UniSafe 36Medium voltage, arc-proof, air-insulated,metal-clad switchboard

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CHARACTERISTICS AND APPLICATIONS

DESCRIPTION

APPARATUS

SWITCHBOARD CHARACTERISTICS

REF 542 PLUS UNIT

INSTRUMENT TRANSFORMERS

TECHNICAL DATA

TYPICAL UNITS

PROTECTION AGAINST TO INTERNAL ARC

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CHARACTERISTICS AND APPLICATIONS

UniSafe 36 characteristics• Metal-clad air insulated switchboard• Designed for medium voltage distribution• Factory-tested for indoor installations• Arc-proof switchboard• Earthed metallic partitions between

compartments

• Mechanical safety interlocks• Compartments made of AluZinc coated steel

sheets• Front access for installation, maintenance and

routine operations• Conventional instrument transformers• Wide range of functional units for any installation

requirement• Easy-to-assemble modular structure.

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Transports• Airports• Ports• Railways• Underground transport.• Light Rail Transport

Services• Shopping Centres• Supermarkets• Hospitals• Infrastructures and civil works.

Applications

Utilities and Power Plants• Power stations• Transformer stations• Switching stations• Main and auxiliary switch-

boards.

Industry• Pulp and Paper• Textile• Chemical• Food• Automotive• Petrochemical.

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Thanks to compactness (all the units are only 1000mm wide), reduced footprint and the possibility ofplacing the switchboard against the installationroom walls of Unisafe 36.

All the operations can be carried out from the frontof the switchboard.

The switchboard is also available in the Back toBack arrangement version for carrying out doublebusbar system configurations.

The entire busbar system (main and branches) ismade with insulated round bars.

Apart from making the main busbar systeminstallation operations extremely simple, thesecharacteristics help to guarantee the performancesrequired by a 36 kV air insulated switchboard.

In order to ensure easy access to the feedercompartment and, at the same time, not to in-crease the switchboard dimensions, the transform-ers for current measurement are specially posi-tioned with a particular triangular shape.

This special layout of the transformers allows allthe electrical parameters of the switchboard andensures more space for the operators duringerection and maintenance procedures.

Metal sheets segregate each compartment and theenergised components are air insulated.

The arc-proof units have been tested in compliancewith IEC 60298 Standards.

The installation requires very simple civil works.The switchboard can be wall-mounted.

The power cables terminals are accessible fromthe front.

Protection degreesThe protection degrees in compliance with IEC60529 Standards are the following:• IP4X on the external housing• IP2X inside the compartments.Cubicles with higher protection degrees (up to amaximum of IP51) can be manufactured uponrequest.

DESCRIPTION

UniSafe 36 is the switchboard version made forapplications over 24kV and up to 36 kV.

UniSafe 36 can be used for higher altitudes above1000 m a.s.l. for rated voltage below 36 kV.The main characteristics of the UniSafe switch-board remain the same.

Standard colourRAL7035

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1 Circuit breaker compartment2 Busbar compartment3 Cable compartment4 Low voltage compartment

Main electrical characteristicsThe electrical characteristics can change depending on different ambientconditions or on protection degrees higher than the standard values.

* Please contact ABB for 31.5kA solution.

Compliance with StandardsThe switchboard and its components comply with thefollowing International and European Standards:

5 Arc channel6 Current transformers7 Voltage transformers8 Earthing switch

Ambient conditionsThe switchboard ratings are guaranteed under thefollowing ambient conditions:

IEC Switchboard 60694

60298 Circuit breakers 62271 SF6 gas 60376 Earthing switches 60129

Minimum ambient temperature – 5 °C

Maximum ambient temperature + 40 °C

Maximum relative humidity 95 %

Maximum altitude 1000 m a.s.l.

In presence of unpolluted and not corrosiveatmosphere.

Rated voltage 36 kV

Rated current ... 2500 A

Rated short time withstand current ... 25 kA*

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APPARATUS

HD4 medium voltage circuit breakers use sulphurhexafluoride (SF6) for arc quenching and as an insulatingmedium.

