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Technical catalog TK 636/05 en

ZX2 Version for ANSI markets

Technical catalog TK 636/03 en

Gas-insulated medium voltage switchgear

Contents
Page

1 Introduction 5
2 Applications 6
3 Characteristics 7
4 Your benefit 8
5 Technical data 9
5.1 Technical data of the panel 9
5.2 Technical data of the circuit-breaker 11
5.3 Technical data of the disconnect and three position disconnect 12
6 Fundamental structure of the panels 13
7 Components 20
7.1 Vacuum circuit-breaker 21
7.2 Three position disconnect 25
7.3 Disconnect 28
7.4 Optional view ports 30
7.5 Busbar 31
7.6 Inner cone termination system 33
7.6.1 Connection of cables 33
7.6.2 Connection of fully insulated bars 34
7.6.3 Connection of surge arresters 34
7.7 Outer cone termination system 35
7.7.1 Selection of cable connectors 36
7.8 Main grounding bar 48
7.9 Test sockets 48
7.10 Capacitive voltage indicator systems 49
7.11 Current and voltage detection devices 50
7.11.1 Ring core current transformers 52
7.11.2 Block-type transformers 53
7.11.3 Current transformers 54
7.11.4 Zero sequence ground-fault transformers 54
7.11.5 Dimensioning of current transformers 55
7.11.6 Voltage transformers 55
7.12 Protection and control units 56
7.13 Sulphur hexafluoride 57
7.14 Gas system in the panels 57
7.15 SF6 density sensor 58
7.16 Plenum systems 59
7.17 Surface treatment 59
8 Range of panels 59
8.1 Panels in single busbar design 60
8.1.1 Feeder panels 60
8.1.1.1 Incoming and outgoing feeder panels with inner cone cable connection system 60
8.1.1.2 Incoming and outgoing feeder panels with outer cone cable connection system 62
8.1.1.3 Panels with operating currents over 2500 A and up to 4000 A 63
8.1.1.4 Cable termination panels 64

2 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

 Page

8.1.2 Busbar sectionalizer panels 65

8.1.2.1 Sectionalizer within a switchgear block 65
8.1.2.2 Sectionalizer using cables (connection of two system blocks) 67
8.1.3 Metering Panels 67
8.2 Panels in double busbar design 69
8.2.1 Feeder panels 69
8.2.1.1 Incoming and outgoing feeder panels with inner cone cable connection system 69
8.2.1.2 Incoming and outgoing feeder panels with outer cone cable connection system 71
8.2.1.3 Cable termination panels 72
8.2.2 Coupling panels 73
8.2.2.1 Sectionalizer within a switchgear block 73
8.2.2.2 Sectionalizer using cables (connection of two system blocks) 74
8.2.2.3 Bus coupler 75
8.2.3 Bus sectionalizer 77
8.2.4 Metering panels 77
8.3 Design to order panels 79
8.4 Panels with rated currents > 2000 A 80
8.4.1 Feeder Panels for rated currents > 2000 A 80
8.4.2 Busbar current > 2500 A 81
8.4.3 Sectionalizers and bus couplers for a rated current > 2000 A 82
9 Arrangement of panels with cooling facilities and panels with integrated busbar measurement 82
10 Busbar grounding 83
10.1 Grounding the busbar by means of an grounding set 83
10.2 Grounding the busbar by means of a sectionalizer and riser or bus coupler 83
11 Building planning 85
11.1 Site requirements 85
11.2 Space required 86
11.3 Minimum aisle widths and emergency exits 87
11.4 Minimum room heights 88
11.5 Hazardous area for pressure relief to the outside 89
11.6 Floor opening and cable axes 90
11.7 Foundation frames 93
11.8 False floor 94
11.9 Grounding of the switchgear 95
11.9.1 Design of grounding systems with regard to touch voltage and thermal stress 95
11.9.2 EMC-compliant grounding of the switchgear 95
11.9.3 Recommendations on configuration of the switchgear earthing 95
11.10 Panel weights 97
12 Non-standard operating conditions 97

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 3

1 Introduction

Switchgear systems and their components rank among the most important facilities for electrical power transmission and distribution. Their
versatile functions and the opportunities they provide contribute to safety in general, they secure the availability of electrical
energy.

Our ZX product family, consisting of panel types:

ZX0.2: ... 27 kV ... 2500 A ... 31.5 kA

ZX2: ... 38 kV ... 3000 A ... 40 kA

ZX2.2: ... 38 kV ... 2500 A ... 40 kA

covers the entire spectrum of primary distribution applications.

Flexible combination, reliability, availability and economy are the attributes that make it easy for our clients in industry and utilities to decide
in favor of ZX series products. With complete conventional solutions utilizing the use of digital protection and control technology, sensor
systems and plug-in connections ensures that ZX systems are unrestrictedly fit for the future, and the primary function of reliable power
distribution is undoubtedly fulfilled. This is ensured by ABB’s uncompromising approach to quality, which leaves no customers´ wishes un-
fulfilled. Aligned to each need, the panel types of the ZX family offer a solution for each requirement. In over 70 countries customers rely on
gas-insulated switchgears from ABB.

The ZX series leave our factory as tested panels and - as a SF6 filled switchgear, are exemplary in terms of safety, economy and availability.
Their compact design allows installation in even the most constricted spaces. The hermetically sealed enclosures make the systems shock-
proof and protect the high voltage components from all environmental influences.

ABB AG’s Medium Voltage Products division develops, manufactures and installs switchgear systems and components for electrical power
distribution in the medium voltage range. The knowledge, global experience and local partners for the panels’ supply and turnkey medium
voltage switchgear systems are based in Ratingen, Germany.

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 5

2 Applications

Power supply companies –– Pipeline systems Transport

–– Foundries
– – Power stations –– Rolling mills –– Airports
– – Transformer substations –– Mining –– Harbors
– – Switching substations –– Railways
Marine –– Underground railways
Industry
–– Platforms Services
–– Steel works –– Drilling rigs
–– Paper manufacture –– Offshore facilities –– Supermarkets
–– Cement industry –– Supply vessels –– Shopping centers
–– Textiles industry –– Ocean liners –– Hospitals
–– Chemicals industry –– Container vessels
–– Food an beverage industry –– Tankers
–– Automobile industry –– Cable laying ships
–– Petrochemicals –– Ferries
–– Raw materials industry

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3 Characteristics

Basic characteristics Connections

–– SF6 gas-insulated with hermetically sealed pressure system – – Inner cone cable plug system in sizes 2 and 3
–– Rated voltages up to 38 kV – – Outer cone cable connection system to EN 50181, type C
–– Up to 3000 A and 40 kA – – Connection ability for surge arresters
–– Single and double busbar design
–– Up to 4000 A in single busbar design Current and voltage metering
–– Stainless steel encapsulation, manufactured from laser cut
sheet material – – Instrument transformers
–– Modular structure
–– Switchgear with a leakage rate of less than 0.1 % annually Protection and control
–– Integrated leakage testing of the panels
–– Indoor installation –– Combined protection and control devices
–– Also suitable for site altitudes over 3281 ft above sea level –– Discrete protection devices with conventional control

Panel variants Protection against maloperation

–– Incoming and outgoing feeder panels –– Electrical switch interlocks

–– Cable termination panels –– Optional: additional mechanical interlocks
–– Termination panels for fully insulated bars
–– Sectionalizer Pressure relief
–– Riser
–– Metering panels – – Via plenums into the switchroom
–– Customized panel versions – – Via plenums to the outside

Circuit-breaker, disconnect and three position disconnect Installation

–– Vacuum circuit-breaker –– Panels joined together by plug-in connectors

–– Disconnect with functions for
– – Busbar connection
– – Disconnection
–– Disconnect/grounding switch (three position disconnect) with
functions for
– – Busbar connection
– – Disconnection
– – Grounding

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 7

4 Your benefit

Maximum operator safety

– – The systematic selection of the materials used during the
–– All live components are enclosed to prevent accidental con- development process, provides for complete recycling or
tact. reuse of those materials at the end of the service life.

–– As the high voltage compartments are independent of exter- – – The panels only leave our production facilities after docu-
nal influences (degree of protection IP65), the probability of a mented routine testing. Thanks to the plug-in technology
fault during operation is extremely low. applied in the areas of the busbars, cables and secondary
systems, extremely short installation times are possible.
–– As evidenced by arc fault testing, our switchgear systems are
suitable for maximum operator safety. – – No gas work is required at site. Thus there is no need to
evacuate and fill the high voltage compartments, test them
–– A further increase in operator safety can be achieved by pro- for leakage or measure the dewpoint of the insulating gas
viding pressure relief to outside the switchgear room. at site.

Minimum overall costs Maximum availability

–– The compact design of the panels reduces the space re- – – The plug-in busbar technology without screw couplings
quired and therefore the size of the station. The result is a allows simple and therefore safe assembly.
lower investment requirement.
– – Due to the extremely low failure probability of the ZX
–– No maintenance is achieved by constant conditions in the switchgear systems and the ability to repair the com-
high voltage compartments in conjunction with the selection ponents in the gas compartments versus replace them,
of suitable materials. The contaminating factors of dust, ver- the ZX switchgear ensures a rapid return to service after
min, moisture, oxidation and polluted air in the high voltage repairs is possible.
compartments are precluded, as the gas-tight compartments
are filled with inert gas. – – In gas-insulated switchgears, grounding of switchgear sec-
As a rule, therefore, isolation of the switchgear to perform tions is performed by a high quality vacuum circuit-breaker.
maintenance work is not required. The circuit-breaker can close onto a short-circuit signifi-
cantly more frequently and reliably than a positively making
–– The panels are designed for an expected service life of over grounding switch.
40 years.

8 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

5 Technical data

5.1 Technical data of the panel

Table 5.1.1: Technical data of the panel

IEEE-ratings

Rated frequency fr Hz 50 / 60
Rated voltage Ur kV 15 27 38
Panels with inner cone Maximum operating voltage kV 15 27 38
cable connection sys- Rated power frequency withstand voltage Ud kV 36 60 70
tem and all other panel Rated lightning impulse withstand voltage Up kV 95 125 150
variants without cable Rated normal current Ir A ...1200
connection, Rated short-time withstand current Ik kA ...40
panel width 26.62 in Rated peak withstand current Ip kA ..104 1)

Rated duration of short-circuit tk s ...3

Rated voltage Ur kV 15 27 38
Panels with inner cone
Maximum operating voltage kV 15 27 38
cable connection sys-
Rated power frequency withstand voltage Ud kV 36 60 80
tem and all other panel
Rated lightning impulse withstand voltage Up kV 95 125 200
variants without cable
Rated normal current (panel width 31.50 in) Ir A ...2000
connection,
Rated normal current (panel width 33.07 in) Ir A ...3000
panel width 31.50 in or
Rated short-time withstand current Ik kA ...40
panel width 33.07 in
Rated peak withstand current Ip kA ..104 1)

Rated duration of short-circuit tk s ...3

Rated voltage Ur kV 15 27 38
Maximum operating voltage kV 15 27 38
Rated power frequency withstand voltage Ud kV 36 60 70
Panels with outer cone
Rated lightning impulse withstand voltage Up kV 95 125 150
cable connection system,
Rated normal current Ir A ... 1200
panel width 26.62 in
Rated short-time withstand current Ik kA ... 40
Rated peak withstand current Ip kA ..104 1)

Rated duration of short-circuit tk s ...3

Single busbar system ...4000
Rated normal current of busbars Ir A
Double busbar system ...3000
I nsulating gas system 2) 3)

Alarm level for insulation pae PSI 17.4

Rated filling level for insulation p re PSI 18.9

Degree of protection for gas filled compartments IP65

Degree of protection of low voltage compartment 4)
IP4X
Ambient air temperature, maximum 5)
°F (°C) 104 (40)
Ambient air temperature, maximum 24 hour averages 5)
°F (°C) 95 (35)
Ambient air temperature, minimum °F (°C) 23 (-5)
Site altitude 6)
ft ...3281

1)
100 kA for rated frequency of 50 Hz
2)
Insulating gas: SF6 (sulphur hexafluoride)
3)
All pressures stated are absolute pressures at 68°F (20 °C)
4)
Higher degrees of protection on request
5)
Higher ambient air temperature on request
6)
Higher site altitude see section “Non standard operating conditions”
Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 9
Internal arc classification

The panels are arc fault tested in accordance with IEC 62271-200.

Table 5.1.2: Internal arc classification of the switchgear in accordance with IEC 62271-200
Classification IAC AFLR
All panels
Internal arc 40 kA 1 s

Key to table 5.1.2:

IAC Internal arc classification

AFLR Accessibility from the rear (R - rear)
Accessibility from the sides (L - lateral)
Accessibility from the front (F - front)
Switchgear installed in closed rooms with access
estricted to authorised personnel only

With pressure relief into the switchgear room, the IAC qualification requires a switchgear installation consisting of at least four panels. If a
plenum leading to the outside is used, at least two panels are required for the IAC qualification.

AFLR according to IEC 62271-200 is similar to type 2B acc. to IEEE C37.20.7 for air insulated switchgear.

Loss of Service Continuity to IEC 62271-200

The various LSC categories of the standard define the possibility to keep other compartments and/or panels energized when opening a main
circuit compartment.
Gas-filled compartments cannot be opened, as they would then lose their functionality. This means that there is no criterion for loss of ser-
vice continuity of inaccessible compartments.

Table 5.1.3: Loss of Service Continuity of the switchgear

Loss of Service Continuity of the switchgear LSC2

Key to table 5.1.3:

LSC2: When accessing the cable terminations of a panel, the busbar and all other panels can remain energized.

Note from VDE 0671-200:2012-08 / IEC 62271-200 Edition 2.0:

“The LSC category does not describe ranks of reliability of switchgear and controlgear.“

Partition class to IEC 62271-200

The partition class to IEC 62271-200 defines the nature of the partition between live parts and an opened, accessible compartment.

Table 5.1.4: Partition class in accordance with IEC 62271-200

Partition class PM

Key to table 5.1.4:

PM: partition of metal

Panels of partition class PM provide continuous metallic and grounded partitions between opened accessible compartments and live parts
of the main circuit.

