1. - €¦ · technical description construction of compact substation the substation housing...

1. Contents 32. Technical description for ABB Orion 400A type (400 kVA), ABB Orion 630A type (630 kVA) and ABB Orion 1000M type (1000 kVA) concrete compact secondary substations 4

Construction of compact substation 5 Housing material 5 IP protection class of the substation 5 Behaviour of the substation in case of internal faults 5 Temperature rise, ventilation 5 Earthing apparatus 5 Noise emission 6 EMC requirements 6 Doors 6 Roof 6 Corrosion protection 6 Surface finishing 6 Oil collection pit 6 Cable connecting compartment 7 Accessories 7 External dimensions of substation 7

3. Electrical equipment 8 Medium voltage switchgear 9 Medium voltage metering cubicle – Type ABB M1060 12 Transformer room 12 Medium voltage interconnections 13 Low voltage distribution panel 14 General description , Orion 400A type of compact substation 14 Incoming of low voltage panel (Orion 400A) 15 Low voltage outgoings (Orion 400A) 15 General description , Orion 630A type of compact substation 15 Incoming of low voltage panel (Orion 630A) 16 Low voltage outgoings (Orion 630A) 16 General description, Orion 1000M type of compact substation 18 Incoming of low voltage panel (Orion 1000M) 18 Low voltage outgoings (Orion 1000M) 18 Description of optional items 19 Equipment installed into the low voltage distribution panel 19 Overcurrent protection MCBs 19 Low voltage interconnection between transformer and low voltage panel 20

4. The maximal technical containt of the substation 215. Markings 226. Tests 22

Type tests 16 Routine tests, acceptance tests 16

7. Standards, guidelines and legislation 228. Attachment 269. Installation Manual for ABB Orion 400A and Orion 630A compact secondary substations 42

Erection 42 Installation 43

10. Installation Manual for ABB Orion 1000M of compact secondary substations 47 Erection 47 Installation 48

11. ABB Orion 400A, Orion630A and Orion1000M type concrete compact secondary substations

Operating and Maintenance manual 52

1. ABB Contents

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2.Technical description for

ABB Orion 400A type (400 kVA), ABB Orion 630A type (630 kVA) and ABB Orion 1000M type (1000 kVA) concrete compact secondary substations.

technical description

Construction of compact substation

The substation housing consist of an aboveground building por-tion and a base, and of doors and ventilation surfaces. The equipment is engineered for a technical service lifetime of 40 years. During that pe-riod, the equipment will be almost free of maintenance.

Housing material

The housing is made of concrete which conforms to electric, ther-mal and mechanic requirements according to standard EN 62271-202. The building is manufactured by casting monolithically, from one piece, and is built without a gap. The compressive strength of concrete conforms to class C35/45. The durability class of concrete according to standard DIN 1045 is XC4; XF1 for the external building element, and XC1 for the internal building element.

Option: The compact substation allows in-stallation on a sloped terrain which means that the rear longitudinal side can be filled with earth up to 250 mm beneath roof level. This backfill will have a slope towards

the frontal part, down to the stan-dard excavation depth.

IP protection class of the substation

The protection class for the whole substation including doors and ventilation units is at least IP43D

according to standard EN 60529. On the inner side of door and on the ventilation surface beneath the roof, a wire mesh is installed in order to prevent ingress of insects into the substation.

Behaviour of the substation in case of internal faults The compact substation is resistant to arc and complies with criteria ac-cording to IEC 62271-202, approach-es IAC-A and IAC-B. Internal arc fault test was performed with a 3-cubicle SF6 insulated switchgear unit (KKT) and a 630 kVA rated transformer for Orion 630A type substation, and with a 3-cubicle SF6 insulated switchgear unit (KKT) and a 1000 kVA transformer for Orion 1000M type compact substation. The mini-mum values of testing short-circuit currents and the arc ignition places according to IEC 62271-200 are shown in the following table.

Temperature rise, ventilation

The substation is designed in such a way that with the use of a normal loss (AC’) transformer with rated

power corresponding to the rated power of the substation will not jeopardize the continuous opera-tion of the compact substation. The cooling of the substation is solved by natural ventilation. There are ventilation slots in the low voltage door of the substation. The roof is lifted up by 30 mm, so the substa-tion has ventillation openings all

around the substation under the roof. The fresh air enters the substa-tion through the ventillation slots of the low voltage door and leaves the substation thru the openings under the roof. In order to ensure that small creatures and insects cannot enter the substation all ventilation openings are covered by mesh and have the IP protection level of IP43D. The heat-run test of the substation was performed ac-cording to IEC 62271-202 standard, and an additional heat-run test was also performed according to RWE prescriptions. The thermal class of ORION 400A and ORION 630A is 15K (test value: 15.2K). The thermal class of ORION 1000M is 15K (test value: 13 K).

Earthing apparatus

The substation electric equipment are earthed via the shortest route possible according to EN 62271-202 standard specifications, and the connecting points of earthing are marked. Each piece of equipment is connected through a NYY 70 mm2 Cu cable to the earthing system of substation. Doors and built-in venti-lation units are electrically con-nected to the door frame through a 1x50 mm2 flexible conductor.The protective earthing of high

voltage units and the normal earthing of low voltage equip-ment can be separated. In the area of low voltage panel, a shock protection junction - a 300 mm long, 40x10 mm flat steel piece bonding (potential equalization) bar - is installed. Its connectors are durably labelled. Between the PEN busbar and the bonding (potential

Medium voltage unit Minimum testing short-circuit current Ignition Arc ignition spot

SF6 insulated unit 20 kA/1s3 pole Gas compartment

2 pole* Cable compartment

* the test short-circuit current has 3-pole infeed so a fault current of 20 ka is produced; for 2-pole ignition the short-circuit current amounts to 17.4 ka.

ABB Catalogue 2009 5


equalization) bar, a detachable flexible Cu link with a cross section of 70 mm2 is installed. The external earthing network of substation can be connected at the right-hand side part of PEN bar, using a dedicated M12 pressed nut.Conductors can be surrounded by means of a commercially available standard earthing tester clamp. The test can also be run within the framework of general maintenance without breaking the joint.For the temporary connection of earthing-shortcircuiting sets, an M12 bolted point for the fixation of earthing is found on the PEN bar. The short circuit withstand capac-ity and time limit on the earthing network of the substation is 14 kA / 1 s (28 kA/1s peak value).

Noise emission

Value obtained during noise emission test for Orion 400A and Orion 630A type compact substa-tion:

The sound pressure level produced by the substation housing includ-ing built-in transformer is by 12.8 dB(A) less than the sound pressure level produced by the free-standing transformer. In both cases, the test was carried out at a distance of 0.2 m to the unit and the substation respectively. The sound pressure test was performed according to standard EN 60076-10.

Value obtained during noise emission test for Orion 1000M type compact substation:

The sound pressure level produced by the substation housing includ-ing built-in transformer is by 13.3 dB(A) less than the sound pressure level produced by the free-standing transformer. In both cases, the test was carried out at a distance of 0.2 m to the unit and the substation respectively. The sound pressure test was performed according to standard EN 60076-10.

EMC requirements

As a part of the type test, the elec-

tromagnetic field of the substation at full load has been tested. The electromagnetic field strength and the magnetic induction on a rel-evant boundary surface reckoned from the substation perimeter wall do not exceed 100 µT health limit value specified in the relevant decree.

Doors

Substation doors comply with arc and pressure withstand criteria. Opening angle is 110 degrees. Door stoppers will automatically snap into their places when reaching a maximum opening angle. Door stoppers are installed in such a way that they should not impede any work on medium voltage and low voltage switchgears. The doors are fitted up with a 3 point-lock. The locks allow a profiled half-cylinder lock pad to be installed and are equipped with rain-protection escutcheon. When delivered, the lock will not include lock pads. As a standard solution the doors are made of 1.5 mm AlZn coated steel-sheet, and painted with a two component PU based painting. The metal parts are tested according to ISO 6988 standard.

Roof

Roof is designed as a separate constructional component which can be removed by lifting it off the supporting structure on the site when replacement is needed. Roof fixation is easy-to-access and detachable after opening the MV and LV doors.

Option: Compact substation can be deliv-ered with tile covered pitched roof. (see drawing no.: ABB ORION-630A-05, ABB ORION-1000M-03).

Corrosion protection

Under normal circumstances the corrosion protection of various steel parts will be compliant for the entire substation lifetime. Ageing (corrosion) tests were carried out according to ISO 6988 standard.

During the test, sulphur dioxide (SO2) in a concentration of 0.67% was applied under average humid-ity conditions. The unit under test was placed - with a cyclic alterna-tion - in a sulphur dioxide bearing ambience at a temperature 40°C for a period of 8 hours, and in normal room atmosphere for a period of 16 hours. Upon the completion of 5 cycles, it could be observed by visual checkup that the surface was free of corrosion. Joints such as bolts and nuts are stainless.