HD4 breaking principle relies on compression and self-blasttechniques in order to achieve the best performances at allservice current values with minimum arc times and gradualarc extinction without chopping, restriking and operatingovervoltages.

These features guarantee a long electrical life for the circuitbreaker and limited dynamic, dielectric and thermal stresseson the network.

The poles, which form the breaking part, are maintenance-free, life-long sealed pressure systems in compliance withIEC 62271 Standards.

HD4 SF6 Circuit breakerUniSafe 36 switchboard is equippedwith SF6 HD4 circuit breaker.The circuit breaker is fitted with atruck for the racking in and out withclosed door.

The light and compact structure ofUnisafe 36 guarantees sturdinessand high mechanical reliability. Thestored energy, free-release mechani-cal operating mechanism allowsopening and closing without theoperator’s intervention.

The operating mechanism and thepoles are fixed to the metal structure,which acts also as a support for thekinematics automation of the movingcontacts.

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3SWITCHBOARD CHARACTERISTICS

CablesThe cable compartment is easily accessible from the front thusmaking it possible to have a wall-standing installation. The unitscan be equipped with single or three core cables depending onthe current rating and the cable cross-section.

Branch connectorsThe feeder compartment houses the branch systemfor connecting the power cables to the circuitbreaker fixed insulating contacts.The branch connectors are made of electrolyticinsulated round copper.

CompartmentsEach unit consists of three power compartments;busbars, feeder, circuit breaker and low voltagecompartment for instruments,auxiliary circuitwiring.Main busbarsThe busbar compartmenthouses the main busbarsystem, which isconnected to the circuitbreaker fixed insulatingcontacts by means ofbranches. The mainbusbars are made ofinsulated electrolyticcopper.The system is air-insulated and busbars areinsulated tubular bars.

Feedercompartment :Lower bushings,currenttransformers andbranchconnectors.

Earthing switchEach feeder unit can beequipped with an earthing switchfor the earthing of the powercables.The same device can also beused for the earthing of thebusbar system (measuring, bustie and rise units). The devicehas short circuit current makingcapacity.On request, its opening andclosing operationscan be prevented by means ofkey or padlocks.The earthing switch is properlymechanicaly interlocked withcircuit breaker and manuallyoperated from the front

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Earthing busbarThe earthing busbar is made of electrolytic copper.It runs through the whole switchboard length thus guaranteinga high safety degree both for the personnel and the installation.

Bushings and shuttersThe bushings consist of insulating monoblocs, which house thepower contacts for the connection between circuit breaker andfeeder / busbar compartments.The shutters are automatically operated when the circuitbreaker is drawn from test to service position and vice versa.On request, two independent padlocks can lock each shutterseperately.

SWITCHBOARD CHARACTERISTICS

InterlocksThe switchboard is equipped with all the interlocks necessary toprevent any incorrect operation that might jeopardise thepersonnel safety and put at risk the installation functionality.

In particular the following interlocks are provided to prevent theseoperations:– circuit breaker closing (undefined truck position)– circuit breaker racking-out (circuit breaker closed)– circuit breaker racking-in (circuit breaker closed)

Access to the cable compartment isachieved either from front or from sideduring the installation of the cubicles at site

Automatic shutters

If the unit is equipped with an earthingswitch, the following interlocks are alsoprovided:– earthing switch closing (circuit

breaker in service or undefinedposition)

– circuit breaker racking-in (earthingswitch closed)

Withdrawable circuit breakercontrol wiring plug&socket

Interlocks on earthing switchoperating mechanism

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– standard set of spare parts and accessories in asingle hardware unit;

– reduced maintenance. The use of REF 542 Plusdrastically reduces the routine maintenance andlimits the damage caused by tampering andmisuse;

– easy function modification and updating bymeans of the unit configuration software evenwhen the switchboard is energised.

