8 mm, hole 10,5 d: Nonisolated 40x8 copper bar with rounded edges 24 kv busbar joints are made in the same manner as 12 and 17,5 kv busbar joints with the following exceptions. 24 kv busbars are always isolated. On the 24 kv busbar joints two-piece field control caps, consisting of aluminium part and EPDM-rubber part, are mounted according to the following figures. Aluminium cap with one cutout for end cubicles. Aluminium cap with two cutouts for middle cubicles (upsidedown). 11
EPDM-rubber cap with a low cutout for lefthand end cubicles. EPDM-rubber cap with a high cutout for righthand end cubicles. EPDM-rubber cap with two cutouts for middle cubicles (upsidedown). a,b c e f a,b e e e a,b c f f Lefthand end cubicle Middle cubicle Righthand end cubicle a: Hexagon head bolt M10x40 b: Spring washer, hole 10,5 c: Copper raising ring, outer diameter 30, height 8 mm, hole 10,5 d: Isolated 40x8 copper bar with rounded edges f: Field control cap (aluminium and EPDM-rubber) 12
Aluminium field control caps. Aluminium field control caps covered by EPDMrubber caps. The torque of the joint for other busbar connections is 35 Nm. Notice that the 24 kv busbar connections should be covered by a shrink tube according to the figure below. This applies also to the voltage transformer primary connection cable except the construction in which the connection cable is joined in a CBC-cubicle to a busbar between a current transformer and a fixed contact of earthing switch EM. 13
The earth electrode is to be connected to the main earthing bar of the cubicle (3x30 mm Cu). The connecting point is marked with the equipment earth symbol. The connection is made with a 10,5 spring washer, M10x25 hexagonal head bolt and a M10 hexagonal nut. The connection bolt is tightened to a torque of 40 Nm. In larger switchgears (more than 8 cubicles) the earth electrode is connected to the both end cubicles of the switchgear. To secure the grounding via metal frame of the switchgear the main earthing bars can be connected together in the front of cubicles using additional earthing bars (3x30 mm Cu). The connection is made with an 8,4 spring washer, M8x30 hexagonal socket-head bolt and a M8 hexagonal nut. The connection bolt is tightened to a torque of Nm. 3 x 30 Cu 14
a) Remove the door from the cable compartment. Notice. The door can be opened only when the switchdisconnector is in the earthed position and the locking unit is in the door open position. b) Loose 4 screws from the baseboard in front of the door step of the cubicle. c) Loose 4 screws from the door step and remove the door step from the cubicle by pushing it straight forward in its side steering tracks. 15
d) Remove the floor plates, including plastic parts, from phases L1 and L2 by pulling them forward in their side steering tracks. e) Remove the front floor plate and the plastic cable sealing of phase L3. The rearmost floor plate of phase L3 should not be removed. Pull the cables through the open bottom into the cubicle. Measure and cut the cables to sufficient length considering the installation of cable terminations and cable lugs. Bend the conductors of phase L1 and L2 out through the open front of the cubicle during the installation of the conductor of phase L3. a) Connection of the conductor of phase L3 Take the plastic cable sealing and thread it on the conductor. Measure the right length of the cable considering the right location of the sealing. Install the necessary cable termination and clamp an appropriate cable lug to the conductor. Loose the nut and spring washer of the connector. Hang the conductor from its cable lug on the bolt of the connector. Install the pressure relief washer, the spring washer and the nut. Tighten the connection to suitable tightness, in the switch-disconnector and circuit-breaker cubicles 55 Nm and the fuse switch-disconnector cubicle 35 Nm. Pull the front floor plate (aluminium) in its side guides tight to the rearmost floor plate and attach them together with M6 bolts. Considering the size of the conductor, take the right size of cable clamp and attach the cable with sufficient tightness to the rearmost bushing considering the straightness of the cable from the fixture to the connection bolt. b) Connection of the conductor of phase L2 Pull the rearmost floor plate (steel) of phase L2 in its side guides tight to the floor bushing of phase L3. Take the precut conductor of phase L2 and continue according to section 3.2 a. c) Connection of the conductor of phase L1 Pull the rearmost floor plate (steel) of phase L1 in its side guides tight to the floor bushing of phase L2. Take the precut conductor of phase L1 and continue according to section 3.2 a. 16
UniSwitch Installation manual a) Install and attach the door step of the cubicle, which was removed when preparing for cable connections (see 3.1 c). b) Install the baseboard in front of the threshold of the cubicle. (See 3.1 b). c) Check that the shields of the feeder (outgoing) cables are connected to the main earthing bar of the cubicle. Check also the wiring if current transformers are installed. 3.4 Examples Cable arrangements for switch-disconnector (SDC) cubicles. 17