Surface finishing

The external coating of substation is a scratch coat finishing directly applied onto the concrete. The surface layer is weatherproof, environment-friendly, UV resistant, and resistant to fungi. The interior of housing is not painted. Standard colouring of substation:

external walls: RAL 9010 Ůroof, doors and ventilation Ů

units: RAL 7032 pebble grey or anodized aluminium color

Option: The compact substations, in addi-tion to the above standard version, are also available with the following external surface finishing:

rendered surface Ůornamental brick Ů

(see drawing no: ABB ORION-630A-06, ABB ORION 1000M-04)

Oil collection pit

For Orion 400A and Orion 630A type compact substations:

It is intended to trap, in case of a transformer failure, the insulat-ing fluid flowing out of the trans-former posing a danger to ambient groundwater. The basin with a capacity of 800 litres is gapless, fully confined, oil- and watertight.

For Orion 1000M type compact substations:

It is intended to trap, in case of a transformer failure, the insulating fluid flowing out of the transformer

ABB Catalogue 20096


as it is dangerous to ambient groundwater. The basin with a capacity of 1000 litres is gapless, fully confined, oil- and watertight which is ensured without a supple-mentary coating.

Cable connecting compartment

Medium voltage and low voltage cables freely run to the connector zone of compact substation. The base part is fitted with cable entry openings whose upper, not sharp edge is located at a distance of 200 mm to the substation bottom. On request, the medium voltage cable inlets can be sealed against water with Hauff HRD type or Hauff HSI type of sealings. The separa-tion walls of the basement is built up to the level of switchgear units so separation walls are used to separate the transformer room, medium voltage and low voltage cable compartments. The separa-tion walls are arranged in such a way that the permissible bending radius specific to medium voltage cables and low voltage cables can be ensured. For the entry of cables to be connected temporarily (such as construction, standby power source / aggregate set), 2 pcs of openings (shuttable from inside) with a diameter of 100 mm are vailable, and they are formed in the wall of the substation, at the side of low voltage panel.

Accessories

Accessories of the delivered substation include:

Operating handle for medium Ůvoltage switchgear

Documentations to the substa- Ůtion (Routine test reports, Instal-lation and Operational Manuals, Electrical drawings)

A prohibition signs saying /DO ŮNOT TURN ON/ and /EARTHED AND SHORT CIRCUITED/, furnished with a magnetic foil on the rear side, for every medium voltage cable con-nection cubicle.

Warning signs on the door of Ůtransformer room, medium voltage

room and low voltage door accord-ing to the local standards.

As a basic solution, no internal lighting is installed inside the substation. Internal lighting can be installed upon request.

External dimensions of substation:

For compact substations type Orion 400A and Orion 630A:

Outer dimension of housing with-out roof projection (drawing no. ABB ORION 630A-01):

width: 1500 mm, Ůheight: 2500 mm, Ůlength: 3000 mm. Ů

Roof projection size reckoned from substation side wall: 100 mmThe substation should be sunk under the ground level by 620 mm and this level is indicated on the building body

Weight of the substation without equipment: 6000 kg.Weight of the substation with MV and LV equiment, without trans-former:7500 kg.

Weight of the substation with MV and LV equiment, with transformer: 10.000 kg. For compact substation type Orion 1000M:

Outer dimension of housing with-out roof projection (drawing no. xxxxx)

widtht: 2400 mm, Ůheight: 2730 mm, Ůlength: 3100 mm. Ů

Roof projection size reckoned from substation side wall: 50-50 mm

The substation should be sunk under the ground level by 700 mm, that level is indicated on the build-ing body

Weight of the substation without equipment:12.000 kg.Weight of the substation with MV and LV equiment, without trans-former: 13.500 kg.Weight of the substation with MV and LV equiment, with transformer: 16.500 kg.

* orion 400a, 630a compact secondary substation

* orion 1000M compact secondary substation


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3. Electrical equipment

electrical equipMent

The switchgear makes it possible to connect the substation on the 12 or 24 (25) kV network. The cable connection cubicle can be direct connection (De cubicle), or load break switch cubicle (C cubicle). The transformer cubicle can be fuse switch disconnector cubicle (F cubicle) or vacuum circuit breaker cubicle (V cubicle). As a standard the cubicles are manually operated, but upon request, can be equipped with motor operation. The cable connection cubicles are equipped with manually operated earth-ing switches intended for a direct earthing of cable connections. A mechanical interlocking will ensure that the cable cover cannot be removed unless the earthing switch is on. The unit has an operating handle having a length which al-lows comfortable operation of the unit without posing a risk of injury.Replacing fuse links in the fuse switch disconnector cubicle (F) can be done easily and without addi-tional tools. The fuse base can be earthet both on busbar and cable side. The front cover of the fuse links are interlocked to the respec-tive cubicle’s earthing switch.The vacuum circuit breaker cubicle (V) contains vacuum breaking chambers. In line with the circuit breaker there is a 3 position isolator. There is a mechanical interlocking between the circuit breaker and the isolator. Behind the front cover of the circuit breaker a self powered protection relay can be found. The circuit breaker equipped with a low-energy tripping coil which is supplied by the ring type cable current transformers. The CTs are installed in the transformer cubi-

cle’s cable compartment. The basic protection is a 2-step time-overcur-rent and earth fault protection.

The switchgear is equipped with capacitive voltage indicators which make it possible tor run visual volt-age detection and phase balance checks. It is possible to install short circuit and earth fault indicators (Alpha E, EKA3, etc) in the cable connection cubicles.

As a standard solution, the SafeRing switchgears are delivered with arc-

proof and interlocked cable cover. The cable connection cubicles of the switchgear can be equipped with RDA12 or RDA24 type surge ar-resters, using a RICS cable termina-tion.Beyond the above described SafeRing switchgear, it is possible to install ABB SafePlus or other manufacturer’s switchgear inside the medium voltage room of the substations.

The switchgear unit complies with specifications of standard

Medium voltage switchgearSafeRing is an SF6 insulated ring main unit for the secondary distribution network. SafeRing is suitable for most switching applications in 12/24(25) kV distribution networks. It is extendible and combined with the SafePlus con-cept, which is ABB’s flexible, modular compact switchgear, they represent a complete solution for 12/24(25) kV secondary distribution networks. SafeRing and SafePlus have identical user interfaces. SafeRing is a completely sealed system with a stainless steel tank containing all living parts and switching functions. A sealed steel tank with constant atmospheric conditions ensures a high level of reliability as well as personnel safety and a virtually mainte-nance-free system.

The SafeRing concept offers a choice of either a switch fuse combination or circuit breaker with relay for protection of the transformer. As the first ring main unit, SafeRing can be supplied complete with an integral remote control and monitoring unit. The switchgears are equipped with manometer for monitoring the SF6 gas pressure inside the tank.

• 2-cubicle switchgears:

KT: ABB SafeRing DeF – 24,

KL: ABB SafeRing DeV - 24


KKT: ABB SafeRing CCF-24,

KKL: ABB SafeRing CCV-24


KKKT: ABB SafeRing CCCF-24

KKTT: ABB SafeRing CCFF-24

KKKL: ABB SafeRing CCCV-24

KKLL: ABB SafeRing CCVV-24

aBB safering ccF-24



IEC 62271-200 “High voltage switch-gear units” Part 200: Metal enclosed AC switchgear unit rated for a nominal voltage of over 1 kV and up to 52 kV, including arc withstand capacity according to Approaches A and B, for all criteria (1 to 6). The built-in isolator switches comply with the specifications set out in

standard IEC 60265-1 “Medium volt-age switchgears” Part 1: Switchgear units rated for a nominal voltage of over 1 kV and up to 52 kV.

The built-in fused isolator switch combination complies with the specifications set out in stan-dard IEC 62271-105 “High voltage

switchgear units” Part 105: AC fused isolator switch combinations.

The built-in earthing switches and isolator switches comply with specifications set out in standard IEC 62271-102 “High voltage switch-gear units” Part 102: High voltage AC isolators and earthing switches..