10 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

5.2 Technical data of the circuit-breaker

Table 5.2.1: Technical data of the circuit-breaker

IEEE-ratings
Rated voltage Ur kV 15 27 38
Maximum operating voltage kV 15 27 38
Rated power frequency withstand voltage Ud kV 36 60 80
Rated lightning impulse withstand voltage Up kV 95 125 200
Rated frequency fr Hz 50 / 60
Rated normal current Ir A ...3000
Rated short-circuit breaking current Isc kA ...40
Rated short-circuit making current Ima kA ...104 1)

Rated short-time withstand current Ik kA ...40

Rated duration of short-circuit tk s ...3

Operating sequence O - 0.3 s - CO - 3 min - CO 2)

Closing time tcl ms ca. 60

Rated opening time t3 ms ≤ 45
Rated break time tb ms ≤ 60

Rated auxiliary voltage V DC 110, 220 3)

Power consumption of charging motor W max. 260

Power consumption of closing coil W 250 - 310
Power consumption of opening coil W 250 - 310
Power consumption of blocking magnet W 10
Power consumption of undervoltage release W 11
Power consumption of indirect overcurrent release W 15

Permissible numbers of operating cycles of the vacuum interrupters

20000 - 30000 4)
x Ir (Ir = Rated normal current)
50 x ISC (ISC = Rated short-circuit breaking current)

Classification according IEC 62271-100

All circuit-breakers for panels,
C2 5), E2, M2
Cable and line charging

1)
100 kA for rated frequency of 50 Hz
2)
Different operating sequences on request
3)
Different auxiliary voltages on request
4)
Dependent on the vacuum circuit-breaker
5)
Back-to-back capacitor switching on request
Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 11
5.3 Technical data of the disconnect and
three position disconnect

Table 5.3.1: Technical data of the disconnect and the three position disconnect
IEEE-ratings
Rated voltage Ur kV 15 27 38
Maximum operating voltage kV 15 27 38
Panels with inner cone Rated power frequency withstand voltage
Ud kV 39.6 66 88
cable connection sys- across the isolating distance
tem and all other panel Rated lightning impulse withstand voltage
Up kV 104.5 137.5 220
variants without cable across the isolating distance
connection Rated normal current Ir A ...1200
Panel width 26.62 in Rated short-time withstand current Ik kA ...40
Rated peak withstand current Ip kA ...104 1)

Rated duration of short-circuit tk s ...3

Rated voltage Ur kV 15 27 38
Maximum operating voltage kV 15 27 38
Panels with inner cone
Rated power frequency withstand voltage
cable connection sys- Ud kV 39.6 66 105
across the isolating distance
tem and all other panel
Rated lightning impulse withstand voltage
variants without cable Up kV 104.5 137.5 220
across the isolating distance
connection
Rated normal current (panel width 31.50 in) Ir A ...2500
Panel width 31.50 in or
Rated normal current (panel width 33.07 in) Ir A ...3000
panel width 33.07 in
Rated short-time withstand current Ik kA ...40
Rated peak withstand current Ip kA ...104 1)

Rated duration of short-circuit tk s ...3

Rated voltage Ur kV 15 27 38
Maximum operating voltage kV 15 27 38
Rated power frequency withstand voltage
Ud kV 39.5 60 105
across the isolating distance
Panels with outer cone
Rated lightning impulse withstand voltage
cable connection system, Up kV 104.5 125 220
across the isolating distance
Panel width 26.62 in
Rated normal current Ir A ... 1200
Rated short-time withstand current Ik kA ... 40
Rated peak withstand current Ip kA ...104 1)

Rated duration of short-circuit tk s ...3

Rated auxiliary voltage V DC 110, 220 3)

Rated normal current 2)

A ...1200 ...3000
Power consumption of mechanism motor W approx. 180
Motor running time on opening or closing the disconnect 4)
s approx. 18 approx. 20
Motor running time on opening or closing the grounding switch 4)
s approx. 18 approx. 20

Classification according IEC 62271-102

E0, M1 (2000 operating cycles)

1)
100 kA for rated frequency of 50 Hz
2)
Higher operating currents on request
3)
Different auxiliary voltages on request
4)
At rated auxiliary voltage
12 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05
6 Fundamental structure of the panels

Modular structure

Each feeder panel consists of the circuit-breaker compartment (A), The circuit-breaker compartment and the busbar compartments are
one or two busbar compartments (B), the cable termination com- filled with SF6 gas. There are no gas connections between the two or
partment (C), the plenum for the circuit breaker compartment and three compartments or to gas compartments in adjacent panels.
for the cable termination compartment (D), one or two plenums for
the busbar compartments (E) and the low voltage compartment (F).

Fig. 6.1: Feeder panel 1200 A, single busbar at front

D A

Fig. 6.2: Feeder panel 2000 A, single busbar at rear Fig. 6.3: Feeder panel 2000 A, double busbar

E E E

B F
B F B

D
A D

C C

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 13

The circuit-breaker compartment (A)

The cable sockets (1.3) and test plug sockets (1.4) and the circuit- The pressure relief disk (1.13) of the circuit-breaker compartment is
breaker poles (1.1) are located in the circuit-breaker compartment . located in the rear wall of the enclosure. The circuit-breaker operat-
ing mechanism (1.2), the gas leakage sensor (1.10) and the filling
The current-carrying connection between the circuit-breaker and the valve (1.11) are located on the mounting plate of the circuit-breaker
three position disconnect in the busbar compartment is effected via (1.14), which is bolted to the front wall of the enclosure.
single pole cast resin bushings (1.12).
The seals of the components are o-ring seals which are not exposed
There are two basic versions of circuit-breaker compartments avail- to any UV radiation.
able:
The circuit-breaker compartments in systems consisting of several
–– Current detection by blocktype transformers (Fig. 6.4) with panels have no gas connections to the neighboring panels, nor is
maximum two cable sockets per phase there any gas connection to the busbar compartments located
– – Current detection by current transformer (Fig. 6.5) above the circuit-breaker compartments.

Sockets (1.4) for plug-in voltage transformers are located under-

neath the circuit-breaker compartment. When voltage transformers
are removed, the sockets can be used as test sockets. If no voltage
transformers are used, the sockets are sealed and insulated with
blanking plugs.

Fig. 6.4: Circuit-breaker compartment with block type transformer, 1200 A

1.12

1.0
1.10
1.11

1.1

1.13 1.2

1.14
1.9
1.3
1.4

1.0 Circuit-breaker compartment (enclosure) 1.10 Gas density sensor for circuit-breaker
1.1 Circuit-breaker pole compartment
1.2 Circuit-breaker mechanism 1.11 Filling valve for circuit-breaker compartment
1.3 Cable socket 1.12 Cast resin bushing to busbar
1.4 Test socket (also for use with other 1.13 Pressure relief disk
plug-in devices) 1.14 Mounting plate
1.9 Block-type transformer
█ Insulating gas SF6

14 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Fig. 6.5: Circuit-breaker compartment with current transformer, 2000 A

1.12

1.0
1.10
1.11

1.15 1.1

1.13 1.2

1.14

1.3
1.4 1.16

1.0 Circuit-breaker compartment (enclosure) 1.12 Cast resin bushing to busbar

1.1 Circuit-breaker pole 1.13 Pressure relief disk
1.2 Circuit-breaker mechanism 1.14 Mounting plate
1.3 Cable socket 1.15 Current transformer
1.4 Test socket (also for use with other plug-in devices) 1.16 Bushing for current transformer secondary wiring
1.10 Gas density sensor for circuit-breaker compartment
1.11 Filling valve for circuit-breaker compartment █ Insulating gas SF6

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 15

The busbar compartment (B)

The busbar compartment (Figs. 6.6 and 6.7) consists of the busbar As a rule, the front busbar compartment contains a three position
system (2.1), which is connected to the single-pole cast resin bush- disconnect (with grounding function). The rear busbar compartment
ings (1.12) below via flat conductors (2.10) and the three position of the single busbar version also contains a three position discon-
disconnect (2.3). nect. In the double busbar version the rear busbar compartment of
cable termination panels contains a disconnect with no grounding
The pressure relief disk (1.13) of the busbar compartment is located function.
in the roof of the enclosure.
As with the circuit-breaker compartment, the seals on the compo-
Front busbar compartment nents are o-ring seals which are not exposed to any UV radiation.

The three position disconnect operating mechanism (2.5), the gas The busbar connection to the adjacent panels is effected by plug-in
leakage sensor (2.7) and the filling valve (2.8) are located on the front connectors (2.2) located at either side of the enclosure. The busbar
wall of the enclosure. compartments in switchgears consisting of several panels, have no
gas connections with the neighboring panels, nor is there any gas
Rear busbar compartment connection to the circuit-breaker compartment located below the
busbar compartments.
The disconnect operating mechanism (2.5), the gas leakage sensor
(2.7) and the filling valve (2.8) are located on the rear wall of the en-
closure. Emergency manual operation of the disconnect is effected
from the low voltage compartment.

Fig. 6.6: Front busbar compartment (B), 1200 A

1.13
2.1
2.2
2.0

2.10
2.9
2.8
2.3
2.5
2.7

1.12

1.12 Cast resin bushing 2.5 Three position disconnect operating mechanism
1.13 Pressure relief disk 2.7 Gas density sensor for busbar compartment
2.0 Busbar compartment (enclosure) 2.8 Filling valve for busbar compartment
2.1 Busbar system 2.9 Grounding contact
2.2 Plug-in busbar connector 2.10 Flat conductor
2.3 Three position disconnect
█ Insulating gas SF6

16 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Fig. 6.7: Rear busbar compartment (B), Double busbar, 2000 A

1.13
2.1
2.2
2.0

2.10

2.6 2.4
2.7
2.8

1.12

1.12 Cast resin bushing 2.6 Disconnect operating mechanism

1.13 Pressure relief disk 2.7 Gas density sensor for busbar compartment
2.0 Busbar compartment (enclosure) 2.8 Filling valve for busbar compartment
2.1 Busbar system 2.10 Flat conductor
2.2 Plug-in busbar connector
2.4 Disconnect █ Insulating gas SF6

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 17

The cable termination compartment (C) and rear plenum (D)

The cable termination compartment (Fig. 6.8) constitutes a support ment. The cable termination compartment is metal-enclosed on
frame for the panel manufactured from bended zinc-plated sheet all sides and protected against accidental contact. The installation
metal. access at the rear of the cable termination compartment is closed
off by a detachable plate.
The cable termination compartment contains the main grounding bar
(3.5), the high voltage cables (3.2) with fitted cable plugs (3.1), cable In the unlikely event of an arc fault in the cable termination or
fasteners (3.3) and - where appropriate, surge arresters or voltage circuit-breaker compartments, pressure is relieved through the
transformers. rear plenum (4.0).

An antimagnetic floor plate (3.6), split for cable installation, serves to

partition the cable termination compartment off from the cable base-

Fig. 6.8: Cable termination compartment (C) and rear plenum (D)

4.0

(D)

3.1

3.5
(C)
1.8
3.0
3.6
3.3
3.2

1.8 Voltage transformers

3.0 Cable termination compartment (C)
3.1 Cable plugs
3.2 High voltage cables
3.3 Cable fastener
3.5 Main grounding bar (mounted on the circuit-
breaker enclosure)
3.6 Floor plate
4.0 Rear plenum (D)

18 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

The pressure relief system for the
busbar - compartment (E)

The upper pressure relief system serves to discharge the pressure in vices and further secondary devices and their wiring are located in
the unlikely event of an internal arc fault in the busbar compartment. the low voltage compartment (Fig. 6.9).

The low voltage compartment (F) The entry for external secondary cables (6.5) is located in the base
plate of the low voltage compartment.
The operating mechanism for the circuit-breaker (1.2), the mecha-
nism for the three position disconnect (2.5), sensors for gas density As a rule the low voltage compartment depth amounts to 19.69 in.
monitoring in the gas compartments (1.10 and 2.7), protection de-

Fig. 6.9: Low voltage compartment (F)

6.6

6.4

6.4

2.5
2.7 6.2
2.8
6.0

6.4
1.10
1.11

1.2 Operating mechanism for the circuit-breaker

1.2
1.10 Sensors for gas density monitoring for
Circuit-breaker compartment
1.14 1.11 Filling valve for circuit-breaker compartment
1.14 Mounting plate for circuit-breaker
2.5 Three position disconnect mechanism
2.7 Gas density sensor for front busbar compartment
6.4 2.8 Filling valve for front busbar compartment
6.3 6.0 Low voltage compartment
6.2 Human-machine interface of a combined protection
and control device
6.3 Opening for loop lines
6.4 Wiring section
6.5 Secondary cable entry
6.6 Low voltage compartment door

6.5

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 19

7 Components

Fig. 7.1: Feeder Panel 1200 A, Single busbar

1.13
4.1 1.0 Circuit-breaker compartment
2.0 2.1 1.1 Circuit-breaker pole
6.0 1.2 Circuit-breaker operating mechanism
1.3 Cable socket
1.4 Test socket (also for use with other
2.3 2.5 plug-in devices)
6.2 1.5 Capacitive voltage indicator system
1.5 1.8 Voltage transformer
1.12
1.9 Block-type transformer
1.0
1.12 Bushing, circuit-breaker/busbar compartment
1.1
4.0 1.13 Pressure relief disk
1.13 1.15 Current transformer
1.9 1.2
2.0 Busbar compartment
1.4 1.3
2.1 Busbar system
3.5 3.1
2.3 Three position disconnect
3.0 2.4 Disconnect
3.2 2.5 Three position disconnect mechanism
3.3 2.6 Disconnect mechanism
3.0 Cable termination compartment
3.1 Cable plug
3.2 High voltage cable
3.3 Cable fastener
3.5 Main grounding bar

Fig. 7.2: Feeder Panel 2000 A, Double busbar 4.0 Plenum, rear
4.1 (for circuit-breaker compartment and cable
2.1 termination compartment)
1.13
4.1 Plenum, top
2.0 6.0
(for busbar compartment)
2.3
2.5 6.0 Low voltage compartment
2.4 6.2
2.6
1.12 6.2 Protection and control device
1.5
1.0 █ Insulating gas SF6
1.15 1.1
4.0
1.13 1.2

1.3
1.4
3.5 3.1

1.8
3.2
3.0 3.3

20 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

7.1 Vacuum circuit-breaker

The fixed mounted vacuum circuit-breakers (Fig. 7.1.1) are three Vacuum interrupter
phase switching devices and fundamentally consist of the operat-
ing mechanism and the three pole parts. The pole parts contain the The outer casing of the vacuum interrupter (Fig. 7.1.2) consists of
switching elements, the vacuum interrupters. ceramic insulators (1), whose ends are sealed off by stainless
steel lids (2). The contacts (4 and 5) surrounded by the potential-
The pole parts are installed on a common mounting plate. The op- free centre screen (3) are made of copper/chromium composite. As
erating mechanism is on the opposite side from the mounting plate. a consequence of the extremely low static pressure of less than
Thus, the pole parts, mounting plate and operating mechanism form 1.45 x 10-6 to 1.45 x 10-10 psi inside the interrupter chamber, only a
a single assembly. The mounting plate for this assembly is screwed relatively small contact gap is required to achieve a high dielectric
to the front wall of the circuit-breaker compartment in a gas-tight strength. The switching motion is transmitted into the enclosed
manner at the factory. system of the vacuum interrupter via a metal bellows (6). An anti-
rotation element (7) is fitted to protect the metal bellows from torsion
The pole parts are located in the circuit-breaker compartment which and to guide the conductor leading to the moving contact. The con-
is filled with SF6, and are therefore protected from external influenc- nection to the operating mechanism is effected by a threaded pin (8)
es. The operating mechanism is located in the low voltage compart- fastened in the feed conductor.
ment and is therefore easily accessible
If contacts through which current is flowing are opened in a vacuum,
Functions of the vacuum circuit-breaker a metal vapor arc arises under short-circuit conditions. This arc cre-
ates the charge carriers required to conduct the current inside the
– – Switching operating current on and off vacuum interrupter. The arc is extinguished at the first natural zero
– – Short-circuit breaking operations of the alternating current after switch-off (i.e. after separation of the
– – Grounding function in conjunction contacts). With the rapid reestablishment of the contact gap in the
with the three position disconnect vacuum, the current flow is then securely interrupted.

For grounding, the three position disconnect prepares the connec-

tion to ground while in the de-energized condition. Actual grounding
is then performed by the circuit-breaker. A circuit-breaker func-
tioning as an grounding switch is of higher quality than any other
grounding switch.

Fig. 7.1.1: Vacuum circuit-breaker Fig. 7.1.2: Vacuum interrupter

2 1 4 2 7

3 5 6 8

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 21

Pole parts (Fig. 7.1.3)

The interrupter (9) inside the pole part is embedded in cast resin or
located in a cast resin pole tube (10). With the breaker closed, the
current flows from breaker terminal (11) to the fixed contact in the
vacuum interrupter, and then onto the breaker terminal via the mov-
ing contact (12). The operating motions are effected by insulated
actuating rods (8).