UniSafe advanced technology along with theoutstanding performances of REF 542 Plus,ensures a real-time, throughout control of the plantand significantly increases ease of use, withconsiderable benefits for running costs andefficiency.The direct connection between apparatus andswitchboard control system fully implements theconcept of an integrated installation at the highestlevel.

REF 542 Unit Plus.

REF 542 Plus unit integrates all theswitchboard secondary functions in asingle, self-checking module.Thanks to its versatile software, theunit provides a wide range of differentinstallation applications. The remark-able functional efficiency of the REF542 Plus unit is enhanced by asimple, easy-to-use interface. Thanksto the use of REF 542 Plus, each

medium voltage UniSafe becomes an integratedand independent unit to meet any customer need.Main characteristics:– integration of all the functions (protection,

measurement, controls, signalling, interlock,automation and communication) in a singledevice;

– single interface between switchboard andoperator for all the units: line, transformer, motor,generator, capacitor banks, bus-tie and meas-urement units;

REF 542 PLUS UNIT

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1 2

MASTER UNIT

3 4

NETWORKCONTROLCENTER

MASTER UNIT

SWITCHGEAR LEVEL

REF 542 Plus

NETWORKCONTROLCENTER

SWITCHGEAR LEVEL

REF 542 Plus

NETWORKCONTROLCENTER

MASTER UNIT 2

SWITCHGEAR LEVEL

CONTROL LEVEL

SCADA

SWITCHGEAR LEVEL

CONTROL LEVELMASTER UNIT 1 MASTER UNIT 2MASTER UNIT 1

DCS/PCS

CONTROL LEVEL CONTROL LEVEL

REF 542 Plus REF 542 Plus

Communication protocols• SPABUS• LON• MODBUS RTU• IEC 60870-5-103

Integrated control system System Layout

Communications cabling• Serial RS485• Optic fiber

1 Single communication gate on single bus2 Double communication gates on redundant bus3 Double communication gates on redundant bus and master

units4 Two systems architecture: SCADA and DCS/PCS.

REF 542 PLUS UNIT

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Voltage transformersThe resin-insulated voltage transformers are usedfor the feeding of measuring instruments andprotections. They are suitable either for fixedinstallation or mounted on withdrawable trucks.They comply with IEC 60044-2 Standards.The withdrawable version equipped with fuses iscustom-made.The voltage transformers can be fitted either withone or two poles. Their performances and accuracyclasses comply with the functional requirements ofthe apparatus they are connected to.The withdrawable version is equipped with mediumvoltage protection fuses, their replacement can becarried out while the switchboard is in service.

Current transformersThe current transformers are resin-insulated andsuitable for the feeding of measuring instrumentsand protections.

These transformers can have a wound core or abushing bar with one or more cores. Their perform-ances and accuracy classes comply with theapparatus requirements.The current transformers comply with IEC 60044-1Standards.The switchboard units can be equipped with one ortwo transformer sets, in accordance with thefollowing combinations:

The current transformers can be equipped alsowith a capacitive socket for being connected tovoltage indicator lamps.

Toroidal current transformersThe toroidal current transformers are resin-insulated and suitable for the feeding of measuringinstruments and protections.These transformers can have a ring or a split core.Their performances and accuracy classes complywith the apparatus requirements.They are suitable both for measuring phasecurrents and determining earth fault currents. Theymeet the requirements of IEC 60044-1 Standards.

Current transformers block typeDimensions according to DIN standards

Optionally Toroidal CT’s available

Withdrawable Voltage transformers forbusbar side with primary fuses

Fixed type for cable side

INSTRUMENT TRANSFORMERS

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busbar system) for closing to earth bymeans of a control.During the racking-inphase, the power cables earthing truck onlylifts the bottomshutter and presets thecontacts connected to the bottom branches(and therefore to the power cables) forclosing to earth by means of a control.These trucks can also be used in bus-tieunits.In this case, they earth the two sidesof the main busbar system

SERVICE TRUCKS

The UniSafe 36 can be fitted with the service truckrequired to complete the switchboard and neededin service operations and during maintenancework.The truck has earthing with making capacity.