1. Nominal voltage 12/24(25) kV

2. Power frequency withstand voltage 28/50 kV

3. Impulse withstand voltage 95/125 kV

4. Rated frequency 50/60 Hz

5. Rated current busbars 630 A

6. Rated current (cable switch) 630 A

7. Rated current (T-off) 200 A

Breaking capacities:

8. active load 630 A

9. closed loop (cable switch) 630

10. off load cable charging (cable switch) 135

11. off load transformer (T-off fuse) 20

12. earth fault (cable swich) 200/150 A

13. earth fault cable charging (cable switch) 115/87 A

14. short circuit breaking current (T-off circuit breaker) 21/16

15. Rated making capacity 52.5/40

16. Rated making capacity (downstream fuse module) 12,5

17. Rated short time current 3 sec. 21/16 kA

18. Rated short time current 1 sec. (downstream fuse module) 5 kA

Service conditions for indoor equipment according IEC 60694

Ambient temperature

19. Maximum value 40 °C

20. Maximum value of 24 hours mean 35 °C

21. Minimum value -25 °C

22. Altitude for erection above sea level 1500 m

23. Relative humidity max 95 %

nominal values for the safering switchgear installed in the substation:•

ABB Catalogue 200910


rated values of load break switch installed in cable connection cubicle (c cubicle)•

1. Rated current: 630 A

2. Rated breaking capacity – active load: 630 A

3. Rated breaking capacity – closed loop 630 A

4. Rated breaking capacity – off load cable charging: 135 A

5. Rated breaking capacity – earth fault: 200/150 A

6. Rated breaking capacity – earth faul cable charging: 115/87 A

7. Rated making capacity: 52,5/40 kA

8. Type of mechanics: snap action

9. Electrical lifetime (at rated current): 100

10. Mechanical lifetime: 1000 O/C

rated values of earthing switch installed in cable connection cubicle (c cubicle)•


2. Rated making capacity 62,5 kA

3. Short time current: 21 kA

4. Time limit for short time current 3 s


6. Mechanical liftime: 1000 O/C

rated values of fuse load break switch installed in cable connection cubicle (F cubicle)•


2. Rated making capacity limited by the fuse link

3. Rated breaking capacity – off load transformer: 20 A

4. Type of mechanics: energy stored ( 2 springs)

5. Mechanical liftime: 1000 O/C

The fuselink installed in the fuse holder of the switchgear can have the follwing dimension:

In case of 24 kV (25kV): 442 mm ŮIn case of 12 kV: 292 mm, with a 150 mm fuse adapter Ů

rated values of fuse circuit breaker cubicle (V cubicle):•


2. Rated breaking capacity: 16 kA

3. Rated making capacity: 40 kA

4. Rated breaking capacity – off load cable charging: 31,5 A

5. Switch on time of the circuit breaker: 40 - 60 ms

6. Total switch off time of the circuit breaker: kb. 75 ms

7. Operating sequence: O-180s-C-O-180s-C-O

8. Mechanical liftime: 2000 C/O



In the medium voltage room there is a possibility to install a medium voltage metering cubicle with 3 pcs of TPU 4(6) type current trans-formers and 3 pcs of TJC 4(6) type voltage transformers. The metering cubicle is situated right next to the medium voltage switchgear on the side of the transformer cubicle (F or V cubicle). The interconnection between the switchgear and

metering cubicle is done by 3x1x35 mm2 N2XS type of medium voltage cable connection. The metering cubicle and the transformer are also connected with 3x1x35 mm2 N2XS type of medium voltage cables (please see drawing: ABB M1060-01).

Transformer room:

Orion 400A type of substation:

In the transformer room one piece of maximum 400 kVA oil insulated transformer can be placed. As a standard solution, the transformer is not included in the scope of delivery. The maximum dimensions of the transformer that can be in-stalled in the transformer room are as follows: (length x width x height) 1550mm x 890mm x 1750 mm. The transformer is cooled by means of natural ventilation.

Orion 630A type of substation

In the transformer room one piece of maximum 630 kVA oil insulated transformer can be placed. As a standard solution, the transformer is not included in the scope of delivery. The maximum dimen-sions of the transformer that can be installed in the transformer room are as follows: (length x width x height):1550mm x 890mm x 1750 mm. The transformer is cooled by means of natural ventilation

In case of Orion 400A and Orion 630A for controlling the no-load tap changer switch of transformer and monitoring the transformer compartment, a clearance of mini-mum 350 mm is provided between the medium voltage switchgear and the low voltage panel. A steel sheet with walk-resistant non-skid surface is installed onto the base.


2. Rated making capacity 52,5/40 kA

3. Short time current 21/16 kA

4. Time limit for short time current: 3 s


rated values of earthing switch•

Medium voltage metering cubicle – Type ABB M1060

aBB safering deV switchgear with M1060 medium voltage measuring cubicle



Option: For a unit configuration in which the distance between medium voltage and low voltage units is less than 350 mm, a control opening is formed on the left hand side wall in order to allow the checkup of transformer compartment. This control opening has the following dimensions: width: 500 mm, height: 800 mm).

Orion 1000M type of substation

In the transformer room one piece of maximum 1000 kVA oil insulated or cast resin insulated transformer can be placed. As a standard solution, the transformer is not in-cluded in the scope of delivery. The maximum dimensions of the trans-former that can be installed in the transformer room are as follws: (L x W x H):1800mm x 1500mm x 2200 mm. The transformer is cooled by means of natural ventilation. For controlling the no-load tap changer switch of transformer and monitoring the transformer compartment, a control opening is formed on the right side wall. This control opening has the following dimensions: width: 500 mm, height: 800 mm).

Medium voltage interconnections

SafeRing type of medium voltage switchgear is installed inside the substation:

The transformer and the switch-gear are connected together with 3x1x35 mm2 N2XSY (or NA2XSY 95 mm2) 12/20 kV cable. The cable contains the cable termination at both end of the cable. At the trans-former side a normal indoor cable termination is installed, while at the switchgear side insulated elbow connection is installed. Insulation test and upon request partial dis-charge test are performed on the cables. The related test certificates are part of the final documentation of the substation.

SafeRing type of switchgear and M1060 type of metering cubicle are installed inside the substation:

The SafeRing’s transformer cubicle and the M1060 metering cubicle are connected together with 3x1x35 mm2 N2XSY (or NA2XSY 95 mm2) 12/20 kV cable. There is also a 3x1x35 mm2 (or NA2XSY 95 mm2) cable connection between

the M1060 metering cubicle and the transformer. The cables contain normal indoor cable termination at the side of the transformer, incom-ing and outgoing outlets of the M1060 metering cubicle.

The cable contains insulated elbow connection at the side of the switchgear. Insulation test and upon request, partial discharge test are performed on the cables. The test certificates are part of the final documetation of the substation.

As a standard, the cable is earthed only on the side of the medium voltage switchgear. Each cable is marked with a uniqe and irremov-able identification tag. To prove the adequacy of the cables, the test report contains the tags id and measured values for each cable. The cable terminations can be interchanged in the cable compart-ment to ensure the possibility of modifying the phase sequence according to the network condi-tion. The medium voltage cables are not led through the low voltage room and do not cross low voltage cables. The medium voltage cables are connected to the transformer on a short circuit proof way and via the shortest route possible.

aBB tnosctW 630 KVa type of oil insulated transformer



Perameters:

1. Rated voltage 420 V

2. Rated insulation level 690 V

3. Rated impulse voltage withstand capacity 6 kV

4. Rated frequency 50 Hz

5. Rated current of busbar 630 A

6. Thermal current of busbar 25 kA

7. Time limit for thermal current 1 s

8. Dynamic current of busbar 52,5 kA

9. Rated current of low voltage outgoings (fuse switch) 630 A,400 A, 250 A, 160 A

10. Incoming switch can be removable busbar

load break switch

circuit breaker

11. Nominal conditional short-circuit current of outgoings 80 kA

parameters of low voltage panel:•

Low voltage distribution panel

Orion 400A type of compact substation

General description

The low voltage panel installed in the substation has a typi-fied construction. Its type is:

LV-630-A-K/ABB. Nominal current of the unit is 630 A. The low voltage panel is a metal base plate contain-ing insulators, low voltage busbars (L1, L2, L3 PEN), and low voltage equipment. The low voltage panel is installed in the low voltage room and the panel is fixed to the inserts of the internal walls of the substa-tion. The low voltage panel is type tested and complies with specifica-tions prescribed in standard IEC 60439-1: Low voltage switchgear and controlgears, Part 1: Typified and partially typified units. The low voltage busbars are made from tin plated copper and have the cross section of 40x10 mm. The distance between the phase bars are 185 mm. The busbars contain M12 pressed-in screw nuts at the scale interval of 100 mm for installing the low voltage fuse switches. The PEN bar is provided with steel M12 pressed-in screw nut at the scale interval of 100 mm for con-necting the outgoing cables’ PEN conductor. The PEN bar is equipped with V-clamps for easy connection

of PEN conductors. The PEN bar is also provided with 4 pcs of M12x35 threaded bolts with the incident spring washers and screws for con-necting the temporary cables’ PEN conductor and other outer earth-ings. The busbar is well-marked with the symbols of L1, L2, L3 and PEN to ensure easy identifacition of the phases. The electric shock pro-tection of the low voltage panel is TN-C (four conductor system). The IP protection class of panel is IP2X.

The low voltage panel ,as a basic, can be equipped with 8 pcs of NH 2 size (400 A) fuse switches. Accord-ing to customer request the panel can also be equipped with NH 00 (160A), NH1 (250A), NH3 (630A) size of fuse switches. Each fuse switch of the low voltage panel is marked with a durable and clearly visible label. The low voltage panel allows for the accommodation of 1 pc of A4 sized network map scheme inside it. On request the distribu-tion panel can be delivered with low voltage surge arrasters which lV - 1250 - a - K/aBB type of lV panel



are installed on the main busbars in such a way that the operator can clearly see them even during operation.