Circuit-breaker operating mechanism

The circuit-breaker operating mechanism (Fig. 7.1.3, item 13) is con-

nected to the pole parts via gas-tight thrust bushings (14).

The circuit-breaker is equipped with a mechanical stored-energy

spring mechanism. The stored-energy spring can be charged either
manually or by a motor. Opening and closing of the device can be
performed by means of mechanical pushbuttons or by electrical
releases (closing, opening and undervoltage releases).

The operating mechanism can be configured for autoreclosing and

with the short motor charging times involved, also for multi-shot au-
toreclosing.

Fig. 7.1.3: Pole part and operating mechanism

11 9 10 12 8 14 13

22 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

The front of the operating mechanism (Fig. 7.1.4) accommodates cal indicators for “Circuit-breaker ON” “Circuit-breaker OFF” (4),
the mechanical on (1) and off (2) pushbuttons, the receptacle for “Stored-energy spring charged”, “Stored-energy spring discharged”
manual charging of the stored-energy spring (3), the mechani- (5), an operating cycle counter (6) and the name plate for the circuit-
breaker (7).

Fig. 7.1.4: Controls for the circuit-breaker operating mechanism

2
4

6
3

The mechanical push-buttons can optionally be fitted with a lock-

ing device (Fig. 7.1.5). When this option is selected, both buttons
can be secured separately with padlocks.

Fig. 7.1.5: Optional locking device for mechanical push-buttons on the circuit-breaker

Example: OFF button secured Example: OFF button enabled for op-
eration

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 23

Secondary equipment for the circuit-breaker mechanism

Table 7.1.1 shows the secondary equipment for the circuit-breaker

operating mechanism in an outgoing feeder panel. The “Standard”
column indicates the equipment necessary for control of the panel.
Furthermore, the use of further devices such as additional auxiliary
switches is possible as an option to meet your specific require-
ments.

Table 7.1.1: Secondary equipment for the circuit-breaker mechanism in feeder panels
Designations

Equipment

Standard

Option
-MAS Charging motor for spring mechanism ●
-BGS1 1)
Auxiliary switch “Spring charged” ●
-MBO1 Shunt release OFF ●
-MBC Shunt release ON ●
-BGB1 Auxiliary switch “CB ON/OFF” ●
-BGB2 2)
Auxiliary switch “CB ON/OFF” ●
-BGB3 2)
Auxiliary switch “CB ON/OFF” ●
-KFN Anti-pumping device ●
-RLE1 Blocking magnet “CB ON” ●
-BGL1 Auxiliary switch for blocking magnet ●
-BGB4 Fleeting contact ≥ 30 ms for C.B. tripped indication ●
-MBU 3)
Undervoltage release ●
-MBO3 3)
Indirect overcurrent release ●
-MBO2 2 nd shunt release OFF ●

1)
For certain versions of the circuit-breaker, auxiliary switches BGS1.1...1.5 are used.
2)
For certain versions of the circuit-breaker, the auxiliary switch may not be required. In such cases the function is performed by auxiliary switch -BGB1.
3)
Combination of -MBU with -MBO3 is not possible.
24 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05
7.2 Three position
disconnect
The three position disconnects are combined disconnect and Three position disconnect operating mechanism
grounding switches. The three switch positions: connecting, dis-
connecting and grounding, are clearly defined by the mechanical
structure of the switch. Simultaneous connection and grounding is The operating mechanism block for the three position disconnect
therefore impossible. consists of the following functional groups (Figs. 7.2.4 to 7.2.6):

The three position disconnects are motor-operated rod-type switch- – – Drive motor
es, whose live switching components are located in the busbar – – Functional unit with micro switches and auxiliary switches for
compartment filled with SF6, while the mechanism block is easily position detection
accessible in the low voltage compartment. – – Mechanical position indicator
– – Mechanical access interlock for emergency manual operation
The switch (Fig. 7.2.1) has its disconnected position in the cen- – – Hand crank receptacle for emergency manual operation
tral position. In the disconnect ON and grounding switch ON limit
positions, the moving contact (sliding part) driven by an insulating The various options for secondary equipment in the mechanism vari-
spindle reaches the fixed contacts (disconnect contact or grounding ants can be found in table 7.2.1.
contact) which are fitted with one or two spiral contacts.

Series connected optional reed contacts (- switches operated by

permanent magnets) detect the correct positions of the three con-
tacts in the grounding switch ON position (Figs. 7.2.2 and 7.2.3).

Fig. 7.2.1: Three position disconnect in disconnect ON position Fig. 7.2.2: Partial view of the three position disconnect in the grounding
switch ON position (reed contact switched on by permanent magnet)

Permanentmagnet
Reed contact

Disconnect Sliding Fixed Insulating

Grounding Fig. 7.2.3: Partial view of the three position disconnect in the central posi-
contact part contact spindle
contact tion

Permanentmagnet
Reed contact

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 25

Fig. 7.2.4: Three position disconnect operating mechanism

Drive motor
Mechanical access interlock for
emergency manual operation
Mechanical position indicator
Functional unit with micro switches and
auxiliary switches

Fig. 7.2.5: Closed mechanical access interlock for emergency manual operation

Mechanical access interlock for

emergency manual operation

Mechanical position indicator

Fig. 7.2.6: Opened mechanical access interlock for emergency manual operation

Hand crank receptacle

26 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Secondary equipment for the three position disconnect
operating mechanism

Table 7.2.1 shows the secondary equipment for the three position the panel. Furthermore the use of further devices such as additional
disconnect operating mechanism in an outgoing feeder panel. The auxiliary switches is possible as an option to meet your specific re-
“Standard” column indicates the equipment necessary for control of quirements.

Table 7.2.1: Secondary equipment for the three position disconnect mechanism in feeder panels
Designations

Equipment

Standard

Option
-MAD Drive motor ●
-BGI15 Microswitch to detect switch position “Disconnect OFF” ●
-BGI16 Microswitch to detect switch position “Disconnect ON” ●
-BGE57 Microswitch to detect switch position “Grounding switch OFF” ●
-BGE58 Microswitch to detect switch position “Grounding switch ON” ●
-BGI1 Auxiliary switch to detect switch position “Disconnect OFF” ●
-BGI1 Auxiliary switch to detect switch position “Disconnect ON” ●
-BGE5 Auxiliary switch to detect switch position “Grounding switch OFF” ●
-BGE5 Auxiliary switch to detect switch position “Grounding switch ON” ●
-BGE3.1
-BGE3.2 Reed contacts to detect the “Grounding switch ON” switch position ●
-BGE3.3
-BGL1
Microswitch for (optional) access blocking of hand crank receptacle for emergency manual operation ●
-BGL2

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 27

7.3 Disconnect

Except for the lack of an grounding contact the design of the dis- The two-part operating mechanism of the disconnect consists of the
connect is the same as that of the three position disconnect. Ac- following functional groups (Figs. 7.3.2 to 7.3.5):
cordingly the two switch positions are “connect” and “disconnect”.
– – Drive motor
Fig. 7.3.1: Disconnect in ON position
–– Functional unit with micro switches and auxiliary switches for
position detection
–– Mechanical position indicator
–– Mechanical access interlock for emergency manual operation
– – Hand crank receptacle for emergency manual operation

Fig. 7.3.2: Rear part of the disconnect operating mechanism with drive Fig. 7.3.3: Front part of the disconnect operating mechanism in the low
motor on the back of the panel voltage compartment. The operating mechanism of the three position
disconnect is located above the disconnect operating mechanism.

Drive motor Disconnect operating Mechanical access

mechanism interlock

Fig. 7.3.4: Closed mechanical access interlock for emergency manual Fig. 7.3.5: Opened mechanical access interlock for emer-
operation gency manual operation

Mechanical position Mechanical access Hand crank receptacle

indicator interlock
28 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05
Secondary equipment for the disconnect

Table 7.3.1 shows the secondary equipment for the disconnect Over and above this, the use of further devices such as additional aux-
operating mechanism in an outgoing feeder panel. The “Standard” iliary switches is possible as an option to meet your specific require-
column indicates the equipment necessary for control of the panel. ments.

Table 7.3.1: Secondary equipment for the disconnect mechanism in feeder panels
Designations

Equipment

Standard

Option
-MAD Drive motor ●
-BGI15 Microswitch to detect switch position “Disconnect OFF” ●
-BGI16 Microswitch to detect switch position “Disconnect ON” ●
-BGI1 Auxiliary switch to detect switch position “Disconnect OFF” ●
-BGI1 Auxiliary switch to detect switch position “Disconnect ON” ●
-BGL1
Microswitch for (optional) access blocking of hand crank receptacle for emergency manual operation ●
-BGL2

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 29

7.4 Optional view ports

The busbar compartments can be equipped with optional view ports The view ports will be covered by a slide mechanism.
to allow operators to verify the switching positions of the three posi-
tion disconnect and the disconnect visually. Provided as an optional accessory, the camera system (Fig. 7.4.2)
makes visual verification of the switches quick, simple and er-
The view ports for the front busbar compartment are located in the gonomic. The camera system mounts directly to the view ports
low voltage compartment, and those for the rear busbar compart- and the operator monitors the position of the disconnect via LCD
ment are located in the cover of the busbar compartment at the rear screen. The camera system will be placed outside the gas com-
of the panel (Fig. 7.4.1). partment when it is needed. This way if a failure occurs with the
camera it can be easily replaced without compromising safe opera-
Using a flashlight to pear through the view ports, the operator can tion of the gear or verification of the disconnect switch.
visually verify that the three position disconnect is disconnected,
connected or in the grounded position.

Fig. 7.4.1: Position of the optional view ports shown in the

example of a double busbar panel

View A
A A

View ports

Fig. 7.4.2: Camera system case

Monitor

Light adapter

Camera

Camera adapter

Power cable

30 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

7.5 Busbar

The busbars, located in the gas compartment of the panels, are from ground potential. The surfaces of all electrically conductive
connected together by plug-in busbar connectors (Figs. 7.5.1 to components (embedded part, spiral contact and contact tube) are
7.5.3). The busbar connection consists of the cast resin busbar silver plated. As the contact tubes are axially movable, no further
socket (1) mounted in the busbar compartment from the inside, the compensation for expansion in the busbars running through a
silicone insulating part (2), the contact tube (3) and the spiral con- switchgear system is necessary.
tacts (4).
The circuit-breaker and busbar compartments are separate cham-
For a busbar current of maximum 1250 A, 2500 A and 3000 A, dif- bers in the gas system. Busbar operation therefore continues to be
ferent cast resin busbar sockets and contact tubes are used. The possible in the event of a fault in the circuit-breaker compartment
number of spiral contacts varies depending on the busbar current. of an outgoing feeder panel. The gas systems of adjacent busbar
The design of these components is uniform within a switchgear compartments are also not connected to each other.
block. For a busbar current > 2500 A, the use of heat sinks on the
busbar spaces is required in accordance with chapter 8.4.2. The plug connector system on the one hand facilitates the delivery of
panels tested at the works for leakage and dielectric strength, and
The electrically conductive connection from the embedded part of on the other hand no gas work is required during installation at site
the cast resin busbar socket to the contact tube, is established by (with the exception of installation of heat sinks on busbar compart-
one, two or four spiral contacts, depending on the rated busbar cur- ments at site).
rent. The silicone insulating part isolates the high voltage potential

Fig. 7.5.1: Busbar socket (1) with insulating part (2), contact tube (3) and
spiral contacts (4)

Fig. 7.5.2: Busbar connection, plugged in at one end Fig. 7.5.3: Busbar connection between the panels

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 31

End panels

End panels are available in versions which permit extension. In is properly pumped out and the busbar compartment is opened.
these versions, the busbar sockets are dielectrically sealed off with It is therefore possible to remove any panel from the middle of a
blanking plugs. If extension is positively unnecessary, busbar end switchgear installation.
insulators (Fig. 7.5.4) are used in place of the conventional busbar
sockets. The busbar interrupted by removal of the panel can be temporarily
bridged with the aid of a coupler box.
Removal of intermediate panels
Direct connection of fully insulated bars to the busbar
The busbar connection with busbar socket, insulating part and con-
tact tube can be dismantled when the busbar is grounded. The SF6 Fully insulated bars can be connected with special busbar sockets
in an end panel (Fig. 7.5.5).

Fig. 7.5.4: Busbar enclosures with busbar end insulators (1) and busbar sockets (2)

1 2

Fig. 7.5.5: Direct connection of fully insulated bars to the busbar

32 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

7.6 Inner cone termination 7.6.1 Connection of cables
system
An overview of the maximum cross-sections of the cables to be
Inner cone sockets (Fig. 7.6.1 - size 2 or 3) fitted in a gas-tight man- connected and the cable plugs usable in various installation situa-
ner in the floor plate of the circuit-breaker compartment facilitate tions can be found in table 7.6.1.1. As the assignment of plug sizes
facilitate the connection of cables (Fig. 7.6.1.1), fully insulated bars to the actual cable used can depend on further cable data, these
(7.6.2.1) or surge arresters (7.6.3.1). are to be discussed with the plug supplier.

The inner cone termination system is above all notable for its total The current carrying capacity of the panels as stated is achieved
insulation and the associated protection against accidental contact. when all the sockets in the panel are evenly fitted with cables.

Tabelle 7.6.1.1: Cable plugs usable in various installation situations

Cable cross-section
Manufacturer Plug size
[kcmil (mm2)]

ABB 350 (185)

AB srl. 750 (400)
2
nkt 500 (300)
Pfisterer 750 (400)
Pfisterer 2 XL 750 (400)
Südkabel 500 (300)
2
Tyco / Raychem 750 (400)
ABB 750 (400)
AB srl. 1000 (630)
3
1000 (630)
nkt
Round single wire: 1500 (800)
Pfisterer 3 (3-S) 1000 (630)
Pfisterer 3 XL 1500 (800)
Südkabel 1000 (630)
3
Tyco / Raychem 1000(630)

Fig. 7.6.1: View into the gas-insulated circuit-breaker compartment with Fig. 7.6.1.1: View into the cable termination compartment
inner cone sockets in air with cable plugs and cables

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 33

7.6.2 Connection of fully 7.6.3 Connection of surge
insulated bars arresters

Connection of fully insulated bars (Fig. 7.6.2.1) in place of cables is Connection of plug-in surge arresters (Fig. 7.9.6) of sizes 2 (12-
possible using sockets of size 3 (up to 1200 A) or special sockets 38 kV) is possible (Fig. 7.6.3.1).
(up to 2500 A).
ABB-Polim® surge arresters are to be used. The surge arresters
consist of zinc oxide varistors, which provide optimum protection
from hazardous overvoltages. The varistors are located in an alu-
minium casing and embedded in silicone.
Fig. 7.6.2.1: Connection of a fully insulated bar using plug size 3

Fig. 7.6.3.1: Connection of surge arresters (1)

34 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

7.7 Outer cone cable connection system

Outer cone device termination components to EN 50181, fitted gas- Shockproof cable connector systems are always to be used. A se-
tight in the wall between the panel module and the cable termination lection of connector systems which can be used within the space
compartment, facilitate connection of cables and surge arresters available is shown in tables 7.7.1.1 to 7.7.1.6. When making your
(Figs. 7.7.1 to 7.7.2). When the shutter on the cable termination selection, please take account of the current and short-circuit ca-
compartment has been removed, the cables are accessible from the pacities of the cables and connector systems. Please consult the
rear of the system. manufacturers for any additional requirement, precise ordering de-
tails and information on any coupling units required.