Earthing truck with making capacityThese trucks carry out the same function as theearthing switches with making capacity.They consist of circuit-breakers only fitted with top(main busbar earthing) or bottom (power cablesearthing) terminals. The contacts without terminalsare short-circuited by means of a copper bar andconnected to earth by means of the apparatustruck.They keep all the characteristics of the circuit-breakers, such as full making capacity and openingof the live circuits under fault conditions.They are used to ensure extremely efficaciousearthing on circuits stressed by a fault. They allowopening and closing operations to be carried outrapidly with remote electric control.The use of these trucks foresees removal of theswitching device from the switchboard (circuit-breaker or contactor) and its replacement with thetruck. The units preset for use of earthing trucksare fitted with a key lock which, if activated,prevents their racking-in.This truck is available in two versions:– main busbar system earthing;– power cables earthing.During the racking-in phase, the mainbusbar earthing truck only lifts the topshutter and presets the contacts connectedto the top branches (and therefore to the main

Power cables earthing truck with making capacity.

Main busbar systemearthing truck withmaking capacity.

Power cables earthingtruck with makingcapacity.

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8PROTECTION AGAINST INTERNAL ARC

An internal arc is extremely rare in metal-cladswitchboards since the apparatus is manufacturedso as to prevent such an occurrence. Anyway,UniSafe36 ensures maximum personnel safetyeven in case of internal arc. The switchboard isbuilt to withstand the overpressures ensuing fromthe internal arc and is fitted with ducts to convey theexhausted gases and prevent damage to operatorsand apparatus. The different units are guaranteedarc-proof in compliance with IEC 60298 Standards,enclosure AA, class accessibility A, criteria 1 to 6.

IEC 60298 Standards for internal arc test –Criteria definitions1 The switchboard doors must remain closed

and the covering units must never open up2 Any component that may result hazardous

for the personnel must never be ejected3 The outside enclosure should never get pierced

in the parts accessible to the personnel4 Vertically arranged indicators outside the

switchboard must not get burnt5 Horizontally arranged indicators outside

the switchboard must not get burnt6 All the earthing connectors must remain

effective.

Internal arc test indicators arrangement. Test carried out by means of an infrared camera.

Fast RecoveryUniSafe 36 switchboards can be equipped withFast Recovery, a specific protection system. Thissystem is based on pressure sensors suitablylocated into the switchboard and directly connectedto the opening releases. The sensors detect thepressure rise at the moment of the internal arcoutburst and promptly open the circuit breaker.Thanks to the Fast Recovery System only the partinvolved in the fault is selectively excluded in lessthan 100 ms (including the circuit breaker openingtime).A rapid elimination of the fault along with the metalsegregation between compartments and the use ofself-extinguishing materials drastically reduces anypossible damage.

Fast Recovery pressuresensor.

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9TECHNICAL DATA

ELECTRICAL CHARACTERISTICS

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10TYPICAL UNITS

Dimensions

without arc duct (width x depth x height) (mm) : 1000 x 2310 x 2161with arc duct (width x depth x height) (mm) : 1000 x 2310 x 2662

Rated main busbar current (A) : 1250 / 1600 / 2000 / 2500

Rated circuit current (A) : 1250

Block type current transformers 1 : YesFixed type voltage transformers without fuses : OptionalCable core current transformers 2 : OptionalEarthing switch : OptionalArc duct : Optional

1 Post insulators replace block type current transformers whenever latter is not required2 Cable connection is typically one cable per phase when cable core current transformers are used

IF unitCircuit Breaker Cubicle, 1250A

Top Cable entry versionsRated mainbusbar current (A) : upto 2500

Rated circuit current (A) : 1250

Dimensionswithout Arc duct WxDxH (mm) : 1000x2960x2161with Arc duct Please contact ABB