By H/1635 fuse length 292 => 605 fuse length 442 => 455 By H/1885 fuse length 292 => 855 fuse length 442 => 705 L L By H/1635 = 400 mm By H/1885 = 650 mm 188 288 Cable arrangements for switch-disconnector cubicle with fuse (SDF) and circuit-breaker cubicle (CBC). The clearance (L) of the VT primary connection cable should be at least 80 mm. 18
The circuit-breaker is to be lifted, preferably with a lifting truck. The correct tightening torques according to table 4 should be applied during the installation. Table 4. Tightening torques for different connections. Connection Torque/Nm Busbar-busbar 35 Busbar-HAD-US (upper poles) 35 (lower poles) Busbar-VD4-S 68 Busbar-SFG 35 Busbar-CT 56 70 Before lifting the circuit-breaker take off the plastic covers and remove connection bars from the upper poles. 19
Lift the circuit-breaker up to the same level as the mounted circuit-breaker floor. Slide the circuit-breaker manually into its leader and push it in. Do not move lifting truck before the circuit-breaker is totally inside the cubicle because the breaker is very heavy in front. Mount the fixing plate at the bottom of circuit-breaker front with 4 fixing screws/nuts. Install the busbars starting with the lower poles of circuit-breaker. After that connect the busbar to the upper poles of circuit-breaker using the connection bar.
If 24 kv HAD circuit-breaker is to be installed the connection bars of the upper poles should be covered by field control cups before connecting the plastic covers. The busbars of 24 kv CBC, SMC and SBC cubicles should be covered by a shrink tube where possible. After mounting of the circuit-breaker put the white control pin into the cable terminal and connect the terminal to the circuit-breaker. Notice the correct position of the flexible tube (HAD-US). 21
Operate the SFG switch-disconnector to the earthed position. Move the interlocking selector to the Door open position. Open the cable compartment door and the secondary apparatus compartment door. Take off the plastic cover (A) by pressing it with two fingers. Loosen the four screws (B) and remove the interlocking unit. A B B B B Operate the SFG switch-disconnector to the open position. Unlock the position indication and operation set by loosening the locking ring and remove the set. Remove the cover plates (2 pcs) of UES-K3/2 and install the motor operating device. 22
Pull up the brass operation shaft and adjust the lifting arm in correct position according to the figure. Push the operation shaft back to the original position. Notice that the motor operating device does not have any fixing screws to tighten. The small play between the motor operating device and the limiting surface does not effect the operation of the mechanism. 10...15 mm Refit the cover plates, the position indication and operation set and the interlocking unit. Further information is available in installation and operating manual for UEMC 40 K8_. The auxiliary switches are to be mounted on the uppermost cover plate of UES-K3/2. Remove the uppermost cover plate and tighten the screws with a torque of max. 1,3 Nm. Use nyloc locking nuts behind the cover plate. Both screws must be tightened with a similar torque. Make sure that the mounting position of the auxiliary switches is correct and they are moving normally after mounting by pushing them. Earthing indication switches are located in the right hand side of cover plate. 23
The auxiliary switches are to be mounted on the cover plate of UES-A3(M)/2. Tighten the screws with a torque of max. 1,3 Nm. Both screws must be tightened with a similar torque. Make sure that the mounting position of the auxiliary switches is correct and they are moving normally after mounting by pushing them. Earthing indication switches are located on the right hand side of cover plate. The shunt trip-coil is to be mounted by means of 2 screws and washers. Some of the customers use current transformers which are not manufactured by ABB Transmit. In such cases the CT s are usually installed by a customer. If voltage indication via CT s is needed the following information should be taken into account. Voltage indicating system CL497/CL498 for CT s meets the requirements of IEC61243-5, if the value of capacitive divider C1 in CT is according to table 5. Table 5. The recommended values for capacitive dividers in CT s. Operating voltage (kv) Value of C1 (pf) 6 7,2 23 40 10 12 19 33 13,8 17,5 13 23 24 10 18 It is also recommended that the stray capacitance value of CT is between 90 pf. 25
The SFG switch-disconnector should be in open position. Lock the position indication and operation set with the locking ring. Check that the location of position indication shaft and disc is in accordance with the figure below. Notice the location of position indication shaft and disc in open position. Motor operating device for UES-A3M/2 is to be mounted by means of 3 screws and washers and the cover for it by means of a screw and a washer. 24