Fig. 7.7.1: View into the cable termination area with outer cones in air Fig. 7.7.2: View into the cable termination compartment in air with shock-
proof cable connectors (ABB type CSE-A) and cables

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 35

7.7.1 Selection of cable connectors

Table 7.7.1.1 a: Selection of cable connectors, panel width 23.62 in, 8.25 kV, max. 600 A
Cables fitted Cable connector manufacturer / connector type
Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Südkabel GmbH
Three cables +

ABB Kabeldon
voltage

current

Surge arrester

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
One cable +
Two cables
One cable

Tyco
[kV] [A] [kcmil (mm2)]
● CSE-A 12630-01
CSE-A 12630-01
●
CSEP-A 12630-01
AWG 3 -
CSE-A 12630-01
AWG 2/0 ●
CSAP-A 12xx
(25 - 70)
CSE-A 12630-01
● CSEP-A 12630-01
CSAP-A 12xx
● 430TB CB12-630 RSTI-58xx
CB12-630 RSTI-58xx
● 430TBM-P2
CC12-630 RSTI-CC-58xx
CB12-630
● 430TBM-P3
2x CC12-630
AWG 3- 430TB CB12-630 RSTI-58xx
●
500 300SA CSA12-... RSTI-CC-58SA
(25 - 300) CB12-630 RSTI-58xx
430TBM-P2
● CC12-630 RSTI-CC-58xx
300SA
CSA12-... RSTI-CC-58SA
CB12-630
12 600 ● 2x CC12-630
CSA12-...
● SET12
SET12
●
SEHDK13.1
AWG 1/0 -
SET12
500 ●
MUT13
(50 - 300)
SET12
● SEHDK13.1
MUT13
● 484TB/G
484TB/G
●
804PB/G
484TB/G
AWG 1/0 - ●
2x 804PB/G
1000
484TB/G
(50 - 630) ●
800SA
484TB/G
● 804PB/G
800SA

36 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Table 7.7.1.1 b.: Selection of cable connectors, panel width 23.62 in, 8.25 kV, max. 600 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Südkabel GmbH
ABB Kabeldon
voltage

current

Surge arrester

Surge arrester
Two cables +
One cable +
Two cables
One cable

Cellpack
[kV] [A] [kcmil (mm2)]
● CSE-A 12630-02
CSE-A 12630-02
●
CSEP-A 12630-02
AWG 1/0 -
CSE-A 12630-02
500 ●
CSAP-A 12xx
(50 - 300)
CSE-A 12630-02
● CSEP-A 12630-02
CSAP-A 12xx
400 - 750
● CB24-1250/2
(185 - 500)
600 - 750
● SEHDT13
(300 - 500)
12 600
1000 (400)
1000 (500) ● CB36-630(1250)
1000 (630)
● CSE-A 12630-03
1000
CSE-A 12630-03
(400 - 630) ●
CSAP-A 12xx
● CTS 1250A 24kV
1000
CTS 1250A 24kV
(500 - 630) ●
CTKSA
● CB42-1250/3
1250 - 1750
CB42-1250/3
(630 - 1000) ●
CSA12-...

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 37

Table 7.7.1.2 a: Selection of cable connectors, panel width 23.62 in, 8.25 kV, max. 1200 A
Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Südkabel GmbH
Three cables +

ABB Kabeldon
voltage

current

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
Two cables

Tyco
[kV] [A] [kcmil (mm2)]
CB12-630 RSTI-58xx
● 430TBM-P2
CC12-630 RSTI-CC-58xx
CB12-630 RSTI-58xx
● 430TBM-P3
2x CC12-630 2x RSTI-CC-58xx
AWG 1/0 -
CB12-630 RSTI-58xx
500 430TBM-P2
● CC12-630 RSTI-CC-58xx
(50 - 300) 300SA
CSA12... RSTI-CC-58SA
CB12-630 RSTI-58xx
● 2x CC12-630 2x RSTI-CC-58xx
CSA12... RSTI-CC-58SA
484TB/G
●
804PB/G
484TB/G
●
2x 804PB/G
AWG 1/0 -
484TB/G
1000
● 804PB/G
(50 - 630)
800SA
484TB/G
● 2x 804PB/G
800SA
CSE-A 12630-02
12 1200 ●
CSEP-A 12630-02
CSE-A 12630-02
●
2x CSEP-A 12630-02
AWG 4/0 -
CSE-A 12630-02
500
● CSEP-A 12630-02
(95 - 300)
CSAP-A 12..
CSE-A 12630-02
● 2x CSEP-A 12630-02
CSAP-A 12..
600 - 750
● 2x SEHDT13
(300 - 500)
CB36-630(1250)
●
CC36-630(1250)
CB36-630(1250)
●
2x CC36-630(1250)
1000 (400)
CB36-630(1250)
1000 (500)
● CC36-630(1250)
1000 (630)
CSA12-...
CB36-630(1250)
● 2x CC36-630(1250)
CSA12-...

38 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Table 7.7.1.2 b: Selection of cable connectors, panel width 23.62 in, 8.25 kV, max. 1200 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Three cables +

ABB Kabeldon
voltage

current

Surge arrester

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
One cable +
Two cables
One cable

Cellpack
Tyco
[kV] [A] [kcmil (mm2)]
CSE-A 12630-03
●
2x CSEP-A 12630-03
1000
CSE-A 12630-03
(400 - 630)
● 2x CSEP-A 12630-03
CSAP-A 12..
● RSTI-x95x
RSTI-x95x
●
RSTI-CCx95x
RSTI-x95x
●
1000 - 1500 2x RSTI-CC-x95x
(400 - 800) RSTI-x95x
●
12 1200 RSTI-CC-68SA
RSTI-x95x
● RSTI-CC-x95x
RSTI-CC-68SA
● CTS 1250A 24kV
1000
CTS 1250A 24kV
(500 - 630) ●
CTKSA
● CB42-1250/3
1250 - 1750
CB42-1250/3
(630 - 1000) ●
CSA12
1750 - 2000
● 489TB/G
(800 - 1200)

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 39

Table 7.7.1.3 a: Selection of cable connectors, panel width 23.62 in, 15 kV, max. 600 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Südkabel GmbH
Three cables +

ABB Kabeldon
voltage

current

Surge arrester

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
One cable +
Two cables
One cable

Tyco
[kV] [A] [kcmil (mm2)]
● CSE-A 24630-01
CSE-A 24630-01
●
CSEP-A 24630-01
AWG 3 -
CSE-A 24630-01
AWG 2/0 ●
CSAP-A 24xx
(25 - 70)
CSE-A 24630-01
● CSEP-A 24630-01
CSAP-A 24xx
● SET24
SET24
●
SEHDK23.1
AWG 3 - 400 SET24
●
(25 - 240) MUT23
SET24
● SEHDK23.1
MUT23
● K430TB CB24-630 RSTI-58xx
CB24-630 RSTI-58xx
● K430TBM-P2
CC24-630 RSTI-CC-58xx
24 600 CB24-630
● K430TBM-P3
2x CC24-630
AWG 3 - K430TB CB24-630 RSTI-58xx
●
500 300SA CSA24-... RSTI-CC-58SA
(25 - 300) CB24-630 RSTI-58xx
K430TBM-P2
● CC24-630 RSTI-CC-58xx
300SA
CSA24-... RSTI-CC-58SA
CB24-630
● 2x CC24-630
CSA24-...
● K484TB/G
K484TB/G
●
K804PB/G
K484TB/G
AWG 1 - ●
2x K804PB/G
1000
K484TB/G
(35- 630) ●
800SA
K484TB/G
● K804PB/G
800SA

40 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Table 7.7.1.3 b.: Selection of cable connectors, panel width 23.62 in, 15 kV, max. 600 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Südkabel GmbH
ABB Kabeldon
voltage

current

Surge arrester

Surge arrester
Two cables +
One cable +
Two cables
One cable

Cellpack
[kV] [A] [kcmil (mm2)]
● CSE-A 24630-02
CSE-A 24630-02
●
CSEP-A 24630-02
CSE-A 24630-02
AWG 3/0 - ●
CSAP-A 24xx
(95 - 300)
CSE-A 24630-02
● CSEP-A 24630-02
CSAP-A 24xx
400 - 750
● CB24-1250/2
(95 - 500)
24 600 600 - 750
● SEHDT23
(300 - 500)
1000 (400)
1000 (500) ● CB36-630(1250)
1000 (630)
● CSE-A 24630-03 CTS 1250A 24kV
1000
CSE-A 24630-03 CTS 1250A 24kV
(400 - 630) ●
CSAP-A 24xx CTKSA
● CB42-1250/3
1250 - 1750
CB42-1250/3
(630 - 1000) ●
CSA24-...

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 41

Table 7.7.1.4 a: Selection of cable connectors, panel width 23.62 in, 15 kV, max. 1200 A
Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Südkabel GmbH
Three cables +

ABB Kabeldon
voltage

current

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
Two cables

Tyco
[kV] [A] [kcmil (mm2)]
CB24-630 RSTI-58xx
● K430TBM-P2
CC24-630 RSTI-CC-58xx
CB24-630 RSTI-58xx
● K430TBM-P3
2x CC24-630 2x RSTI-CC-58xx
AWG 3 -
CB24-630 RSTI-58xx
500 K430TBM-P2
● CC24-630 RSTI-CC-58xx
(25 - 300) 300SA
CSA24... RSTI-CC-58SA
CB24-630 RSTI-58xx
● 2x CC24-630 2x RSTI-CC-58xx
CSA24... RSTI-CC-58SA
K484TB/G
●
K804PB/G
K484TB/G
●
2x K804PB/G
AWG 1 -
K484TB/G
1000
● K804PB/G
(35- 630)
800SA
K484TB/G
● 2x K804PB/G
800SA
CSE-A 24630-02
24 1200 ●
CSEP-A 24630-02
CSE-A 24630-02
●
2x CSEP-A 24630-02
AWG 4/0 -
CSE-A 24630-02
500
● CSEP-A 24630-02
(95 - 300)
CSAP-A 24..
CSE-A 24630-02
● 2x CSEP-A 124630-02
CSAP-A 24..
600 - 750
● 2x SEHDT23
(300 - 500)
CB36-630(1250)
●
CC36-630(1250)
CB36-630(1250)
●
2x CC36-630(1250)
1000 (400)
CB36-630(1250)
1000 (500)
● CC36-630(1250)
1000 (630)
CSA12-...
CB36-630(1250)
● 2x CC36-630(1250)
CSA12-...

42 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Table 7.7.1.4 b: Selection of cable connectors, panel width 23.62 in, 15 kV, max. 1200 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Three cables +

ABB Kabeldon
voltage

current

Surge arrester

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
One cable +
Two cables
One cable

Cellpack
Tyco
[kV] [A] [kcmil (mm2)]
● CTS 1250A 24kV
CTS 1250A 24kV
●
+CTKSA
1000 CSE-A 24630-03
●
(400 - 630) 2x CSEP-A 24630-03
CSE-A 24630-03
● 2x CSEP-A 24630-03
CSAP-A 24..
● RSTI-x95x
RSTI-x95x
●
RSTI-CCx95x
24 1200 RSTI-x95x
●
1000 - 1500 2x RSTI-CC-x95x
(400 - 800) RSTI-x95x
●
RSTI-CC-68SA
RSTI-x95x
● RSTI-CC-x95x
RSTI-CC-68SA
● CB42-1250/3
1250 - 1750
CB42-1250/3
(630 - 1000) ●
CSA24
1750 - 2000
● K489TB/G
(800 - 1200)

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 43

Table 7.7.1.5 a: Selection of cable connectors, panel width 23.62 in, 38 kV, max. 600 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Three cables +

ABB Kabeldon
voltage

current

Surge arrester

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
One cable +
Two cables
One cable
[kV] [A] [kcmil (mm2)]
● CB36-630
CB36-630
●
CC36-630
AWG 3 -
CB36-630
500 ●
CSA36-...
(25 - 300)
CB36-630
● CC36-630
CSA36-...
● M484TB/G
● M484TB/M-P2
● M484TB/M-P3
AWG 1 - M484TB/G
●
1000 800SA
(35 - 630) M484TB/M-P2
●
800SA
38 600
M484TB/M-P3
●
800SA
AWG 1/0 - ● CSE-A 36630-01
AWG 2/0 CSE-A 36630-01
●
(50 - 70) CSEP-A 36630-01
● M430TB
● M400TB/G
● M400TB/G-P2
● M430TBM-P2
AWG 1/0 -
M430TB
400 ●
300SA
(50 - 240)
M400TB/G
● ●
400PBxx
M430TBM-P2
●
300SA

44 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Table 7.7.1.5 b: Selection of cable connectors, panel width 23.62 in, 38 kV, max. 600 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Südkabel GmbH
Three cables +

ABB Kabeldon
voltage

current

Surge arrester

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
One cable +
Two cables
One cable

Cellpack
Tyco
[kV] [A] [kcmil (mm2)]
● RSTI-68xx
RSTI-68xx
●
RSTI-CC-68xx
AWG 1/0 -
RSTI-68xx
500 ●
RSTI-CC-68SAxx
(50 - 300)
RSTI-68xx
● RSTI-CC-68xx
RSTI-CC-68SAxx
AWG 1/0 -
750 ● CTS 630A 36kV
(50 - 400)
● M484TB/G
M484TB/G
●
M804PB/G
M484TB/G
●
2x M804PB/G
M484TB/G
AWG 1/0 - ●
800SA
1000
M484TB/G
(50 - 630)
● M804PB/G
800SA
M484TB/G
38 600
● 2x M804PB/G
800SA
AWG 3/0 - ● SET36
500 SET36
●
(70 - 300) MUT33
AWG 4/0 -
500 ● CSE-A 36630-02
(95 - 300)
● SEHDT33
600 - 750
SEHDT33
(300 - 500) ●
MUT33
1000 (400) ● CB36-630(1250)
1000 (500) CB36-630(1250)
●
1000 (630) CSA36-...
● M440TB/G
● M440TB/G-P2
600 - 1000 M440TB/G
●
(300 - 630) 400PBxx
M440TB/G-P2
●
400PBxx
1000
● CSE-A 36630-03
(400 - 630)

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 45

Table 7.7.1.6 a: Selection of cable connectors, panel width 23.62 in, 38 kV, max. 1200 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Südkabel GmbH
Three cables +
voltage

current

Surge arrester

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
One cable +
Two cables
One cable

Cellpack
Tyco
[kV] [A] [kcmil (mm2)]
CB36-630
●
CC36-630
CB36-630
●
2 x CC36-630
AWG 3 -
CB36-630
500
● CC36-630
(25 - 300)
CSA36-...
CB36-630
● 2 x CC36-630
CSA36-...
AWG 1 - ● M484TB/M-P2
1000 M484TB/M-P2
●
(35 - 630) 800SA
● M400TB/G-P2 CTS 630A 36kV
● M430TBM-P2
AWG 1/0 -
M400TB/G
400 ●
+400PBxx
(50 - 240)
M430TBM-P2
●
+300SA
RSTI-68xx
●
RSTI-CC-68xx
RSTI-68xx
●
2x RSTI-CC-68xx
38 1200 AWG 1/0 -
RSTI-68xx
500
● RSTI-CC-68xx
(50 - 300)
RSTI-CC-68SA
RSTI-68xx
● 2x RSTI-CC-68xx
RSTI-CC-68SA
M484TB/G
●
M804PB/G
M484TB/G
●
2x M804PB/G
AWG 1/0 -
M484TB/G
1000
● M804PB/G
(50 - 630)
800SA
M484TB/G
● 2x M804PB/G
800SA
● SEHDT33
600 - 750 ● 2x SEHDT33
(300 - 500) SEHDT33
●
MUT33
● M440TB/G-P2
600 - 1000
M440TB/G-P2
(300 - 630) ●
400PBxx