The low voltage panel as a basic solution contains the following:

Removable busbars in the in- Ůcoming. Removing this busbar sec-tion will separate the transformer from the outgoings. It is possible to install 3 pcs of low voltage current transformers on the separable bus-bar. Each of the removable busbars has a 13mm hole so an aggregate can be connected here using cable lugs. The removable busbar section area can only be accessed after removing the tranparent covering plate. The covering plate can be lead sealed.

A-meter with 1 pcs of current Ůtransformer on L2 phase

1 piece of 16A socket with pro Ů

tection circuit

Transformer thermal protection Ůcircuit

Auxiliary circuit for short circuit Ůindicator (EKA3) (optional)

V-meter (optional) Ů3 pcs of 4 mm sized sockets for Ů

phase identification (option)Internal lighting (optional) ŮCapacitor bank supplied via Ů

NH00 size fuse switch (option)

Incoming of low voltage panelThe upper part of low voltage busbars (L1, L2, L3, PEN) are shaped to ensure that 2 pcs of insulated copper cables can be connected per phase. As a basic solution the incoming is a removable busbar, but can be changed to 630A load break switch or circuit breaker which protects the low voltage

panel against short circuits and overcurrents. After the removable busbar or the incoming switching device the busbar is provided with aggregate connection ear with a 13 mm hole in it. The aggregate con-nection ear is always covered by a front plate (IP2x).

Low voltage outgoingsThe basic low voltage panel can be equipped with 8 pcs of NH2 size (400A) fuse switches.

The panel can be enlarged with an extension module. The extension module can receive 4 more NH2 size fuse switches. The connec-tion elements of the fuse switches enable us to connect 4x240 mm2 sm/50 mm2 low voltage cables.


Orion 630A type of compact substation

Perameters:











load break switch

circuit breaker


General description

The low voltage panel installed in the substation has a typified con-struction. Its type is: LV-1250-A-K/ABB. Nominal current of the unit is 1250 A. The low voltage panel is

a metal base plate containing the insulators, low voltage busbars (L1, L2, L3 PEN), and low voltage equipment. The low voltage panel is installed in the low voltage room and the panel is fixed to the inserts of the internal walls of the substa-

tion. The low voltage panel is type tested and complies with specifica-tions prescribed in standard IEC 60439-1: Low voltage switchgear and controlgears, Part 1: Typified and partially typified units. The low voltage busbars are made from tin



plated copper and have the cross section of 60x10 mm. The distance between the phase bars is 185 mm. The busbars contain M12 pressed-in screw nuts at the scale interval of 100 mm for installing the low volt-age fuse switches. The PEN bar is provided with steel M12 pressed-in screw nut at the scale interval of 100 mm for con-necting the outgoing cables’ PEN conductor. The PEN bar is equipped with V-clamps to ensure easy con-nection of PEN conductors. The PEN bar is also provided with 4 pcs of M12x35 threaded bolts with the incident spring washers and screws for connecting the tempo-rary cables’ PEN conductor and other outer earthings. The busbar is well-marked with the symbols of L1, L2, L3 and PEN to ensure easy identifacition of the phases. The electric shock protection of the low voltage panel is TN-C (four conduc-tor system). The IP protection class of the panel is IP2X.

The low voltage panel ,as a basic, can be equipped with 8 pcs of NH 2 size (400 A) fuse switch. Accord-ing to customer request the panel can also be equipped with NH 00 (160A), NH1 (250A), NH3 (630A) size of fuse switches. Each fuse switch of the low voltage panel is marked with a durable and clearly visible label. The low voltage panel allows

for the accommodation of 1 pc of A4 sized network map scheme inside it. On request the distribu-tion panel can be delivered with low voltage surge arrasters which are installed on the main busbars in such a way that the operator can clearly see them even during the operation. The low voltage panel as a basic solution contains the following:

Removable busbars in the in- Ůcoming. Removing this busbar sec-tion will separate the transformer from the outgoings. It is possible to install 3 pcs of low voltage current transformers on the separable busbar. Each removable busbar has a 13mm hole so an aggregate can be connected here using cable lug. The removable busbar section area can only be accessed after remov-ing the tranparent covering plate. The covering plate can be lead sealed.


1 piece of 16A socket with pro- Ůtection circuit






Incoming of low voltage panelThe upper parts of low voltage busbars (L1, L2, L3, PEN) are shaped to ensure that 3 pcs of insulated copper cables can be connected per phase.

As a basic solution, the incoming is a removable busbar, but can be changed to 1250A load break switch or circuit breaker which pro-tects the low voltage panel against short circuits and overcurrents.

After the removable busbar or the incoming switching device the busbar is provided with aggregate connection ear with a 13 mm hole in it. The aggregate connection ear is always covered by a front plate (IP2x).

Low voltage outgoings

The basic low voltage panel can be equipped with 8 pcs of NH2 size (400A) fuse switches. The panel can be enlarged with an extension module. The extension module can receive 4 more NH2 size fuse switches. The connection elements of the fuse switches allow to con-nect 4x240 mm2 sm/50 mm2 low voltage cables.

lV - 1600 - a - K/aBB type of lV panel




Orion 1000M type of compact substation

Perameters:











load break switch

circuit breaker


aBB orion 1000M type of compact secondary substation



General description

The low voltage panel installed in the substation has a typified con-struction. Its type is: LV-1600-A-K/ABB. Nominal current of the unit is 1600 A. The low voltage panel is a metal base plate containign the insulators, low voltage busbars (L1, L2, L3 PEN), and low voltage equipment. The low voltage panel is installed in the low voltage room and the panel is fixed to the inserts of the internal walls of the substa-tion. The low voltage panel is type tested and complies with specifica-tions prescribed in standard IEC 60439-1: Low voltage switchgear and controlgears, Part 1: Typified and partially typified units. The low voltage busbars are made from tin plated copper and have the cross section of 80x10 mm. The distance between the phase bars is 185 mm. The busbars contain M12 pressed-in screw nuts at the scale interval of 100 mm for installing the low voltage fuse switches.

The PEN bar is provided with steel M12 pressed-in screw nut at the scale interval of 100 mm for con-necting the outgoing cables’ PEN conductor. The PEN bar is equipped with V-clamps to ensure the easy connection of PEN conductors. The PEN bar is also provided with 4 pcs of M12x35 threaded bolts with the incident spring washers and screws for connecting the tempo-rary cables’ PEN conductor and other outer earthings. The busbar is well-marked with the symbols L1, L2, L3 and PEN to ensure easy identifacition of the phases. The electric shock protection of the low voltage panel is TN-C (four conduc-tor system). The IP protection class of panel is IP2X.

The low voltage panel ,as a basic, can be equipped with 12 pcs of NH 2 size (400 A) fuse switches. Accord-ing to customer request the panel can also be equipped with NH 00 (160A), NH1 (250A), NH3 (630A) size of fuse switches. Each fuse switch of the low voltage panel is marked with a durable and clearly visible label. The low voltage panel allows

the accommodation of 1 pc of A4 sized network map scheme inside it. On request, the distribution panel can be delivered with low voltage surge arrasters which are installed on the main busbars in such a way that the operator can clearly see them even during the operation.

The low voltage panel as a basic solution contains the following:

Removable busbars in the in- Ůcoming. Removing this busbar sec-tion will separate the transformer from the outgoings. It is possible to install 3 pcs of low voltage current transformers on the separable busbar. Each removable busbar has a 13mm hole so an aggregate can be connected here using cable lug. The removable busbar section area can only be accessed after removing the tranparent covering plate. The covering plate can be lead sealed.


1 piece of 16A socket with pro- Ůtection circuit






Incoming of low voltage panel

The upper parts of low voltage busbars (L1, L2, L3, PEN) are shaped in such a way that 5 pcs of insulated copper cables can be connected per phase. As a basic solution the incoming is a removable busbar, but can be changed to 1600A load break switch or circuit breaker which protects the low voltage panel against short circuits and overcurrents. After the removable busbar or the incoming switching device the busbar is provided with aggregate connection ear with a 13 mm hole in it. The aggregate con-nection ear is always covered by a front plate (IP2x).