Feeding two seperate lines withtwo set of current transformers

Rated main busbar current (A) : upto 2500Rated circuit current (A) : 1250

Dimensionswithout Arc duct

WxDxH (mm) : 2000x2310x2161with Arc duct

WxDxH (mm) : 2000x2310x2662

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TYPICAL UNITS

Dimensions

without arc duct (width x depth x height) (mm) : 1000 x 2370 x 2161with arc duct (width x depth x height) (mm) : 1000 x 2370 x 2662

Rated main busbar current (A) : 1600 / 2000 / 2500

Rated circuit current (A) : 1600 / 2000

Block type current transformers 1 : YesFixed type voltage transformers without fuses : OptionalEarthing switch : OptionalArc duct : Optional

1 Post insulators replace block type current transformers whenever latter is not required

IF unitCircuit Breaker Cubicle, 1600A / 2000A

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TYPICAL UNITS

IF unitCircuit Breaker Cubicle, 2500A

Dimensions 1

without arc duct (width x depth x height) (mm) : 2000 x 2310 x 2161with arc duct (width x depth x height) (mm) : 2000 x 2310 x 2662

Rated main busbar current (A) : 1600 / 2000 / 2500

Rated circuit current (A) : 1600 / 2000 / 2500

Block type current transformers 2 : YesFixed type voltage transformers without fuses (cable side) : OptionalWithdrawable type voltage transformers with fuses (busbar side) : OptionalEarthing switch : OptionalArc duct : Optional

1 Narrow version of UniSafe 36 is available for 4x cable per phase connections. Dimensions of this version arewithout ar duct WxDxH (mm) : 1000x2965x2161, with arc duct WxDxH (mm) : 1000x2965x26622 Post insulators replace block type current transformers whenever latter is not required

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TYPICAL UNITS

Dimensions

without arc duct (width x depth x height) 1 (mm) : 1000 x 2310 x 2161with arc duct (width x depth x height)1 (mm) : 1000 x 2310 x 2662

Rated main busbar current (A) : 1250 / 1600 / 2000 / 2500

Rated circuit current (A) : 1250

Block type current transformers 2 : YesWithdrawable type voltage transformers with fuses : OptionalEarthing switch : OptionalArc duct : Optional

1 The width of each Bus tie and Riser cubicle is 1000 mm. Each panel can be used seperately for various combinations2 Post insulators replace block type current transformers whenever latter is not required

BT & R unitBus tie and Riser Cubicle, 1250A

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TYPICAL UNITS

BT & R unitBus tie and Riser Cubicle, 1600A / 2000A / 2500A

Dimensions

without arc duct (width x depth x height) 1 (mm) : 1000 x 2310 x 2161with arc duct (width x depth x height)1 (mm) : 1000 x 2310 x 2662

Rated main busbar current (A) : 1600 / 2000 / 2500

Rated circuit current (A) : 1600 / 2000 / 2500

Block type current transformers 2 : YesWithdrawable type voltage transformers with fuses : OptionalEarthing switch : OptionalArc duct : Optional

1 The width of each Bus tie and Riser cubicle is 1000 mm. Each panel can be used seperately for various combinations2 Post insulators replace block type current transformers whenever latter is not required

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TYPICAL UNITS

Dimensions

without arc duct (width x depth x height) (mm) : 1000 x 2310 x 2161with arc duct (width x depth x height) (mm) : 1000 x 2310 x 2662

Rated main busbar current (A) : 1250 / 1600 / 2000 / 2500

Rated circuit current (A) : 1250

Withdrawable type voltage transformers with fuses : YesEarthing switch : OptionalArc duct : Optional

M unitMeasuring Cubicle, 1250A

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TYPICAL UNITS

IFD unitDirect Cable Connection Cubicle

Dimensions

without arc duct (width x depth x height) (mm) : 1000 x 2310 x 2161with arc duct (width x depth x height) (mm) : 1000 x 2310 x 2662

Rated main busbar current (A) : 1250 / 1600 / 2000 / 2500Rated circuit current 1 (A) : 1250Block type current transformers 2 : YesWithdrawable type voltage transformers with fuses : OptionalFixed type voltage transformers without fuses : OptionalCable core current transformers 3 : OptionalEarthing switch : OptionalArc duct : Optional