46 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Table 7.7.1.6 b: Selection of cable connectors, panel width 23.62 in, 38 kV, max. 1200 A
Cables fitted Cable connector manufacturer / connector type

Cable cross-section
Maximum operating

Maximum operating

nkt cables GmbH

Three cables +
voltage

current

Surge arrester

Surge arrester

Surge arrester
Two cables +
Three cables

EUROMOLD
One cable +
Two cables
One cable

Cellpack
Tyco
[kV] [A] [kcmil (mm2)]
● CB36-630(1250)
CB36-630(1250)
●
CC36-630(1250)
CB36-630(1250)
●
2x CC36-630(1250)
1000 (400) CB36-630(1250)
●
1000 (500) CSA36-..
1000 (630) CB36-630(1250)
● CC36-630(1250)
CSA36-..
CB36-630(1250)
● 2x CC36-630(1250)
CSA36-..
● CTS 1250A 36kV
1000
CTS 1250A 36kV
(400 - 630) ●
38 1200 CTKSA
● RSTI-x95x
RSTI-x95x
●
RSTI-CC-x95x
RSTI-x95x
●
1000 - 1500 2x RSTI-CC-x95x
(400 - 800) RSTI-x95x
●
RSTI-CC-68SAxx
RSTI-x95x
● RSTI-CC-x95x
RSTI-CC-68SAxx
● CB42-1250/3
1250 - 1750
CB42-1250/3
(630 - 1000) ●
CSA36
1750 - 2000
● M489TB/G
(800 - 1200)

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 47

7.8 Main grounding bar
accommodate surge arresters (Fig. 7.9.6) for cable tests, for in-
The main grounding bar of the switchgear system runs through sulation testing of the panels, for testing of the protection systems
the cable termination compartments of the panels. The grounding by primary current injection and for maintenance grounding of the
bars in the individual panels are connected together during installa- relevant outgoing feeder panel. Suitable testing and grounding and
tion at site. The cross-section of the main ground bar is 789 kcmil short-circuiting devices are available for these purposes (Figs. 7.9.3
(ECuF30 1,58 in x 0.394 in). to 7.9.5).

Details on grounding the switchgear can be found in section 11.8. The test sockets must be closed off with blanking plugs of high di-
electric strength during normal operation of the panel.

Panels with outer cone termination system

7.9 Test sockets Testing and grounding sets are connected to the fitted cable plugs
via special connection adapters. The connection adapters are to be
selected to match the cable plugs used. Further information can be
Panels with inner cone termination system
found in the manufacturer’s documentation.

Outgoing cable panels and cable termination panels are equipped

with test sockets (Figs. 7.9.1 and 7.9.2). The test sockets are ac-
cessible in the cable termination compartment, and are used to

Fig. 7.9.2: View from the rear into the cable termination compartment: Test
sockets (1) – access blocked by insulating blanking plugs; main ground-
ing bar (transport condition) (2); cable blanking plug (3) for unused cable
Fig. 7.9.1: View into the circuit-breaker compartment: test sockets sockets, and wiring for capacitive indicator unit (4).

2 3 1 4
Fig. 7.9.3: Current test plug Fig. 7.9.4: Voltage test plug

48 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Fig. 7.9.5: Grounding or short-circuiting device for inner Fig. 7.9.6: Surge arrester
cone systems

7.10 Capacitive voltage indicator systems

Two types of capacitive, low impedance voltage indicator systems – – Phase-selective overvoltage indication
are available for checking of the off-circuit condition of a feeder. – – Three phase symbolic display:
The coupling electrode is integrated in the test sockets or in the – – Voltage present / no voltage present
sensors and – when an additional capacitive voltage indicator sys- (Threshold value for voltage presence indication:
tem is fitted in the panel door – in the cable sockets. The capaci- 0.1 - 0.45 x U N )
tive voltage indicator system is located at the rear of the panel. A – – Integrated maintenence test passed
further system in the low voltage compartment door can also be – – Voltage signal too high (Overvoltage indication)
used.

Both systems used are voltage detection systems (VDS) accord-

System WEGA 2.2 C (Fig. 7.10.2)
ing to IEC 61243-5.

The systems used allows phase comparison with the aid of an ad- As system WEGA 1.2 C, but:
dition, compatible phase comparator. – – Two integrated relay contacts (changeover contacts) for
signals/interlocks
– – Auxiliary voltage for relay function required
System WEGA 1.2 C (Fig. 7.10.1) (LC-Display function via measuring signal)
– – LED indication
–– LC-Display – – green for U = 0
–– Three phase –– red for U ≠ 0
–– No additional indicator unit required
–– Auxiliary voltage not required
–– Maintenance-free with integrated self-test in
built-in condition

Fig. 7.10.1: System WEGA 1.2 C Fig. 7.10.2: System WEGA 2.2 C

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 49

7.11 Current and voltage
detection devices
The areas of application for current and voltage detection devices
are

– – Protection applications
– – Measurement
– – Billing metering

Current and voltage transformers comply with the ANSI - standard.

Please consult ABB regarding current and voltage transformer data.

Current transformers

The inductive transmission principle of a current transformer is based

on the use of a ferromagnetic core. Irrespective of its structure as a
bushing-type, block-type transformer, bar-primary or wound-primary
transformer, a current transformer is in principle subject to hysteresis
and saturation. In the rated current range, the primary and second-
ary currents are proportional and in phase.

Voltage transformers

Inductive voltage transformers are low capacity transformers in

which the primary and secondary voltage are proportional and in
phase. The primary and secondary windings are electrically isolated
from each other.

50 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

The following current and voltage detection devices can be used – – Device D: Zero sequence ring core transformer for ground
(see Fig. 7.11.3): fault detection below the panel (in the cable basement)

–– Device A: Ring core current transformer for fitting to the outer –– Device E: Optional bushing-type current transformer between
cone bushing the three position disconnect and circuit-breaker, located in a
sectionalizer and riser panel
– – Device B: Block-type transformer in the circuit-
breaker compartment – – Device F: Voltage transformer (outside the gas compartment
only, plug-in type)
– – Device C: Current transformer in the circuit breaker compart-
ment Current and voltage transformers are certifiable.

Fig. 7.11.3: Current and voltage detection devices

B
A

E
C

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 51

7.11.1 Ring core current transformer

Ring core current transformers (Fig. 7.11.1.1) are used in pan- winding. The cross-section of the connecting wires is AWG 13
els with outer cone connection systems. A distinction is made (larger cross-sections on request).
between two versions, depending on the rated current and
the panel width. Only when the ring core current transformer Panels with only one cable per phase can also be fitted on re-
has been slid onto a primary conductor - an outer cone bush- quest with ring core current transformers in the form of straight-
ing or a cable - has a functioning device created. through transformers for cables.

Ring core current transformers are located outside the gas

compartment and comprise the iron core and the secondary

Fig. 7.11.1.1: Ring core current transformer

1)
Depending on rated primary current

52 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

7.11.2 Block-type transformers

The block-type instrument transformer (Fig. 7.11.2.1) used in out-

going feeder panels with inner cone cable connection system for
rated currents up to 1200 A 1) and in various bus tie panels for rated
currents up to 2500 A.

The block-type transformer consists of cast resin in which the cor-

responding components are embedded. It is located in the gas
compartment, and is therefore protected from external influences.
The terminal board is easily accessible from the outside and lead-
sealable. The cross-section of the connecting wires is AWG 13
(larger cross-sections on request).
At low primary currents, the block-type transformer provides the
opportunity to lay the primary conductor around the iron core in
several windings (wound-primary transformer). This can significantly
increase the performance of the transformer.

When only current transformers are used, the device can contain up
to three current transformer cores in a 23.62 in wide panel and up to
five current transformer cores in an 31.50 in wide panel.

Fig. 7.11.2.1: Block-type transformer, device B

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 53

7.11.3 Current 7.11.4 Zero sequence ground-
transformers fault transformers

Outgoing feeder panels for currents > 1200 A are fitted with cur- Ground fault transformers (device D, Fig. 7.11.4.1) are special ring
rent transformers as shown in Fig. 7.11.3.1. These transformers are core transformers. As all the power cables in a panel are routed
located in the gas compartment and can accommodate up to five through the transformer, the opening in the transformer has to be
cores. correspondingly large. As a result of their size, ground fault trans-
The secondary wiring of the current transformer is routed out of the formers are installed in the cable basement below the panel.
gas compartment into the low voltage compartment via secondary
bushings below the circuit-breaker. The cross-section of the con-
necting wires is AWG 13 (larger cross-sections on request).

Fig. 7.11.3.1: Current transformer, device C Fig. 7.11.4.1: Zero sequence groundfault transformer, device D

54 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

7.11.5 Dimensioning of
current transformers
The stipulations and recommendations of IEC 61936, section 6.2.4.1 Further information for different protection systems
“Current transformers”, lEC / EN 60044-1 and lEC 60044-6 are to be
observed in the design of current transformers. The rated overcur- If the current transformers to be used in the network concerned
rent factor and burden of current transformer cores are to be select- (e.g. on the opposite side of the network) have already been speci-
ed in such a way that protection devices can function correctly and fied, early coordination of the switchgear configuration is advisable.
measuring systems are not damaged in the event of a shortcircuit. This requires, but is not limited to, the provision of data on the ratio,
rated capacity, accuracy class, and the resistance of the secondary
Protection purposes winding and wiring. Further configurations for the particular applica-
tion can then be requested.
Protection cores are logically operated at above rated current. The
function of the selected protection system is essentially determined
by the connected current transformer. The requirements to be
fulfilled by the current transformers for the selected protection or 7.11.6 Voltage transformers
combination device can be found in the documentation from the
protection equipment supplier. For an accurate switchgear proposal,
these current transformer data are to be provided with the product The voltage transformers are always located outside the gas com-
inquiry and then finally agreed by the operator and manufacturer in partments. They are of the plug-in type (plug size 2 to EN 50181
the order. and DIN 47637). In feeder panels and in integrated meterings with-
out isolating systems the voltage transformers can be dismantled for
The direct path to the right current transformers is via the technical test purposes.
documentation of the selected protection device. The current trans-
former requirements of the relay can be found there. Voltage transformers in metering panels can be isolated. Integrated
meterings can be equipped with an isolating device for the voltage
Measuring purposes transformers. Isolating devices include an earthing function for the
isolated voltage transformers. In integrated meterings isolator devic-
In order to protect measuring and metering devices from damage es for voltage transformers can be equipped with auxiliary switches.
in the case of a fault, they should go into saturation as early as
possible. The rated burden of the current transformer should be Voltage transformers in outgoing feeder panels of 23.62 in width are
approximately the same as the operating burden consisting of the suitable for rated voltages up to 34.5 kV (60 Hz).
measuring instrument and cable. Further details and designations
can be found in EN 60044-1. Primary fused voltage transformers are available on request.

Recommendations

In principle, we recommend a rated secondary current of 1 A. The

current transformer ratings for ABB protection devices are known. Fig. 7.11.6.1: Plug-in type voltage transformer, device G
The transformer data can be selected to suit the protection applica-
tion and the network parameters. However, if a third party devices
are to be connected, we recommend a review by our engineers at
an early stage. Taking account of the burdens and overload capaci-
ties, our experts can examine the entire current transformer require-
ments of the third party protection devices on request.

1)
Depending on rated primary current
Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 55
7.12 Protection and control units

ABB provides the right protection and automation solution for

every application.

Table 7.12.1 below provides an overview of the most important

protection devices with notes on their range of applications. Fur-
ther information can be obtained in the Internet (http://www.abb.
de/mediumvoltage) or from the responsible ABB contact for you.

Table 7.10.1: Application of protection and control units

Application Communication protocol

Bay control and measurement

Transformer protection
Unit designition

Feeder protection

Voltage regulation

IEC 60870-5-103
Motor protection

IEC 61850

DNP 3.0
Modbus
REF620 ● ● 1)
● ● ● ●
Main
REM620 2)
● ● 1)
● ● ● ●
protection
RET620 2)
● ● ● 1)
● ● ● ●
REF615 ●
Backup
REM615 ●
protection
RET615 ●

1)
For panels with single bus bar
2)
On request

56 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

7.13 Sulphur hexafluoride connectors (Fig. 7.14.1). The gas compartments of the individual
panels in a row are not connected together.

Each panel has gas filling connectors (Fig. 7.14.1 - see also section
Sulphur hexafluoride (chemical symbol SF6) is non-toxic, non-com- 6), through which the gas compartments can be filled with gas, for
bustible, chemically inactive gas with a high dielectric strength. instance in the case of repairs.

Its unique electrical and thermal properties have made the design The service pressure in the individual gas compartments is moni-
of new, more efficient switchgear possible. The change from con- tored by separate density sensors (temperature-compensated pres-
ventional insulation to the non-flammable, chemically inactive and sure sensors, Fig. 7.14.2). A shortfall below the insulation warning
non-toxic, heavy gas sulphur hexafluoride has led to significant level (17.40 PSI) in a gas compartment is indicated on the protection
savings in space and materials, and to greater safety for the installa- and control unit or by a signal lamp. Temporary operation of the
tions. Switchgear systems insulated with sulphur hexafluoride have panel at atmospheric pressure ( > 14.5 PSI) is in principle possible
become highly successful especially in applications where space if the SF6 content of the insulating gas is at least 95 % (exception:
is constricted and compact design is required. On account of their 17.40 PSI required for test voltages > 70/170 kV).
insensitivity to air-pollution, enclosed SF6 systems are also used in
the chemicals industry, in desert areas and at coastal locations. As an option, the thermal effects of an internal arc fault can be lim-
ited by an Ith protection function. For this purpose, the signal from an
SF6 has been used in HV-switchgear since 1960. additional switching contact for all the gas density sensors (thresh-
old 27.56 PSI) is logically linked to an overcurrent excitation system
and used to trip defined circuit-breakers. The logic operation is per-

7.14 Gas system formed by the combined protection and control unit, and reduces
the breaking time to only approx. 100 ms.
in the panels Leakage testing of the gas compartments during manufac-
turing process

SF6 is used as the insulating medium. The leakage rate of the gas compartments is determined by integral
leakage testing:
The gas compartments are designed as hermetically sealed pressure Inside a pressure test cabin, following evacuation of the gas com-
systems. As they are filled with SF6, constant ambient conditions are partments, the panel is filled with helium. The leakage rate of the
permanently ensured for the entire high voltage area of the panel. It gas compartments is determined by measurement of the proportion
is not necessary to top up the insulating gas during the expected of helium in the test cabin. The helium is then recovered as the gas
service life of the system. Under normal operating conditions, no compartments in the panel are evacuated again. Thereafter, the gas
inspections on the insulating gas are necessary. The insulating gas compartments are filled with insulating gas at the rated filling pres-
is maintenance-free. sure.
A successful leakage test is therefore the necessary condition for
The circuit-breaker compartment and the busbar compartment in filling the systems with insulating gas.
each panel are separate gas compartments with their own gas filling

Fig. 7.12.1: Gas filling connector Fig. 7.12.2: Density sensor

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 57

7.15 SF6 density sensor

Fig. 7.15.1 shows the function of the SF6 density sensor. Between Gas losses
the measuring chamber and a reference chamber there is a moving
mounting plate which operates electrical contacts. A loss of gas in the monitored gas compartment results in a drop
in pressure in the measuring volume and thus a movement of the
Temperature compensation mounting plate (to the left in Fig. 7.15.1). The contact for the pres-
sure loss signal is operated.
The pressure in the monitored gas compartment rises with increas-
ing temperature. However, the temperature in the reference chamber Two versions of SF 6 density sensors
and thus the pressure of the reference volume, increases to the
same extent. This does not lead to any movement of the mounting Two versions of the density sensors (Figs. 7.15.2 and 7.15.3) are
plate. used.