Low voltage outgoings

The basic low voltage panel can be equipped with 8 pcs of NH2 size (400A) fuse switches. The panel can be enlarged with an extension module. The extension module can receive 4 or 6 more NH2 size fuse switches. The connection elements of the fuse switches make it pos-sible to connect 4x240 mm2 sm/50 mm2 low voltage cables.

aBB tmax type of cB


aBB XlBM2


Capacitor bank unit

The substation can be equipped with a capacitor unit connected through a fuse switch. The power factor capacitors applied comply with test specifications prescribed in standard IEC 61921 “Power capacitors, low voltage power fac-tor capacitor banks”. The nominal current of fuse link to be inserted is indicated on the fused isolator switch. Nominal power of capacitors:

Orion 400A 10 kvarOrion 630A 15 kvarOrion 1000M 20 kvar

Public lighting modul

On the left-hand side of the low voltage panel a 350 mm wide space is available for the public lighting modul (PLM). In the incoming of the PLM there is a NH00 size fuse switch and a contactor. The contolling circuit of the contactor contains a 3 position switch (off, on, remote control) so the PLM can be swithed on locally or remote controlled. On the PLM free space and wiring are available for installing a power meter. The PLM contains 12 pcs of 32A MCB outgoings. The outgoing terminals of the PLM allow con-nection of cables with a maximum cross section of 70 mm2.

Description of optional items:

Equipment installed into the low voltage distribution panel

Parameters of fuse switches in-stalled into the low voltage panel. The built-in fuse switches comply with test specifications as set out in

standard IEC 60947-3 “Low voltage switchgear and controlgear” Part 3: Switches, isolators, isolator switches and fused switchgear combina-tions. The application category of units: AC-22 B type (non-frequent activa-tion, permanent operation). The fuse switch allows to connect un-

prepared conductors to a terminal by means of a fastening piece (V-clamps). The fuse switches can be 1-pole or 3-pole operated accord-ing to customer request. Maximum cross section for connecting cable is 4x240 mm2 sm/50 mm2. Fuse bases do not include low voltage fuse links.

Large consumer module

This module is adjusted to the design of the standard low voltage panel. Left from the power infeed, an NH4 size fuse switch (with 1250 A knives) can be installed. This fuse switch allows the connection of 4 pcs of 240 mm2 cable conductors per phase. When supplied, 4 pcs of bolted plastic press plate type cable fasteners, in size adjusted to cable size are supplied with the large consumer module.

public lighting modul (plM)


Overcurrent protection MCBs:

The installed overcurrent protec-tion MCBs comply with test speci-fications as set out in standard IEC 60947-2 “Low voltage switchgear and controlgear” Part 2: Circuit breakers.Type of device applied: Nominal current: 2, 4, 6, 16 A

Features Unit Quantity

1. Nominal operating voltage (Ue) V 400

2. Nominal insulation voltage (Ui) V 440

3. Nominal frequency Hz 50

4. Nominal short-circuit breaking capacity (Icn) in auxiliary circuits: kA 25*

Features of overcurrent protection McBs: •

upon request fuses can be installed instead of McBs in the auxiliary circuits.•


Low voltage interconnection between transformer and low voltage panel

Orion 400A:

The low voltage cable connection between the low voltage panel and the transformer can be:

Using NSGAFÖU type of 185mm2 single phase cable:Phases: 2 pcs/phasePEN:2 pcs/phase

Using H07V-K type of 240 mm2 single phase cable:Phases: 2 pcs/phasePEN:2 pcs/phase

The NSGAFÖU type of cable is insu-lated for 1.8/3 kV, the H07V-K type of cable is insulated for 450/750V. The cable ends are assembled with cable lugs.

Orion 630A :





Orion 1000M





Cabeling of transformer’s thermal protection and gas protection :

The wiring is done by 3x1.5mm2 MT cable. The cable can be found in the transformer room. This cable has to be connected to the transformer’s protection unit according to the drawing attached to the substation’s final docu-mentation. The other side of the MT cable is connected by the factory to the tripping coil of the medium voltage switchgears’s transformer cubicle. On request the thermal protection can also be wired to the main circuit breaker of the low voltage panel.


the MaXiMal technical containt oF the suBstation

the maximal technical containt of the substations can be found in the below chart. •

Orion 400A and Orion 630A type of substations

Medium voltage switchgear

Safering DeF, CCF, DeV, CCV X X

Safering CCCF, CCFF, CCCV, CCVV X X

Low voltage panel

Incoming

Removable busbar X X X X

Fuse switch X X X X

Circuit breaker X X X X

Public lighting modul x xOutgoings

Maximal number of NH2 size fuse switch (size of NH1, NH3 are identical to NH2, 2 pcs of NH00 is identical to 1 pcs of NH 2)

10 12 8 10

Capacitor bank unit X X X X

4.

The maximal technical containt of the substations

Orion 1000M type of substation


Safering DeF, CCF, DeV, CCV X

Safering CCCF, CCFF, CCCV, CCVV X

M1060 metering cubicle X -

Low voltage panel

Incoming

Removable busbar X X

Fuse switch X X

Circuit breaker X X

Public lighting modul X -

Outgoings

Maximal number of NH2 size fuse switch (size of NH1, NH3 are identical to NH2, 2 pcs of NH00 is identical to 1 pcs of NH 2)

12 14

Capacitor bank unit X X

Remarks:

Instead of 1 pcs of NH1, NH2, NH3 fuse switch 2 pcs of NH 00 size fuse switch can be installed. Adapter is needed when ŮNH00 size fuse switch is installed instead of NH1, NH2 or NH3 fuse switch.

The Orion 1000M type of substation can contain a maximum of 4-cubicle SafeRing 36 type of switchgear. Ů


MarKings, tests, standards, guidelines and legislation

5. Markings The safety signs inside and outside the substation are made according to the local requirements.As a standard the substation is provided with the following signs:

Five safety rules of neutralization procedure ŮWhat to do in case of electric shock ŮWarning sign on the medium voltage room and transformer room (lightning symbol and „Caution! High Voltage! Danger Ů

to Life!”, warning sign on the low voltage door (DANGER! 400V!)Data plate of the substation (manufacturer, year and place of production, production number) Ů

6. TestsType tests

The following type tests have been performed on the substation in accordance with IEC 62271-202 standard. The tests were accomplished in an accredited and independent laboratory.

Corrosion tests ŮIP tests ŮMechanical tests ŮNoise emission tests ŮHeat-run test ŮDielectric test ŮShort circuit tests ŮOperational tests ŮEMC test (measurement of magnetic field) ŮArc-fault tests Ů

Routine tests, acceptance tests

The routine tests specified for substation and installed equipment will be performed on the site of manufacturer, after the substation has been manufactured. The protocol of routine test comprise the following tests according to standard IEC 62271-202.

Dielectric test on high voltage interconnection ŮTest on auxiliary and control circuits ŮFunctional tests (check of substation and installed components) ŮVerification of correct wiring Ů

7. Standards, guidelines and legislation All components, assemblies, materials and parts are in compliance with relevant standards being effective and with generally recognized technical rules. The substation does not contain any material containing PCB or asbestos, or halogenized hydrocarbons or any other hazardous materials to be mandatorily marked. The compact substation has been manufactured in accordance with standards and laws as listed hereinafter.

The routine test report is part of the sub-station final documentation and will be delivered together with the substation.


standards, guidelines and ligislation

IEC 60038 IEC standard voltages

IEC 61140 Protection against electric shock

ISO/IEC GUIDE 74 Graphical symbols — Technical guidelines for the consideration of consumers’ needs

IEC 60502-1

Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV)

IEC 60502-2

Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 2: Cables for rated voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)

IEC 60502-4

Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 4: Test requirements on accessories for cables with rated volt-ages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)

IEC 60446 Basic and safety principles for man-machine interface, marking and identification – Identification of conductors by colours or alphanu-merics

IEC 60364-1 Electrical installations of buildings - Fundamental principles

IEC 60364-4-41 Electrical installations of buildings - Protection for safety - Protec-tion against electric shock

IEC 60287-1-1 Electric cables - Calculation of the current rating - Current rating equations (100% load factor) and calculation of losses - General

IEC 60287-1-1 Insulation coordination for equipment within low-voltage systems - Part 1: Principles, requirements and tests

IEC 60044-1 Instrument transformers, current transformers

IEC 60059 Standardized current values according to IEC

IEC 60099-4 Metal oxide surge diverters without spark gap, for AC systems

IEC 60265-1 High voltage switchgears: switchgears rated for a nominal voltage of over 1 kV and less than 52 kV

IEC 60269-1 Low voltage fuses. General specifications

IEC 60269-2 Low voltage fuses. Additional requirements relevant to fuses used by authorized personnel

IEC 60282-1 High voltage fuses. Current limiting fuses

IEC 60298 Metal enclosed AC switchgear units rated for a nominal voltage of over 1 kV and up to 52 kV


standards, guidelines and legislation

IEC 60439-1 Low voltage switchgears and controlgears, Part 1: Typified and partially typified units

IEC 60445 Man-machine link, basic principles of safety for designation and identification. Identification of electric product terminals and dedi-cated conductor ends including alphanumerical rules thereof

IEC 60447 Man-machine link, basic principles of safety for designation and identification. Principles of operation

IEC 60529 Protection degrees provided by enclosure of electric products

IEC 60617-7 Electric drawing symbols. Switchgears, controlgears and protective devices

IEC 60660 Testing indoor type line-post insulators made of organic matter for systems rated for a nominal voltage of over 1 kV and less than 300 kV

IEC 60694 Common specifications of standards for high voltage switchgear units

IEC 60898 Overcurrent protection cutouts for household and similar units

IEC 60947-1 Low voltage switchgears and controlgears. General specifications

IEC 60947-2 Low voltage switchgears and controlgears. Part 2: Circuit breakers

IEC 60947-3 Low voltage switchgears and controlgears. Part 3: Switches, isola-tors, isolator switches and fused switch combinations

IEC 60999 Connector components. Electric copper conductors. Safety re-quirements for fastening units with and without bolt.