1 Rated circuit current 1600A / 2000A / 2500A versions are available. Please consult ABB for details2 Post insulators replace block type current transformers whenever latter is not required3 Cable connection is typically one cable per phase when cable core current transformers are used

Direct busbar connection to main busbar

(with Duresca brand Busbars)

Rated main busbar current (A) : upto 2500

Dimensionswithout Arc duct

WxDxH (mm) : 2000x2310x2662with Arc duct

WxDxH (mm) : 2000x2310x3177

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TYPICAL UNITS

IFM unitCircuit Breaker Cubicle with Measurement

Version with withdrawable fused voltage transformers connected to cable sideRated main busbar current (A) : 1250 / 1600 / 2000 / 2500Rated circuit current (A) : 1250 / 1600 / 2000 / 2500

Version with fixed type fused voltage transformers connected to cable sideRated main busbar current (A) : 1250 / 1600 / 2000 / 2500Rated circuit current (A) : 1250

Dimensions

without arc duct

WxDxH (mm) :1000x2960x2161

with arc duct

WxDxH (mm) :1000x2960x2662

Rated main busbar current (A) : 1250 / 1600 / 2000 / 2500Rated circuit current (A) : 1600 / 2000 / 2500

Dimensions

without arc duct

WxDxH (mm) :2000x2310x2161

with arc duct

WxDxH (mm) :2000x2310x2662

Dimensionswithout arc ductWxDxH (mm) :2000x2310x2161with arc ductWxDxH (mm) :2000x2310x2662

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TYPICAL UNITS

BM unitBusbar Measuring with Busbar Current Transformers

Dimensions

without arc duct (width x depth x height) (mm) : 2000 x 2310 x 2244with arc duct (width x depth x height) Please contact ABB

Rated main busbar current (A) : 1250

Rated circuit current (A) : 1250

Block type current transformers : YesArc duct : Optional

Above single line diaram and sectional drawing is given for information and illustration purpose only.In accordance with the requirement, busbar current transformers can be place between any type ofcubicles. Please contact ABB for detailed information.

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TYPICAL UNITS

Dimensions

without arc duct (width x depth x height) (mm) : 1000 x 3820 x 2161with arc duct (width x depth x height)1 (mm) : 1000 x 3820 x 2671

Rated main busbar current (A) : 1250 / 1600 / 2000 / 2500

Rated circuit current (A) : 1250 / 1600 / 2000 / 2500

Block type current transformers 1 : YesFixed type voltage transformers without fuses : OptionalCable core current transformers 2 : OptionalEarthing switch : OptionalArc duct : Optional

1 Post insulators replace block type current transformers whenever latter is not required2 Cable connection is typically one cable per phase when cable core current transformers are used

DIF unitDuplex Circuit Breaker Cubicle

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TYPICAL UNITS

DIFD unitDuplex Direct Cable Connection Cubicle

Dimensions

without arc duct (width x depth x height) (mm) : 1000 x 3820 x 2161with arc duct (width x depth x height) (mm) : 1000 x 3820 x 2671

Rated main busbar current (A) : 1250 / 1600 / 2000 / 2500

Rated circuit current (A) : 1250

Withdrawable type voltage transformers with fuses : OptionalCable core current transformers 1 : OptionalEarthing switch : OptionalArc duct : Optional

1 Cable connection is typically one cable per phase when cable core current transformers are used

Other duplex solutions

DBT unitDuplex Bus tieand riser cubicle

DM unitDuplex measuringcubicle

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ABB Elektrik Sanayi A.S.Organize Sanayi Bölgesi2. Cadde No. 16 Yukari Dudullu81260 Istanbul TurkeyPhone No. : +90 216 528 22 00Fax No. : +90 216 365 29 43e-mail: unisafe36.mail@tr.abb.comWeb site://www.abb.com