Self-supervision 1. A common indication for gas loss, wire breakage, defective plug
connection and defective pressure sensor for the reference volume.
A drop in pressure of the reference volume results in a movement of
the mounting plate (to the right in Fig. 7.15.1). The self-supervision 2. Separate indications for a) gas loss, wire breakage and defective
contact is operated. As the system is designed as a closed circuit, plug connection, and b) defective pressure sensor for the reference
both, wire breakages and defective plug and terminal connections volume, wire breakage and defective plug connection.
are signaled as faults. -

Fig. 7.15.1: Schematic diagram of the function of the SF6 density sensor

1 2 4 6

5 3
1 Monitored gas compartment
2 Measuring volume
3 Enclosed volume for temperature compensation (reference volume)
4 Mounting plate moved by interaction of forces (pressure of measuring volume
against pressure of reference volume)
5 Contact for self-supervision (p > 21.76 PSI)
6 Contact for gas loss (p < 17.40 PSI)

Fig. 7.15.2: Version 1 of the SF6 density sensor Fig. 7.15.3: Version 2 of the SF6 density sensor

> 21.76 PSI

a) Self-supervision

< 17.40 PSI < 21.76 PSI

> 21.76 PSI
< 17.40 PSI
> 17.40 PSI
< 21.76 PSI b) Gas loss
> 17.40 PSI
Gas loss Self-supervision
58 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05
7.16 Plenum systems 7.17 Surface treatment

In the unlikely event of an internal arc fault in a gas compartment, The gas-tight enclosures of the panels consist of stainless steel
the relevant pressure relief disk opens. sheets. The cable termination compartments, the low voltage com-
partments, the covered plenums at the rear and the plenums on
There is an opportunity to discharge pressure via plenums; either via the busbar compartments are manufactured from galvanised sheet
an absorber into the switchgear room or via extended plenums to steel; therefore surface treatment is not required in these cases.
the outside of the building.
The covers at the rear of the panels and the end covers at the sides
Pressure relief via plenums and absorbers into the switch- of the switchgear system can be supplied galvanized or alternatively
room (Fig. 7.16.1) coated with a powder stove enamel in ANSI 61 (light grey).

Discharge of pressure from the circuit-breaker compartments and Other colours for the painted components are available on request.
cable termination compartments is effected via the rear plenum, and
then through a plenum designed as a broad end cover at the side
of the switchgear block into the upper duct. Discharge of pressure 8 Range of panels
from the busbar compartments is directed into the upper plenum.
The pressure surge is cooled in the (plasma) absorber located above
the upper duct and released into the switchgear room.
The following panel variants are available in single and double busbar
Pressure relief to the outside via plenums and absorbers versions:
(Fig. 7.16.2)
–– Incoming and outgoing feeder panels
Discharge of the pressure takes place in principle in the same way –– Cable termination panels
as pressure relief via absorbers. The pressure is discharged into the –– Sectionalizer panels
open air by means of a customized plenum extension leading to an –– Metering panels
opening in the outside wall of the switchroom –– Customized panel versions

The building wall through which the plenum is led to the outside Please note: The stated panel depths refer to a low voltage com-
must not contain any combustible materials. The area outside below partment depth of 19.69 in.
the pressure relief discharge opening is to be fenced off and marked
with warning signs. There must not be any accessible areas such
as stairs or walkways above the pressure relief opening. Storage of
combustible materials in the areas mentioned is prohibited. The di-
mensions of the hazardous area can be found in the section entitled
“Hazardous area for pressure relief to the outside”.

Fig. 7.16.1: Plenum (discharging into the switchroom) Fig. 7.16.2: Plenum (discharging to the outside)

Plenums Absorber

109.65“ 1)

102.36“ 1)

90.55“

1)
Without taking account of voltage transformers or heat sinks on busbar compartments

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 59

8.1 Panels in single busbar design

8.1.1 Feeder panels

8.1.1.1 Incoming and outgoing feeder panels

with inner cone cable plug system

Fig. 8.1.1.1.1: Feeder panel 1200 A with block-type transformer and two Fig. 8.1.1.1.2: Feeder panel 2000 A with current and voltage transformer
cable per phase and three cables per phase

90.55”
90.55”

73.23” 73.23”

Fig. 8.1.1.1.3: Feeder panel 2500 A (width 33.07 in) with current and volt- Fig. 8.1.1.1.4: Feeder panel 3000 A (width 33.07 in) with current and
age transformer and four cables per phase voltage transformer and four cables per phase

113”
90.55”

87” 87”

60 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

 Insulating cable-
blanking plug

Voltage transformer

Surge arrester Inner cone socket 2nd coupling electrode

1..3 x Size 2 or for capacitive voltage
1..4 x Size 3 indicator in the door

Table 8.1.1.1.1: Overview of variants of incoming and outgoing feeder panels with inner cone termination system
U r: ... 38 kV (test voltages 70 kV / 150 kV)
I r: ... 800 A (1 x size 2)
Panel width 23.62 in:
I r: ... 1200 A (2 ... 3 x size 2 and 1 ... 2 x size 3) 1)

I p: ... 40 kA
U r: ... 38 kV
I r: ... 1200 A (1 ... 3 x size 3) 1)
Panel width 31.50 in:
I r: ... 2000 A (3 ... 4 x size 3)
I p: ... 40 kA

U r: ... 38 kV
Panel width 33.07 in: I r: ... 3000 A (3 ... 4 x size 3)
I p: ... 40 kA

1)
Three sockets per phase only in conjunction with current transformers to Fig. 7.11.3.1

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 61

8.1.1.2 Incoming and outgoing feeder panels
with outer cone cable plug system
Fig. 8.1.1.2.1: Feeder panel with outer cone, 1200 A

90.55”
73.23”

Voltage
transformer,
isolatable and
plugged

maximum 3 cables
per phase

maximum 3 cables per phase +

surge arrester

Table 8.1.1.2.1: Overview of variants of feeder panels with outer cone termination system
U r: ... 38 kV (test voltages 70 kV / 150 kV)
Panel width 23.62 in: I r: ... 1200 A
I p: ... 40 kA

62 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.1.1.3 Panels with operating currents over 3000 A
and up to 4000 A

Incoming feeder panels ( Ir up to 4000 A, Fig. 8.1.1.3.1) Outgoing feeder panels within a block with parallel busbars
( I r up to 2500 A, Fig. 8.1.1.3.2)
In this version, the busbars of two double busbar panels of 31.75 in
width each are connected in parallel by the disconnects. These two The feeder current coming from the two parallel busbars is fed via
panels thus perform the function of a single busbar panel for cur- the two disconnects and the circuit-breaker to the cable sockets.
rents up to 4000 A. This double busbar panel thus performs the function of a single bus-
bar panel with one busbar for currents up to 4000 A.
The operating current coming from the cable sockets is fed via the
two circuit-breakers and the four disconnects in the two panels to Display of the switch positions and control of the switching devices
the two parallel busbars. are effected by the human-machine interface of the protection and
control unit. The function of the panel as a single busbar panel is
Display of the switch positions and control of the switching devices shown on the display of this human-machine interface.
are effected at the master control unit (only one of the two human-
machine interfaces is used for display and control). The function of The grounding switch is operated while the pure disconnect remains
the two panels as a single busbar panel is shown on the display of in the OFF position.
this human-machine interface.
The variants for this panel version can be found in section 8.2.1.
The two grounding switches are operated while the pure discon-
nects remain in the OFF position.

Fig. 8.1.1.3.1: Example of an incoming feeder in single busbar design with

Ir = 4000 A, consisting of two panels with a width of 31.75 in each.
90.55”

87”

Fig. 8.1.1.3.2: Example of an outgoing feeder for parallel busbars

90.55”

73.23”

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 63

8.1.1.4 Cable termination panels
Fig. 8.1.1.4.1: Cable termination panel 2000 A Fig. 8.1.1.4.2: Cable termination panel 1200 A with voltage transformer at
the cable

90.55”
90.55”

73.23” 73.23”

Insulating cable
blanking plug

Voltage transformer

Surge arrester
Inner cone socket 2nd coupling electrode
2 x size 2 or 3 or for capacitive voltage
3 or 4 x size 3 indicator in the door

Table 8.1.1.4.1: Overview of variants for cable termination panels

U r: ... 38 kV (test voltages 70 kV / 150 kV)
Panel width 23.62 in: I r: ... 1200 A (2 x size 2 or 3)
I p: ... 40 kA

U r: ... 38 kV
Panel width 31.50 in: I r: ... 2000 A (3 or 4 x size 3)
I p: ... 40 kA
U r: ... 38 kV
Panel width 33.07 in: I r: ... 3000 A (3 or 4 x size 3)
I p: ... 40 kA

64 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.1.2 Busbar sectionalizer panels

8.1.2.1 Sectionalizer within a switchgear block

The sectionalizer panel contains the circuit-breaker, two three po- In addition, sectionalizers can be fitted with current transformers
sition disconnects and a block-type current transformer. between the circuit-breaker and the three position disconnects. In
the sectionalizer panel, the position of the busbar changes from
front to rear or vice versa.

Fig. 8.1.2.1.1: Sectionalizer panel 1200 A with block-type CT Fig. 8.1.2.1.2: Sectionalizer panel 2000 A with current transformers
90.55”

90.55”
73.23” 73.23”

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 65

Fig. 8.1.2.1.1.3: Sectionaliser panel 2500 A (width 840 mm) with Fig. 8.1.2.1.1.3: Sectionaliser panel 3000 A (width 840 mm) with
current transformers current transformers

2870
2300

2210 2210

Bushing-type CT

Block-type CT

Table 8.1.2.1.1: Overview of variants for sectionalizer panels

U r: ... 38 kV (test voltages 70 kV / 150 kV) Two variants:

Panel width 23.62 in: I r: ... 1200 A - Without transformers
I p: ... 40 kA - Block-type CT

Four variants:
U r: ... 38 kV - Without transformers
Panel width 31.50 in: I r: ... 1200 A or ...2000 A - Block-type CT
I p: ... 40 kA - Bushing-type CT
- Block-type CT + Bushing-type CT

... 38 kV
U r: 2 variants:
... 2500 A or
Panel width 33.07 in: I r: - Block-type CT or sensor
... 3000 A
I p: - Block-type CT or sensor + Bushing-type CT
... 40 kA

66 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.1.2.2 Sectionalizer using cables
(connection of two system blocks)

Fig. 8.1.2.2.1: Sectionalizer using cables (connection of two system blocks)

90.55”

73.23” 73.23”

The overview of variants can be found in sections

8.1.1.1 (feeder panels) and 8.1.1.3 (cable termination
panels).

8.1.3 Metering Panels

The following methods of busbar metering are available: The integrated busbar metering system with plugged-in and
isolatable voltage transformers
The metering panels
Above the busbar compartment of an outgoing feeder panel with
The metering panel contains a three position disconnect for isolating integrated busbar metering, there are sockets for plug-in voltage
the voltage transformers. transformers and a series isolating device with optional auxiliary
switches. As a snap-action operating mechanism is used, opera-
Integrated metering with plugged-in voltage transformers tion of the isolating device is even possible when the busbar is live.
The following limitations must be taken into account in the planning
Sockets for plug-in voltage transformers are provided above the when an integrated busbar metering system with isolatable voltage
busbar compartment in outgoing feeder panels with integrated transformers is used:
measurement. The following limitations to the use of integrated
measurement must be taken into account at the planning stage: – – For 31.75 in wide panels including.
–– For panels without cooling systems.
–– For 31.75 in wide panels. –– Integrated metering in sectionalizer panels is possible with
– – For panels without cooling systems. pressure relief at both sides.
– – Integrated metering in sectionalizer panels is possible with –– The distance from the end of the system with plenum must
pressure relief at both sides. be three panel widths.
– – The distance from the end of the system with plenum must –– The ceiling height must be at least 137.80 in.
be three panel widths. –– The transport unit height is 91.73 in.
– – The ceiling height must be at least 118.11 in. –– Gas work at site is necessary.
– – The transport unit height is 90.55 in.

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 67

Fig. 8.1.3.1: Metering panel (Example: Measurement of the front busbar),
panel depth 31.50 in, with three-position disconnect

90.55”

73.23”

Fig. 8.1.3.2: Integrated busbar metering system with plug-in voltage trans- Fig. 8.1.3.3: Integrated busbar metering system with plug-in and isolatable
formers (example for measurement of the rear busbar) voltage transformers for max. test voltages of 85 kV / 185 kV (example for
measurement of the front busbar)

123.23”
103.35”

73.23”
73.23”

Table 8.1.3.1: Overview of variants of metering panels

Metering panel with three position disconnect

Integrated busbar measurement
Panel width 31.50 in: U r: ... 38 kV - Voltage transformers plugged in (Fig. 8.1.3.2)
- Voltage transformers plugged in and isolatable (Fig. 8.1.3.3) (test voltages
70 kV / 150 kV)

68 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.2 Panels in double busbar design

8.2.1 Feeder panels

8.2.1.1 Incoming and outgoing feeder panels

with inner cone cable plug system

Fig. 8.2.1.1.1: Feeder panel 1200 A with block-type transformer or sensor Fig. 8.2.1.1.2: Feeder panel 2500 A with current and voltage transformer
and two cables per phase and three cables per phase
90.55”

90.55”
73.23” 73.23”

Fig. 8.2.1.1.3: Feeder panel 2500 A (width 33.07 in) with current and volt- Fig. 8.2.1.1.4: Feeder panel 3000 A (width 33.07 in) with current and volt-
age transformer and four cables per phase age transformer and four cables per phase 113”
90.55”

87” 87”

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 69

 Insulating cable
blanking plug

Voltage transformer

Surge arrester
Inner cone socket 2nd coupling electrode
1..3 x size 2 or for capacitive voltage
1..4 x size 3 indicator in the door

Table 8.1.1.1.1: Overview of variants of incoming and outgoing feeder panels with inner cone termination system
U r: ... 38 kV (test voltages 70 kV / 150 kV)
I r: ... 800 A (1 x size 2)
Panel width 23.62 in:
I r: ... 1200 A (2 ... 3 x size 2 and 1 ... 2 x size 3) 1)

I p: ... 40 kA
U r: ... 38 kV
I r: ... 1200 A (1 ... 3 x size 3) 1)
Panel width 31.50 in:
I r: ... 2000 A (3 ... 4 x size 3)
I p: ... 40 kA

U r: ... 38 kV
Panel width 33.07 in: I r: ... 2500 A, ... 3000 A (4 x size 3)
I p: ... 40 kA

1)
Three sockets per phase only in conjunction with current transformers to Fig. 7.11.3.1

70 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.2.1.2 Incoming and outgoing feeder panels
with outer cone cable plug system
Fig. 8.2.1.2.1: Feeder panel with outer cone, 1200 A

90.55”
73.23”

Voltage
transformer,
isolatable and
plugged

maximum 3 cables
per phase

maximum 3 cables per phase +

surge arrester

Table 8.2.1.2.1: Overview of variants of feeder panels with outer cone termination system
U r: ... 38 kV
Panel width 23.62 in: I r: ... 1200 A
I p: ... 40 kA

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 71

8.2.1.3 Cable termination panels

Fig. 8.2.1.3.1: Cable termination panel 1200 A (Example with continuous Fig. 8.2.1.3.2: Cable termination panel 2000 A (Example with continuous
busbar at the front) busbar at the rear and voltage transformer on the outgoing feeder)

90.55”
90.55”

73.23” 73.23”

or

Insulating cable
blanking plug

Voltage transformer

Surge arrester Inner cone socket 2nd coupling electrode

2 x size 2 or 3 or for capacitive voltage
3 or 4 x size 3 indicator in the door

Table 8.2.1.3.1: Overview of variants for cable termination panels

U r: ... 38 kV (test voltages 70 kV / 150 kV)
Panel width 23.62 in: I r: ... 1200 A (2 x size 2 or 3)
I p: ... 40 kA

U r: ... 38 kV
Panel width 31.50 in: I r: ... 2000 A (3 or 4 x size 3)
I p: ... 40 kA
U r: ... 38 kV
Panel width 33.07 in: I r: ... 2500 A, ... 3000 A (4 x size 3)
I p: ... 40 kA

72 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.2.2 Coupling panels

8.2.2.1 Sectionalizer within a switchgear block

Two panels are required for a complete busbar sectionalizer. The

sectionalizer panel contains the circuit-breaker and a three position
disconnect. The riser panel contains only a three position discon-
nect. Installation variants “sectionalizer left – riser right” and vice
versa are possible.