IEC 61230 Work under live voltage. Portable earthing, or earthing and short circuiting devices

IEC 61293 Marking nominal data of power supply on electric equipment. Safety requirements

IEC 61921 Power capacitors. Low voltage power factor capacitor banks

IEC 62271-105 High voltage switchgear units, Part 105: AC fuse-switchgear combi-nations

IEC 62271-200 High voltage switchgear units, Part 200: Metal enclosed AC switch-gear units rated for a nominal voltage of over 1 kV and up to 52 kV

ISO 6988 Metallic and other inorganic coats. Testing with sulphur dioxide during condensation


standards, guidelines and ligislation

IEC 50 International Electrotechnical Dictionary

IEC 129 AC isolators and earthing switches

IEC 273 Specifications of indoor and outdoor line post insulators of systems rated for a nominal voltage of over 1 kV

IEC 1238 Pressed and mechanical joining pieces for copper or aluminium conductors of power cables

IEC 60502 Power cables with extruded insulation, for a nominal voltage rang-ing from 1 kV (Um=1.2 kV) to 30 kV (Um=36 kV) and their fittings.

ISO/IEC 17050 Evaluation of compliance. Declaration of supplier on compliance.

IEC 62271-202 High -voltage switchgear and controlgear - Part 202: Prefabricated HV/LV substations

26. BImSchVOn health limits concerning inhabitants, specific to electric, mag-netic and electromagnetic fields in the frequency range from 0 Hz to 300 GHz


attachMent

8.AttachmentsABB SafeRing type of SF6 insulated compact medium voltage switchgear

2 way units:

Height: 1336 mm ŮWidth: 696 mm ŮDepth: 765 mm Ů

3 way units


4 way units



attachMent


installation

9.Installation Manual for ABB Orion 400A and Orion 630A compact secondary substationsFor the erection and installation of ABB Orion 400 and Orion 630 compact substations, no complicated and time-consuming operations are needed. For the installation, neither a concrete foundation nor any other special trade civil work is required. Erecting the substation consists of lifting it by means of a crane into a preliminary made base pit.

Erection

As a first step of erection, excavate a base pit in size corresponding to the compact substation (Figs. 6 and 7).

Pit dimensions:- length: substation length + 1000 mm = 4000 mm- width: substation width + 1000 mm = 2500 mm- depth: 920 mm (substation excavation depth: 620 mm)

Prepare a 300 mm thick bed consisting of a mixture of gravel and sand with a diameter of 7 to 25 mm, at the bottom of excavated base pit. Ram, then level the gravel bed. When the obtained bed is perfectly leveled, foundation work is considered to be completed.

As a next step, crane the substation into the base pit. To lift the substation, use special RD36 type lifting eyes (4 pcs) insertable into threaded holes in the side wall of transformer substation. They are supplied by ABB for lifting when delivering the compact substation (Fig. 1). To lift the substation into place use a dedicated crane with a safety working load corresponding to the weight of the compact substation, and two lifting rod. The lifting rods are provided by ABB for lifting when delivering the compact substation. The weight of Orion 400A and Orion 630A substation is 7500 kg (without trans-former). After the substation has been erected into the base pit, a clearance of at least 200 mm must be provided between the lowest point of substation door frame and the ground level, in order to allow for appropriate operability of units, proper ventilation of the substa-tion, and to avoid ingress of water into the substation.

Fig. 1


installation

Installation

To lift the transformer to its place, carry out the following operations after the compact transformer substation has been erected.

To lift the transformer into its place by means of a crane, remove the substation roof. The roof is secured to the concrete body by means of 2 pcs of M16 bolts which are found at two diagonally opposite corners of the roof inside the substation. At the other two diagonally opposite corners of the substation, two additional steel centre pins are found which are intended to help you position and fix the roof (Fig. 2).As a first step, remove bolts fixing the roof (2 pcs of M16 bolts) shown in Fig. 2. To lift off the roof, screw lifting eyes supplied with the substation into bores located on the two longitudinal sides of the roof (Fig. 3). Then, the roof can be lifted off, and the transformer can be lifted into the substation.

To ensure appropriate ventilation for the transformer, mount wheels of transformer beneath the transformer, and install a vibration absorber underlay under each wheel.

Fig.2


installation

In the compact substation, medium voltage and low voltage cables with cross section and number corresponding to the transformer rated power are provided, as follows.

For 400 kVA:Medium voltage cable: N2XSY 3x1x35 mm2 12/20 kV type cable, mounted with a cable termination at both ends (with a Size 12 cable lugs on the transformer side).Low voltage cables: 4x2x1x185 mm2 NSGAFöU 1,8/3kV (or H07K-V 4x2x1x240 mm2). Mounted with M12 size cable lugs at one end, with cable lugs and shrinking tube supplied for the other cable end (colour marking of conductors: L1: green, L2: yellow, L3: red, N: blue).

For 630 kVA:Medium voltage cable: N2XSY 3x1x35 mm2 12/20 kV type cable, mounted

with a cable termination at both ends (with a Size 12 cable lugs on the transformer side).Low voltage cable: 4x3x1x185 mm2 NSGAFöU 1,8/3kV (or 4x3x1x185 mm2 H07K-V). Mounted with M12 size cable lugs at one end, with cable lugs and shrinking tube supplied for the other cable end (colour marking of conductors: L1: green, L2: yellow, L3: red, N: blue).

After the transformer has been lifted to its place by means of a crane on the site, connect medium voltage and low voltage cables provided and connect earthing cables to earthing points of the transformer. If the transformer has a thermal protection, also connect the 3x1.5 mm2 MT cable to the transformer thermal pro-tection unit’s N.O. trip contacts according to a circuit diagram shown in a manual supplied with the substation. After the transformer has been connected, replace the roof.Finally remove lifting eyes used for lifting the roof (Fig. 3).

Insert the 2 pcs of M16 bolts fixing the roof back into the holes. It is recommended to store dismantled lifting eyes in the cable space of low voltage compartment.

During the installation of the compact substation, install an appropriate shock protection system around the sub-station according to relevant standards in such a way that earthing resistance should be less than 2 ohms.Inside the transformer substation, the electric units, the metal supporting structures, and doors and windows are at

Fig.3

Fig.4


installation

factory earthed in the shortest route. Inside the substation, a shock protection junction has been installed (Fig. 4) in the low voltage compartment. It is that point to which the earthing conductors of installed equipments, the metal parts found inside the substation and the PEN bar of the low voltage panel are connected, using a 50 and 70 mm2, respectively, green/yellow wire (with a cable lugs at both cable ends). If the transformer is installed into the station on the site, then its earthing points must also be connected to the above mentioned junction, using the available earthing conductor.

The external earthing network and potential control frame shall be entered into the substation through a low volt-age cable entry found in the sidewall of substation. Connect the external earthing network (earthing frame) to the PEN bar. To connect the earthing conductor (or flat steel piece) a hole with a diameter of 13 mm is provided on the PEN bar. The external potential control frame must be connected to the bonding (potential equalization) bar. To connect the frame, a hole with a diameter of 11 mm is provided on the bonding bar.

The installed external earthing system must be connected using safe and du-rable electric and mechanical joints.

In the transformer substation, medium voltage and low voltage cables with cross section and number corresponding to the rated power of the transformer are provided, as follows.

If Hauff HRD cable glands are to be installed, observe the following mounting sequence:

Before entering medium voltage cables into the substation, pass the cables through the cable gland. Then, connect each cable to the medium voltage switchgear, and insert the gland into a rupture in the concrete. After adjusting the cables, use the M6 bolts to fix the sealing. By fastening the bolts, the rubber sealing will fill the space between cables, and the space between the gland and the concrete hole, thereby ensuring watertight condition of cable entries.

In case of using Hauff HSI system:

The core element of the HSI cable gland is embedded into the concrete foundation. After removing the covering plate of the core element, the adequate HSI cable gland has to be installed into its place. The HSI set contains heat shrinking tubes, what need to be put on the cable gland before entering the cable to the substation. When the cables are connected, the sealing can be realized by heating the shrinking tubes on the cable gland. Please study carefully the manual of the cable gland!

Upon completion of installation, perform backfill of surplus earth and compact it. It is recommended to lay walk-resistant paving tiles in a width of 80 cm around the substation.