Fig. 8.2.2.1.1: Sectionalizer panel for the front busbar, 2000 A Fig. 8.2.2.1.2: Riser panel for the front busbar, 2000 A
90.55”

90.55”
73.23” 73.23”

Bushing-type CT
(only in panel width 31.50 in)

Block-type CT

Table 8.2.2.1.1: Overview of variants for couplings within a switchgear block

U r: ... 38 kV (test voltages 70 kV / 150 kV)
Sectionalizer panel: without CTs
Panel width 23.62 in: I r: ... 1200 A
Riser panel: with block-type CT
I p: ... 40 kA
Sectionalizer panel: without CTs
U r: ... 38 kV or with bushing-type CTs
Panel width 31.50 in: I r: ... 2000 A Riser panel: without CTs,
I p: ... 40 kA with block-type CTor
block-type CT+ bushing-type CT
U r: ... 38 kV
Sectionaliser panel: without CTs
Panel width 33.07 in: I r: ... 2500 A
Riser panel: with block-type CT/
I p: ... 40 kA

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 73

8.2.2.2 Sectionalizer using cables (connection of two system
blocks)

Two panels are required for a complete busbar sectionalizer. The

sectionalizer panel contains the circuit-breaker and a three position
disconnect. The riser panel contains only a three position discon-
nect.

The overview of variants can be found in sections 8.2.1.1 (feeder

panels) and 8.2.1.2 (cable termination panels).

Fig. 8.2.2.2.1: Connection of two system blocks using cables

(bus sectionalizer), 1200 A
90.55”

73.23” 73.23”

74 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.2.2.3 Bus coupler

Fig. 8.2.2.3.1: Bus coupler, 1200 A with block-type CTs Fig. 8.2.2.3.2: Bus coupler, 2000 A, with CTs between the circuit-breaker
and the three position disconnects

90.55”

90.55”
73.23” 73.23”

Fig. 8.2.2.3.3: Bus coupler, 2500 A (width 33.07 in) with block-type CTs or Fig. 8.2.2.3.4: Bus coupler, 3000 A (width 33.07 in) with block-type CTs or
sensors sensors

2870
2300

2210 2210

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 75

 Bushing-type CT

Block-type CT

Table 8.2.2.3.1: Overview of variants for bus coupler panels

U r: ... 38 kV (test voltages 70 kV / 150 kV) Two variants:

Panel width 23.62 in: I r: ... 1200 A - Without transformers
I p: ... 40 kA - Block-type CT

Four variants:
U r: ... 38 kV - Without transformers
Panel width 31.50 in: I r: ... 1200 A or ...2000 A - Block-type CT
I p: ... 40 kA - Bushing-type CT
- Block-type CT + Bushing-type CT

... 38 kV
U r: 2 variants:
... 2500 A or
Panel width 840 mm: I r: - Block-type CT or sensor
... 3000 A
I p: - Block-type CT or sensor + Bushing-type CT
... 40 kA

76 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.2.3 Bus sectionalizer

Fig. 8.2.3.1: Bus coupler without circuit-breaker 2000 A

Section A-A

90.55”
A

73.23”

Table 8.2.3.1: Overview of variants for the bus coupler panels without circuit-breaker

U r: ...38 kV
I r: ...2000 A or
Panel width 31.50 in:
I r: ...2500 A (cooling only with heat sinks)
I p: ...40 kA

8.2.4 Metering Panels

The following methods of busbar metering are available: The integrated busbar metering system with plugged-in and isolat-
able voltage transformers
The metering panels
Above the busbar compartment of an outgoing feeder panel with
The metering panel contains three position disconnects for isolating integrated busbar metering, there are sockets for plug-in voltage
the voltage transformers. transformers and a series isolating device with optional auxiliary
switches. As a snap-action operating mechanism is used, opera-
Integrated metering with plugged-in voltage transformers tion of the isolating device is even possible when the busbar is live.
The following limitations must be taken into account in the planning
Sockets for plug-in voltage transformers are provided above the when an integrated busbar metering system with isolatable voltage
busbar compartment in outgoing feeder panels with integrated transformers is used:
measurement. The following limitations to the use of integrated
measurement must be taken into account at the planning stage: – – For 31.50 in wide panels.
–– For panels without cooling systems.
–– For 31.50 in wide panels. –– The distance from the end of the system must be three panel
– – For panels without cooling systems. widths to the side plenum.
– – The distance from the end of the system with plenum must –– The ceiling height must be at least 137.80 in. The transport
be three panel widths. unit height is 91.73 in.
– – The ceiling height must be at least 118.11 in. –– Gas work at site is necessary.
– – The transport unit height is 90.55 in.

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 77

Fig. 8.1.3.1: Metering panel, panel depth 31.50 in, with three-position
disconnect

90.55”

73.23”

Fig. 8.2.4.2: : Integrated busbar metering system with plug-in voltage Fig. 8.2.4.3: Integrated busbar metering system with plug-in and isolatable
transformers (example for measurement of the rear busbar) voltage transformers for max. test voltages of 85 kV / 185 kV
103.35”

123.23”

73.23”

73.23”

Table 8.1.4.1: Overview of variants of metering panels

Metering panel with three position disconnect
Integrated busbar measurement
Panel width 31.50 in: U r: ... 38 kV - Voltage transformers plugged in (Fig. 8.1.3.2)
- Voltage transformers plugged in and isolatable (Fig. 8.1.3.3) (test voltages
70 kV / 150 kV)

78 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.3 Design to order panels

The panel variants presented in sections 8.1 to 8.2 are standard and implement technical proposals to fulfil your requirements.
panels. Should you require panel variants which are not listed there IAC qualification according to IEC 62271-200 of special panels
when planning your switchgear, please contact the ABB office re- may not be possible in all cases.
sponsible for your area. Our design team will be pleased to submit

Fig. 8.3.1: Termination panels for fully insulated bars

(Example: connection of two system blocks, 38 kV, 40 kA, 2000 A)
90.55”

73.23” 73.23”

Fig. 8.3.2: Panel for capacitor switching (38 kV, 40 kA, 800 A) Fig. 8.3.3: Feeder panel 2000 A with current transformers at both sides of
the circuit-breaker, bus bar at front or rear

90.55”
90.55”

73.23” 87”

Fig. 8.3.4: Feeder panel 2500 A with current transformers at both sides of Fig. 8.3.5: Feeder panel 2000 A with current transformers at both sides of
the circuit-breaker, cooling by heat sinks and forced cooling, bus bar at the circuit-breaker
front or rear
112.99”

90.55”

87”

87”
Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 79
8.4 Panels for rated currents The cooling facilities required at

> 2000 A – – higher ambient air temperatures and/or

– – higher rated currents

At a maximum ambient air temperature of 104 °F (40 °C), a maxi- may deviate from the cooling methods stated above. Such special
mum 24 hour average ambient air temperature of 95 °F (35 °C) cases can be investigated on request.
and a rated frequency of 60 Hz (standard operating conditions),
no cooling facilities are required for a rated current of up to
2000 A.

For higher rated currents, depending on the application, the fol- 8.4.1 Feeder Panels for rat-
lowing cooling measures are required:
ed currents > 2000 A
B, C: Heat sink on the busbar compartment
B1, C1: Heat sink on the busbar compartment within the The panel width of feeder panels for a rated current > 2000 A is
pressure relief duct generally 33.07 in. For rated currents up to 2500 A (fig. 8.4.1.1), a
D: Heat sink at the circuit-breaker compartment heat sink is used at the circuit-breaker compartment. With a rated
E: Radial flow fan below the heat sink D current of up to 3000 A (fig. 8.4.1.2) heat sinks on the busbar
F: Radial flow fan at the heat sink B and/or C compartments and fans are also used.

Fig. 8.4.1.1: Cooling of feeder panels for a feeder current up to 2500 A

D D D

Double busbar Single busbar at the front Single busbar at the rear

Fig. 8.4.1.2: Cooling of feeder panels for a feeder current up to 3000 A

C F B F B C F

D D D

E E E

Double busbar Single busbar at the front Single busbar at the rear

80 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

8.4.2 Busbar current > 2500 A

With a busbar current of up to 3000 A, heat sinks on the busbar

compartments are required on each panel (fig. 8.4.2.1). Up to a
busbar current of maximum 2800 A, factory-installed heat sinks
can be used on the busbar compartments. These heat sinks are
located inside the pressure relief channels (figure 8.4.2.2).

Fig. 8.4.2.1: Cooling with a busbar current up to 3000 A

C B B C

Double busbar Single busbar at the front Single busbar at the rear

Fig. 8.4.2.2: Cooling with a busbar current up to 2800 A

C1 B1 B1 C1

Double busbar Single busbar at the front Single busbar at the rear

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 81

8.4.3 Sectionalizers and 9 Arrangement of panels
bus couplers for a with cooling facilities and
rated current > 2000 A panels with integrated bus-
bar measurement
Coupling panels on double busbar systems up to 2500 A are
equipped with a heat sink behind the circuit-breaker compart- The following is to be observed when installing panels with cooling
ment as well as heat sinks C1 and B1 (fig. 8.4.3.1). For a rated facilities and panels with busbar measurement:
current of a maximum of 3000 A, sectionalizers are available for
single busbar systems and bus coupler panels for double busbar –– Panels with heat sinks (B or C, section 8.4) or with busbar
systems. Heat sinks behind the busbar compartment and fans are measurement can be positioned from the fourth panel at the
used (fig. 8.4.3.2). absorber end onwards (section 7.16). (The distance from the
absorber must be at least one panel width.)

Fig. 8.4.3.1: Cooling with sectionalizer or bus coupler panels with a

– – Coupling panels with a width of 840 mm which are not
busbar current up to 2500 A equipped with heat sinks can be positioned from the third
panel onwards.

Further conditions for the use of integrated busbar measurement

C1 B1
can be found in sections 8.1.3, 8.2.4.

Fig. 8.4.3.2: Cooling with sectionalizer or bus coupler panels with a

busbar current up to 3000 A

C F B

82 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

10 Busbar grounding Outer cone systems

The connection of a grounding and short circuiting device to the main

grounding bar is effected via the rear side of the last cable connec-
This section outlines the ways in which the busbar can be grounded. tors. In the case of a grounded feeder panel the voltage-proof termi-
The details of these operations can be found in the relevant instruc- nations of the cable connector are exchanged with current-carrying
tion manuals. terminations (Fig 10.1.2). Grounding of the busbar is affected via the
closed feeder disconnect and subsequently closed circuit-breaker

10.1 Grounding the busbar by (Fig. 10.1.3).

means of a grounding
10.2 Grounding the busbar
and short-circuiting
by means of a
device
sectionalizer and riser
Inner cone systems or bus coupler
With the outgoing feeder grounded, the test sockets or cable sock-
ets can be fitted with a grounding and short circuiting device (Fig. Grounding is affected by the three position disconnect and the
7.9.5 and Fig. 10.1.1) connected to the main grounding bar. Ground- circuit-breaker in a bus coupler (see Fig. 10.2.1) or bus sectionalizer
ing of the busbar is affected via the closed feeder disconnect and (see Fig. 10.2.2).
subsequently closed circuit-breaker (Fig. 10.1.3).

Fig. 10.1.1: Connecting a grounding and short-circuiting device to a feeder Fig. 10.1.2: Connecting a grounding and short-circuiting device to a feeder in
in case of an inner cone system (only one phase shown) case of an outer cone system (only one phase shown)

Current carrying termina-

tion with grounding ball stud
Special plug of a
grounding and short- Outer cone (built-in the panel)
circuiting device

Terminal

Test socket or
cable socket
(built-in the panel)

Flange of the ground-

ing and short-
circuiting device
Cable connector

Grounding cable
of a three-phase
grounding and short- Grounding cable of a
circuiting device three-phase grounding
and short-circuiting device

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 83

Fig. 10.1.3: Busbar grounding by grounding and short-circuiting device, double busbar

ON

ON

Grounding and short-

circuiting device

Fig. 10.2.1: Busbar grounding by bus coupler, double busbar

ON

ON

Grounding
Switch: ON

Fig. 10.2.2: Busbar grounding by sectionalizer, single busbar

ON

ON

Grounding
Switch: ON

84 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

11 Building planning

11.1 Site requirements

The switchgear can be installed Ventilation of the switchroom

–– on a concrete floor, or Lateral ventilation of the switchroom is recommended.

– – on a raised false floor.
Service conditions
Concrete floor
The service conditions according to IEC 62271-1 for indoor switch-
A concrete floor requires a foundation frame set into the floor top- gear are to be ensured.
ping. The evenness and straightness tolerances for the base of the
switchgear system are ensured by the foundation frame. The foun- The ambient air is not significantly polluted by dust, smoke, corrosive
dation frame can be supplied by ABB. and/or flammable gases, vapors or salt.
Floor openings for power and control cables can be configured as
cutouts for each panel, as continuous cutouts (one each for power The conditions of humidity are as follows:
and control cables) or as drill holes. The floor openings are to be
free from eddy currents (drill holes for power cables three phase – – – the average value of the relative humidity, measures over a
without ridges in between). period of 24 hours, does not exceed 95 %:
–– the average value of the water vapor pressure, over a period
False floor of 24 hours, does not exceed 0.32 PSI;
–– the average value of the relative humidity, over a period of
Below the switchgear, the supporting sections of the raised false one month, does not exceed 90 %;
floor serve as a base for the panels. A foundation frame is not as a –– the average value of the water vapor pressure, over a period
rule necessary. of one month, does not exceed 0.26 PSI.

Pressure stress on the switchroom Heaters are to be fitted in the low voltage compartments to pre-
clude condensation phenomena (outside the gas-tight enclosures)
With pressure relief inside the switchroom, a pressure rise in the resulting from major rapid temperature fluctuations and correspond-
room can be expected in the highly unlikely event of an internal arc ing humidity. The specified temperature conditions according to
fault. This is to be taken into account when planning the building. IEC 62271-1 (> 23 °F (-5 °C)) are also to be ensured by means of
The pressure rise can be calculated by ABB on request. Pressure room heating.
relief openings in the switchroom may be necessary.

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 85

11.2 Space required

Planning of the space required for the switchgear must take account of the
− − escape routes,
− − hazardous area in case of pressure relief to the outside,
− − the possibility of inserting panels into an existing row,
− − the boundary conditions for IAC qualification, and
– – space required for dismantling and assembly of voltage transformers.

Fig. 11.2.1: Example of a single row installation (Top view, dimensions in inches)

1.97 1) 9.84 2) > 31.50 5)

> 31.50 5)

6)
73.23 6)
panel depth
> Maximum

+ 11.81 4)

6)
3)

> 3.94
> Panel width + 8
Fig. 11.2.2: Example of a double row installation (Top view, dimensions in inches)

1.97 1) 9.84 2)
> 31.50 5)

6)
73.23 7)

> panel width + 8

panel depth
> maximum

+ 11.81 4)

6) 3)
73.23 7)
> 31.50 5)

6)

> 3.94 > 31.50 5)

1)
End cover
2)
Lateral plenum
3)
Door height: > 90.55 in (with integrated measurement: > 98.43 in, with heat sinks mounted on a busbar compartment: 125.98 in).
4)
Recommended dimension taking account of the insertion of panels into an existing row (can possibly be reduced as stated in section 11.3).
5)
Recommended dimension; can be reduced under certain circumstances as stated in section 11.3.
6)
Recommendable: 20 in, observe the notes on escape routes in section 11.3.
7)
With heat sinks at the circuit-breaker compartment: 87 in.

86 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

11.3 Minimum aisle widths and emergency exits

The aisle width in front of the switchgear is to be planned with atten- escape routes. ... Exits shall be arranged so that the length of the
tion to the need to remove panels from or insert panels into existing escape route within the room ... does not exceed … 65.62 ft. ... If
rows, and to the requirements of the relevant standards (see IEC an operating aisle does not exceed 32.81 ft, one exit is enough.
61936 and IEC 62271-200). The minimum and recommended mini- An exit or emergency possibilities shall be provided at both ends
mum aisle widths can be found in tables below. of the escape route if its length exceeds 32.81 ft. ... The minimum
height of an emergency door [possibly the 2nd door] shall be 78.74
“Aisles shall be at least 31.50 in wide. ... Space for evacuation shall in [clear height] and the minimum clear opening 29.53 in.” 1)
always be at least 19.69 in, even when removable parts or open
doors, which are blocked in the direction of escape, intrude into the

Table 11.3.1: Restrictive conditions on minimizing the aisle widths in front of the switchgear

Minimum aisle width Recommended aisle width Aisle width required for
(Doors close in the direction taking no account of remov- removal and insertion of
of the escape route) al or insertion of panels panels

[in] [in] [in]

Panel block consisting exclusively of

> 31.50 > 43.31
panels of 23.62 in width
> maximum panel depth
Single row installation
+ 11.81
Panel block with at least one panel of
> 39.37 > 51.18
31.50 in or 33.07 in width

Minimum aisle width Recommended aisle width Aisle width required for
taking no account of remov- removal and insertion of
al or insertion of panels panels

[in] [in] [in]

Panel block consisting exclusively of

Double row panels of 23.62 in > 55.12 > 66.93
installation width > maximum panel depth
(with operator aisle be-
+ 11.81
tween the system blocks) Panel block with at least one panel of
> 70.87 > 82.68
31.50 in or 33.07 in width

1)
IEC 91936

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 87

Installation and maintenance areas behind and to the
sides of the switchgear

Table 11.3.2 shows the required distances to walls behind and to

the side of the switchgear.
Take notice of the downgrading of the internal arc classification if
distances are minimized.

Table 11.3.2: IAC qualification on reduction of the wall distance behind the switchgear and the side wall distance

Wall distance behind Wall distance to the side of the IAC qualification when a pressure IAC qualification when a pressure
the switchgear switchgear (at one or both ends of the relief duct discharging into relief duct discharging to
switchgear) the switchgear room is used the outside is used
[in] [in]

> 31.50 > 31.50 AFLR

> 23.62 1)
> 31.50 AFL
AFLR
> 31.50 > 19.69 AFR
> 23.62 1)
> 19.69 AF

11.4 Minimum room heights

Table 11.4.1: Minimum room heights

Pressure relief into the Pressure relief to the outside Integrated metering on at Integrated metering with Tall heat sink on at least one
switchgear room least one panel plug-in, isolatable voltage panel
(absorber) transformers on at least one
panel

[in] [in] [in] [in] [in]

> 110.24 2)
> 118.11 > 137.80 > 125.98

1)
Reducing to at least 19.69 in on request
2)
According to IEC 62271-200: IAC - qualification AFLR

88 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

11.5 Hazardous area for pressure relief to the outside

In the case of an internal arc fault, hot gases can suddenly

emerge from the outlet of the plenum. The area around the outlet
of a plenum for relief to the outside constitutes a hazardous area
which must be fenced off by the switchgear operator to prevent
persons from entering that area.
The size of the hazardous area depends on the level of the ex-
pected short-circuit current. Please consult Fig. 11.5.1 and table
11.5.1 for the dimensions of the hazardous area.

Table 11.5.1: Dimensions of the hazardous area

Short-circuit current A (distance to the side) R (distance to the front) H (distance to the top)
[kA] [ft] [ft] [ft]
20 / 25 3.28 6.56 6.56
31.5 / 40 4.92 8.20 8.20

Fig. 11.5.1: Dimensions of the hazardous area for pressure relief to the
outside

Hazardous area

Outlet of the ple- View A

num in the outer
wall of the switch- A A
gear room

H
R

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 89

11.6 Floor openings and cable axes

Fig. 11.6.1: Feeder Panel with block-type CT, Fig. 11.6.2: Feeder Panel with block-type CT,
panel width 23.62 in, dimensions in inches panel width 31.50 in, dimensions in inches

11.81 15.75

5.91 5.91 8.27 8.27

Outlines of the
panel

Opening for primary

cables

Primary cables

73.23
73.23

13.78

13.78
7.28

7.28
7.48 5.12

5.12 “
25.91
25.91

7.48
Opening for sec-
10.43

10.43
ondary cables

3.35 16.93
3.35 24.80
23.62
31.50

90 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

Fig. 11.6.3: Feeder panel, Panel width 31.50 in, Fig 11.6.4: Feeder panel, panel width 33.07 in,
dimensions in inches dimensions in inches
16.54
15.75
8.27 8.27
8.27 8.27
73.23

3 x 6.10

24.61

3 x 6.10

24.61
87
7.48 5.12
26.18

7.48 5.12
10.43

26.18

10.43
3.35 24.80

31.50
4.13 24.80

33.07
Fig. 11.6.5: Panel for capacitor switching ZX2-C,
dimensions in inches
15.75
8.27 8.27
24.61
6.10
73.23

12.01
38.39

7.48
10.43

3.35 24.80

1.57 28.35

31.50

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 91

Fig. 11.6.6: Panel with outer cone cable plug system, panel width 23.62 in, Fig. 11.6.7: Panel with current transformers at both sides of the circuit-
dimensions in inches breaker, dimensions in inches

15.75
11.81
Cable axes as 8.27 8.27
7.48 7.48
per number and
type of plug
connectors
13.78

20.87
Axis of test
socket

86.22 (87.01 for forced cooling at the rear)

73.23

9.06
28.74

24.61
46.02

3 x 6.10
7.48

7.48 4.53
10.43

2.95 17.72 27.36

10.43
23.62

3.35 24.80

31.50

For the following panels, only the openings for sec-

ondary cables in the concrete floor are required:

–– Sectionalizer and riser panels 1)

–– Bus coupler 1)
–– Sectionalizer panels without circuit breaker
–– Metering panels (not integrated metering)

1)
Within a switchgear block

92 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

11.7 Foundation frames

The optional foundation frames consist of aluminium sections. They The foundation frames are fastened to the concrete floor and em-
are supplied pre-assembled for one panel each. Foundation frames bedded in the floor topping.
of 23.62 in, 31.50 in width are used, depending on the panel width.
When installing the foundation frame at site, observe the form and
position tolerances stated in the order documents.

Fig. 11.7.1: Foundation frame and outlines of the panel,

panel width 31.50 in, dimensions in inches

Outlines of the
panel

Additional section,
16.54

required when volt-

age transformers
are fitted in the
cable termination
compartment and
the floor plate is not
64.29

supported, e.g. by
73.23

24.61

concrete.
7.48 5.12
10.43
8.15

7.36

front
3.35 24.80

31.50

Fig. 11.7.2: Foundation frame for the panel width 31.50 in

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 93

11.8 False floor

Fig. 11.8.1 is an aid to planning of the false floor.

The floor plates of the panels have L13 x 14 (mm) slots for fastening
the panels to the frame sections. Provide M 8 threads or bore holes
for screws M 8 in the frame sections at the positions of the slots.

Fig. 11.8.1: Example of a false floor in the area of a five-panel ZX2 switch-
gear system as an aid to planning (plan view, dimensions in inches).

Additional supporting beam (only required

when voltage transformers are fitted in the
Outline of the panel cable termination compartment)

1.57
Heat sink
87 1)

73.23

64.29

62.72
35.16
11.81
A

9.84 6.89

8.15
6.89 17.72 17.72 7.68

3.94 15.75 3.94 23.62 23.62 4.72

23.62 23.62 31.50 33.07 23.62

Detail A (dimensions in inches)

0.55
–– 0.51 in x 0.55 in slot in the floor plate of the panel
–– M 8 thread or bore hole for screw M 8 in the frame
section of the false floor
0.51
re r
le
bo 8 o
ho
M

94 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

11.9 Grounding of the 11.9.3 Recommendations on
switchgear configuration of the
switchgear grounding

11.9.1 Design of grounding

systems with regard We recommend that the switchgear be grounded as shown in
to touch voltage and Figs. 11.9.3.1 and 11.9.3.2.
A ring consisting of 3.15 in x 0.20 in copper strip is to be located
thermal stress beneath the switchgear and connected at several points with a
maximum spacing of 16.4 ft to the grounding system of the building.
The foundation frame, the main grounding bar in the panels and the
The grounding system for the station building and the grounding grounding bar in the low voltage compartments are to be connected
system for the switchgear are to be designed in accordance with at multiple points to the ring located beneath the switchgear. De-
IEC 61936. tails on the use of materials and the number of connections can be
found in Figs. 11.9.3.1 and 11.9.3.2.
The switchgear system is to be fitted with a continuous copper
grounding bar with a cross-section of 789.4 kcmil (ECuF30, 1.57
in x 0.39 in). The connection of this grounding bar to the station
grounding system is to be effected in accordance with the above
standards.

11.9.2 EMC-compliant
grounding of the
switchgear

Observe IEC 61000-5-2 and IEC 61000-6-5 to project the

grounding system for the station building and the design, laying
and connection of external control cables.

Establish the switchgear grounding due to the guidelines in the

following section.

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 95

Fig. 11.9.3.1: Grounding recommendation, shown schematically as a sectional elevation of the lower part of a panel including the concrete floor
9

3
5

Cable compartment 11
10

8 4
A A

1 1
2 2

Fig. 11.9.3.2: Grounding recommendation, plan view (section A-A of Fig. 11.9.3.1)
11

Section A-A
6
3

9 10

2
2
5 4
7
8

1 Ring below the switchgear, material ECuF30, cross-section 3.15 in x 0.20 in

2 Several connections from (1) to the building ground at distances of max. 16.4 ft
material ECuF30, cross-section 3.15 in x 0.20 in
3 Short-circuit proof grounding of the switchgear in both end panels and at least
every third panel, material: ECuF30, cross-section: 1.57 in x 0.39 in
4 Low impedance grounding of the grounding bar in the low voltage compartment
of each panel, material: tinned copper braid, cross-section: 0.79 in x 0.12 in
5 Low impedance grounding of the switchgear in each panel,
material: tinned copper braid, cross-section: 0.79 in x 0.12 in
6 Grounding of the foundation frame, at least every third foundation frame,
material: galvanised steel strip, cross-section: 1.18 in x 0.14 in
7 Outline of the panel
8 Foundation frame
9 Main grounding bar
10 Grounding bar in the low voltage compartment
11 Grounding point on the foundation frame

96 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

11.10 Panel weights

Table 11.10.1: Panel weights

Panel width Weight, max.
Panel type
[in] [lb] [kg]

23.62 3086 1400

Single busbar
31.50 4409 2000
23.62 3527 1600
Double busbar
31.50 5291 2400
Side plenum
551 250
(increase in weight of the relevant end panel)

12 Non-standard operating conditions

Non-standard operating conditions may require special action. A –– Outer cone panels with a voltage transformer isolat-
number of non-standard requirements and the measures which may ing device and test voltages > 50/125kV
be necessary are listed below. Over and above this, our design team –– C-panels with a load current > 800 A
will be pleased to make a technical proposal to meet your specific –– C-panels with an ambient temperature > 86 ° F
requirements.
–– At site altitudes > 3281 ft, a reduction of the permis-
Seismic withstand capability sible operating current and/or the ambient tempera-
ture may be necessary. An individual examination
Panels are tested to IEEE Std. 693 Draft 6; 1997. 1) can be made on request.

Climate The non-standard operating conditions include in

particular
With high humidity and/or major rapid temperature fluctuations,
electrical heaters must be fitted in the low voltage compartments. – – Higher ambient air temperature (maximum >
104 °F and maximum 24 hour average > 95 °F) see
Site altitudes > 3281 ft above sea level Fig. 12.1

The panels are suitable for site altitudes > 3281 ft above sea level – – Ambient air contaminated by dust, smoke, corrosive
with the following exceptions. or flammable gases or salt.

– – All panels with test voltages > 70/170kV

1)
Additional measures required (on request)

Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05 | 97

Fig. 12.1: Relationship between ambient air temperature and current carrying capacity

Current carrying capacity / A

4000

3500

3000

2500

2000

1500
Panels with Ir = 2500 A at 104 °F
Panels with Ir = 2000 A at 104 °F
1000 Panels with Ir = 1200 A at 104 °F
Panels with Ir = 800 A at 104 °F

500
23 32 41 50 59 68 77 86 95 104 113 122 131

Ambient air temperature / °F

98 | Technical catalog ZX2 Version for ANSI markets TK 636 - Revision 05

For your notes
 1VBA680636P0102 REV. 05, Novemver 2018

— —
ABB AG We reserve the right to make technical We reserve all rights in this document and
Oberhausener Str. 33 changes or modify the contents of this in the subject matter and illustrations con-
D-40472 Ratingen document without prior notice. With re- tained therein. Any reproduction, disclo-
Germany gard to purchase orders, the agreed par- sure to third parties or utilization of its
ticulars shall prevail. ABB AG does not ac- contents – in whole or in parts – is forbidden
cept any responsibility whatsoever for without prior written consent of ABB AG.
potential errors or possible lack of infor- Copyright© 2016 ABB
abb.com/mediumvoltage mation in this document. All rights reserved