Documents concerning the operation and maintenance of installed equip-ment are provided in the Substation Manual which will be delivered with the substation and should be normally kept in a document holder on the internal

side of the substation.

Fig.5


installation

Fig.6

Fig.7


installation

10.Installation Manual for ABB Orion 1000M type of compact secondary substationFor the erection and installation of ABB Orion 1000M compact substations, no complicated and time-consuming operations are needed. For the installation, neither a concrete foundation nor any other special trade civil work is required. Erecting the substation consists of lifting it by means of a crane into a preliminary made base pit.

Erection

As a first step of erection, excavate a base pit in size corresponding to the compact substation (Figs. 6 and 7).

Pit dimensions:- length: substation length + 1000 mm = 4100 mm- width: substation width + 1000 mm = 3400 mm- depth: 920 mm (substation excavation depth: 620 mm)

Prepare a 300 mm thick bed consisting of a mixture of gravel and sand with a diameter of 7 to 25 mm, at the bottom of excavated base pit. Ram, then level the gravel bed. When the obtained bed is perfectly leveled, foundation work is considered to be completed.

As a next step, crane the substation into the base pit. To lift the substation, use special RD36 type lifting eyes (4 pcs) insertable into threaded holes in the side wall of transformer substation. They are supplied by ABB for lifting when delivering the compact substation (Fig. 1). To lift the substation into place use a dedicated crane with a safety working load corresponding to the weight of the compact substation, and two lifting rod. The lifting rods are provided by ABB for lifting when delivering the compact substation. The weight of Orion 1000M substation is 13 500 kg (without transformer). After the substation has been erected into the base pit, a clearance of at least 200 mm must be provided between the lowest point of substation door frame and the ground level, in order to allow for ap-propriate operability of units, proper ventilation of the substation, and to avoid ingress of water into the substation.

Fig.1


installation

Installation

To lift the transformer to its place, carry out the following operations after the compact transformer substation has been erected.

To lift the transformer into its place by means of a crane, remove the substation roof. The roof is secured to the concrete body by means of 2 pcs of M16 bolts which are found at two diagonally opposite corners of the roof inside the substation. At the other two diagonally opposite corners of the substation, two additional steel centre pins are found which are intended to help you position and fix the roof (Fig. 2).As a first step, remove bolts fixing the roof (2 pcs of M16 bolts) shown in Fig. 2. To lift off the roof, screw lifting eyes supplied with the substation into bores located on the two longitudinal sides of the roof (Fig. 3). Then, the roof can be lifted off, and the transformer can be lifted into the substation.

To ensure appropriate ventilation for the transformer, mount wheels of transformer beneath the transformer, and install a vibration absorber underlay under each wheel.

Fig.2


installation

In the compact substation, medium voltage and low voltage cables with cross section and number corresponding to the rated power of the trans-former are provided, as follows.

For 630 kVA:Medium voltage cable: N2XSY 3x1x35 mm2 12/20 kV type cable, mounted with a cable termination at both ends (with a Size 12 cable lugs on the transformer side).Low voltage cables: 4x3x1x185 mm2 NSGAFöU 1,8/3kV (or H07K-V 4x3x1x240 mm2). Mounted with M12 size cable lugs at one end, with cable lugs and shrinking tube supplied for the other cable end (colour marking of conductors: L1: green, L2: yellow, L3: red, N: blue).

For 1000 kVA:Medium voltage cable: N2XSY 3x1x35 mm2 12/20 kV type cable, mounted with a cable termination at both ends (with a Size 12 cable lugs on the transformer side).Low voltage cable: 4x4x1x185 mm2 NSGAFöU 1,8/3kV (or 4x4x1x185 mm2 H07K-V). Mounted with M12 size cable lugs at one end, with cable lugs and shrinking tube supplied for the other cable end (colour marking of conductors: L1: green, L2: yellow, L3: red, N: blue).

After the transformer has been lifted to its place by means of a crane on the site, connect medium voltage and low voltage cables provided and connect earthing cables to earthing points of the transformer. If the transformer has a thermal protection, also connect the 3x1.5 mm2 MT cable to the transformer thermal pro-tection unit’s N.O. trip contacts according to a circuit diagram shown in a manual supplied with the substation. After the transformer has been connected, replace the roof.

Finally remove lifting eyes used for lifting the roof (Fig. 3).

Fig.3

Fig.4


installation

Insert the 2 pcs of M16 bolts fixing the roof back into the holes. It is recommended to store dismantled lifting eyes in the cable space of low voltage compartment.

During the installation of the compact substation, install an appropriate shock protection system around the sub-station according to relevant standards in such a way that earthing resistance should be less than 2 ohms.

Inside the transformer substation, the electric units, the metal supporting structures, and doors and windows are at-factory earthed in the shortest route. Inside the substation, a shock protection junction has been installed (Fig. 4) in the low voltage compart-ment. It is that point to which the earthing conductors of installed equip-ments, the metal parts found inside the substation and the PEN bar of the low voltage panel are connected,

using a 50 and 70 mm2, respectively, green/yellow wire (with a cable lugs at both cable ends). If the transformer is installed into the station on the site, then its earthing points must also be connected to the above mentioned junction, using the available earthing conductor.

The external earthing network and potential control frame shall be entered into the substation through a low voltage cable entry found in the sidewall of substation. Connect the external earthing network (earthing frame) to the PEN bar. To connect the earthing conductor (or flat steel piece) a hole with a diameter of 13 mm is provided on the PEN bar. The external potential control frame must be connected to the bonding (potential equalization) bar. To connect the frame, a hole with a diameter of 11 mm is provided on the bonding bar.

The installed external earthing system must be connected using safe and durable electric and mechanical joints.Medium voltage cable entries are not at-factory sealed. Upon request, ABB can provide cable glands (Hauff HRD) to seal them (Fig. 5). The substation can be supplied with Hauff HSI type of cable glands as well.

If Hauff HRD cable glands are to be installed, observe the following mounting sequence:

Before entering medium voltage cables into the substation, pass the cables through the cable gland. Then, connect each cable to the medium voltage switchgear, and insert the gland into a rupture in the concrete. After adjusting the cables, use the M6 bolts to fix the sealing. By fastening the bolts, the rubber sealing will fill the space between cables, and the space between the gland and the concrete hole, thereby ensuring watertight condition of cable entries.

In case of using Hauff HSI system:The core element of the HSI cable gland is embedded into the concrete foundation. After removing the covering plate of the core element, the adequate HSI cable gland has to be installed into its place. The HSI set contains heat shrinking tubes, what need to be put on the cable gland before entering the cable to the substation. When the cables are connected, the sealing can be realized by heating the shrinking tubes on the cable gland. Please study carefully the manual of the cable gland!

Upon completion of installation, perform backfill of surplus earth and compact it. It is recommended to lay walk-resistant paving tiles in a width of 80 cm around the substation.

Documents concerning the operation and maintenance of installed equipment are provided in the Substation Manual which will be delivered with the substation and

should be normally kept in a document holder in the internal side of the substation.

Fig.5


installation

Fig.6

Fig.7


operating and Maintenance Manual

General rules

Entry into the substation is forbid-den, and is impossible due to the fact that the room is very tight. So, in regard to type, these substations are outside operated. Do not touch or enter any part - not intended for operation - of the substation until the substation has been made dead (neutralized). As a standard solu-tion the doors are fitted-up with a 3 point lock. The locks allow a pro-filed half-cylinder lock pad to be in-stalled. Each door is equipped with a door stopper which automatically latches when the door reaches its end position. The latch of the door stopper must be released before closing the door. Upon completion of control and maintenance of the substation, close the doors of the compact substation, and before leaving check whether the doors are properly closed and locked.

Operation of ORION 400A and ORION 630A

Operating the transformer substa-tion is possible from outside, after opening a double-leafed door on a longitudinal side of the transformer substation. The right hand side door has a lock in order to prevent unauthorized from entering. The low voltage panel is found - when looking at the longitudinal side of transformer substation equipped with a door - behind the right hand side door. After opening and prop-ping up the door you can control the low voltage compartment

from outside. The door of medium voltage compartment is found to the left and cannot be opened until the low voltage compartment door has been opened, by moving the push locks installed at the top and bottom parts of the door. The SF6 insulated medium voltage switch-gear unit (RMU) is found behind the left hand door. As standard, a three-cubicle SafeRing CCF type switchgear unit will be installed in the medium voltage compartment of the compact substation. In that case, the transformer compartment will have no door. In such case, an access to the tap changing switch of transformer will be accessible, after opening both door leaves, through a free space between the medium voltage switchgear unit and the low voltage panel. Should a 4-cubicle SafeRing CCCF type switchgear unit be installed in the medium voltage compartment, an additional transformer door will be built on the shorter wall on the side of the transformer substa-tion, found toward the low voltage panel. In that case, the tap chang-ing switch of transformer will be accessible from there.

Operation of ORION 1000M

In case of ORION 1000M the medium voltage switchgear and low voltage panel can be found in two different compartments. Both compartments can be accessed after opening the double-leafed door. There are concrete separation walls among the transformer room,

the medium voltage compartment and the low voltage compartment. As a basic solution the transformer room has a separate door. The tap changing switch of the trans-former can be accessed from here. As a standard the substation is equipped with a 3-way SafeRing CCF, but a 4 or 5-cubicle RMU can also be installed.

Operation and main-tenance of medium voltage unitThe operation and maintenance of the switchgear must be performed according to Instructions for Instal-lation and Operation titled “SafeR-ing / SafePlus SF6-insulated Ring Main Unit and Compact SwitchgearInstallation and operating instruc-tions (No: 1VDD005976 GB NOPO-WSR 5976 GB)“

Turning the medium voltage unit on and off Load break switches installed into line cubicles type C of the switchgear unit have a snap action mechanism. They are operated with a double-arm operating handle belonging to the switchgear unit accessories. Direction of rotation is clearly indicated on the front panel of medium voltage switchgear. An unintentional switching opera-tion is excluded because even the insertion of operating handle

11.ABB Orion 400A, ABB Orion 630A and ABB Orion 1000M type Concrete Compact Secondary Substations

Operating and Maintenance Manual

ABB Katalógus 200952


is prevented by means of a me-chanical cover of the driving stud in order to avoid a forbidden opera-tion. Switching state is indicated by position indicators linked with the load break switch mechanism, fit to the switching scheme on the front panel. Closing covers are found in front of the switching coulisses, allowing any of the three switching positions - ON, OFF, Earthed - to be padlocked.

An isolator switch installed into transformer cubicle type F has spring energy storage drive which is at default manually operated but can also be tripped by an N.O. release which operates in the case where the thermal protection unit of transformer has tripped, or by means of a mechanism fitted to a striker mechanically indicating fuse blowout. As a result, even a single pole blowout of fuse link will cause 3-pole disconnection.

Voltage checkup

Capacitive voltage dividers are in-stalled into the bushings realizing a medium voltage cable connection of the switchgear. As a standard, the ON state of power is indicated by a VPIS type integrated voltage indicators (LED) on the front panel of the given cubicle of the switch-gear. Identification of the phases is achieved by labels on the front of the voltage indicator.

Removing the cable compartment cover

The cable compartment cover of line and transformer cubicles of switchgear and the fuse space cover of transformer cubicle are interlocked with the earthed posi-tion of an insulator switch installed in the given cubicle.

Covers may not be removed unless the isolator switch is earthed, so always make sure - before opening the cover - that the isolator switch is earthed.

Fuse insertion and replacement

To handle fuse space - after turning off the cubicle’s isolator switch - turn earthing switch on. A red display at the bottom part of front panel, beneath the fuse link symbol indicates fuse blowout. Fused switch cubicles (F- modules) are de-livered without fuse links. Perform fuse replacement always in all of the three phases, and ensure that the striker should be in the required position. The required position is indicated on the internal side of the fuse canister’s covering plate.

Cable connection

SafeRing / SafePlus switchgear units are equipped with outer cone bush-ings which comply with specifica-tions for cable connectors set out in DIN 47636T1 and T2/EDF HN 525-61 standards. Possible exchange of phases has absolutely no problem for single-phase cables. For 3 phase cables - due to the tight cable space - take special care when cutting them to size and inserting them in such a way that the cable should remain straight at the cable terminations.

How to handle SF6 gasThe switchgear unit is completely sealed which means that SF6 gas is inside a solid enclosure. Handling the SF6 gas requires no special instructions, specifications, rules. The unit is always supplied with a pressure indicating manometer. Before operating the unit, always check gas pressure on the manom-eter. If the pointer is in the green zone, pressure is okay. If the pointer is in the red zone, pressure is very low, and do not operate the unit. In that case, fill the unit with gas after switching-around neutralization. For an arcing fault, arc products (decomposition products of SF6, combustion products of insulant) will get first into the cable space, then through the arc cooling chan-nel into the transformer space,

then to open air and will disperse within a short period. SF6 gas is an inert gas with large molecules, existing in the atmosphere as well. Its decomposition products and the combustion products of insulant and the metal vapours are toxic when in high concentration. Proceed as follows to remove small amount of SF6 gas residual in the substation:

After a trouble causing an arc- Ůing fault, do not approach the sub-station neutralized on the power feed side and do not stay near it until the fume having an unpleas-ant odour has dispersed.

After opening the substation Ůdoors, parts found at a deep point such as transformer oil collection pit, cable spaces must be vacuum cleaned. Then, dust bag must be annihilated.

Neutralize a possibly produced Ůwhite powder using lime hydrate or sodium carbonate solution.

Wash the cover using sodium Ůbicarbonate solution.

Operating the low voltage panelOnly skilled and properly trained personnel may operate the low voltage panel. The Operator shall be responsible for ensuring and checking it. The operation of unit must be regulated in Instructions for Operation to be issued by the Operator. The operating personnel shall bring with them the safety facilities required for the operation of the unit. If required by the Cus-tomer, the earthing/short-circuiting device will form part of the trans-former substation. During main-tenance operation, specifications indicated in standards shown in the Instructions for Operation shall be governing, and relevant labour safety and accident prevention rules and precautions must be ob-served. Agents, washing fluids used for the work may be fire hazardous, accident hazardous and harmful to health, therefore, use them as intended only, with an enhanced caution. The low voltage panel requires no special fire protection measures.


Low voltage panelRemove dust from the low Ů

voltage roomClean ventilation surfaces ŮCheck connections, bars ŮCheck fixing pieces of installed Ů

devices and moving elements of the house (doors, door stopper, lock etc)

Check fuse links ŮCheck existence of labels ŮCheck earthing cables and Ů

connectionsCheck and clean insulators ŮCheck auxiliary and control Ů

circuits (internal lighting, socket, transformer thermal protection circuit, etc)

If circuit breaker is installed, Ů check the operation of the breaker and test the protection

Check current joints once every Ů 10 years


Check gas pressure in the Ů medium voltage unit

Clean MV switchgear and clean Ů MV room

Check operation of MV Ů switchgear (open, closed, earthed positions)

Check interlockings of the Ů switchgear

If circuit breaker panel is Ů installed, check the operation and the protection of the circuit breaker

Transformer and transformer room

Clean transformer and Ů transformer room

Check the condition of MV and Ů LV cables

Check the condition of MV and Ů LV connections

Check thermal protection Ů

unit of transformer, and check the adherent circuit.

Check the oil level of the Ů transformer

Check the earthing of the Ů transformer

Check insulation of the Ů transformer (on the base of Operator decision)

Collect oil sample from the Ů transformer and test it (on the base of Operator decision)

Materials required for maintenance operation

Earthing – short circuiting Ů device

Solvents, degreasing fluids, Ů denatured alcohol, cloth, rag

Vacuum cleaner ŮTorque wrenches, screwdrivers, Ů

fork spansDouble-hand operating handle ŮAmpere and Volt meter (Multi Ů

Meter)Insulation tester ŮVial for oil sample Ů

MaintenanceChecking the techni-cal conditionCheck the unit visually at least once a year, for the following:

Is sufficient room provided for Ů the work?

Condition of low voltage distri- Ů bution unit

Number and intact state of Ů switching devices

Readouts shown by built-in Ů instruments

Condition of built-in fuse links. Ů

Instructions for maintenance

Use only materials of the same type as the original one for the main-tenance of the unit because the properties, function and physical parameters of other types may be different.

Maintenance work on the compact substation shall be performed by personnel belonging to the Op-erator, or by authorized personnel appointed by the Operator. Before maintenance operation, neutralize the substation by disconnecting

the transformer cubicle of medium voltage switchgear. For any main-tenance work on the low voltage line, the outgoing feeders must be earthed according to the following:

Remove fuse links after Ů opening switch covers.

Connect clamp jaw contacts of Ů the earthing unit to the PEN bar of the unit.

Insert three connection Ů elements - having a cover - of earthing device into L1, L2 and L3 phases of the unit.

Operating the low voltage panelThe low voltage outgoing feeders (fused switches) are suitable for conducting, making and breaking normal currents and small overload

currents. Apply a vigorous move-ment to pull out fuse base cover when turning the unit off, and to push it back when turning on. When turning off one fused switch, push back the switch cover without fuse link. This state of fuse base

will prevent live points from being touched upon, and the transparent covers will allow checking discon-nected state. For high overload or fault currents the fuse will blow out according to its characteristics.

Materials required for maintenance operation



általános leírásáltalános leírás

ABB Mérnöki, Kereskedelmi és Szolgáltató Kft.Modular SystemsCompact Secondary SubstationsH- 1138 Budapest, Váci út 152 - 156Tel.: +36 1 443 2235Fax: +36 1 443 2288www.abb.hu

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