Medium voltage products

UniGear MCC
Arc-proof, air insulated motor control
center with fused vacuum contactor
2
Index

4 1. Description

6 2. Air insulated switchgear

10 3. IEC Classification

12 4. Design features

14 5. Fully type-tested

16 6. Safety

20 7. VSC vacuum contactor

22 8. Instrument transformers

24 9. Measurement sensors

28 10. Cable terminations

30 11. Distribution automation

42 12. Typical units

44 13. Technical data

3
1. Description

• A real 400 A load current with double fuses per phase in a

400 mm wide panel. The UniGear switchgear family is now
extended with a new motor control center solution, the
UniGear MCC.
• Designed for the highest degree of safety and reliability, the
UniGear MCC provides for maximum ease of use.
• All operations and maintenance actions are made from the
front of the panel, which is equipped with mechanical safety
interlocks between vacuum contactor and earthing switch.
• The vacuum contactor is the well-proven VSC type with
magnetic actuator.
• For optimal flexibility, the UniGear MCC is designed to
be used in combination with other versions of UniGear
switchgear, such as ZS1, 550 and 500R.

4
Characteristics of UniGear MCC Applications
Range Utilities and power plants
• …7.2 kV, …400 A, …50 kA • Substations
• IEC standards • Power generation stations
• Standard and customized versions • Transformer stations
• Switching stations
Features • Main and auxiliary switchgear
• Slim and compact panel only 400mm wide
• Fused vacuum contactor with magnetic actuator Industry
• Cable termination height up to 600mm • Pulp and paper
• Cement
Safety • Textiles
• Fitted with safety interlocks and visible earthing connection • Chemicals
• Internal arc classification IAC AFLR • Food
• Classified as LSC-2A, PM • Automotive
• Petrochemical
Flexibility • Quarrying
• Wide range of applications • Oil and gas pipelines
• Traditional and IEC 61850 based protection and control • Metallurgy
solutions • Rolling mills
• Mines

Marine applications
• Drilling platforms
• Off-shore oil rigs
• Cruise ships
• Container ships
• Tankers
• Cable ships
• Ferries

Transport
• Airports
• Ports

Infrastructure
• Shopping malls
• Hospitals
• Educationals

5
2. Air insulated switchgear

The UniGear range is now completed with the compact A real 400 A load current with double fuses per phase in a
contactor unit with fuses, the motor control center. 400 mm wide panel.
UniGear MCC is the result of many years of experience The vacuum contactors are capable of frequent switching
with the design, manufacturing and application of vacuum with low switching over voltages. The switchgear can be
contactors across the entire range of industrial and utility configured to meet the actual process requirements.
installations. Thanks to the use of fuses as the main means of protection, it
This panel use a magnetic actuator of vacuum contactor and can be used in installations with fault currents up to 50 kA.
it is designed specifically for motor, transformer and capacitor This unit is able to combine maximum accessibility of all
bank switching and protection for rated voltages up to 7.2 kV the components with limited dimensions available today for
and rated currents up to 400 A. medium voltage switchgear.
The innovative integration of the components offers a solution
with extremely reduced weight and footprint, allowing efficient
use of space in electrical installations.
The most evident characteristic of this unit is its
compactness, just 400 mm.
It therefore finds ideal application in installations with a high
number of contactor outgoing feeders or in situations with
very limited space available.
The use of the contactor unit with fuses is preferable to
the use of circuit-breakers when a high number of daily
operations is required.
The interrupters for use in the contactor guarantee an
extremely high number of closing and opening operations
under normal load conditions and with a maximum rated
short-time withstand current of 6 kA.
The electrical life of the contactor is defined as being in
category AC3 with 100,000 operations (closing-opening),
400 A interrupted current (for more informations please make
reference at page 20).
The use of medium voltage protection fuses strongly limits the
fault let-through energy, allowing the contactor to be used in
installations even with high fault currents.
This characteristic also helps to safeguard the levels of
insulation and increase the electrical life of the cables and of
the connected machine.

MF MF MF MF MF IF BT R IF MF MF MF MF MF

Figure 1 : Compound configuration with UniGear ZS1

6
For the same reason, the switchgear unit can use earthing The contactor position is defined in the followings:
switches for the power cables with reduced making capacities • inserted: contactor in operation position with earthing
compared to the rest of the switchgear components, but switch open
suitable in any case for the fault current available on the load • test: contactor in the middle position with eathing switch
side of the fuses. open
The limiting properties of the fuses also allow cables with • removed: contactor in extracted position with earthing
reduced cross-sections to be used for the connection switch closed
between the switchgear and the machines to be protected
(reductions between 60 and 80% can be obtained), leading to
a considerable reduction in costs.
UniGear MCC has the same overall dimensions (height and
depth) and the same main busbars arrangement as UniGear
ZS1 with a maximum current of 4000 A.
The unit can be coupled directly to others UniGear ZS1, 550
and 500R without the using of adaptor panel; a very flexible
solution.
For this panel, positioning back to the wall is possible.
In fact, the switchgear does not require access from the rear
for the installation and maintenance procedures.
All the service operations are carried out from the front.

As a standard solution, it is possible to connect up to two cables

per phase (maximum cross-section of 240mm²). The connection
height of the cables in relation to the floor is 600 mm.
The surge arresters as optional can also be inserted in the
cable area.

UniGear MCC uses ring core current transformers as the

standard solution, which are fixed onto “CT Rods”. On the
same CT rod can be fixed the sensors instruments.

The UniGear MCC switchgear is fitted with all the interlocks

and accessories needed to guarantee level of safety for
equipment and personnel and reliability for the installation and
for the operators.
The operations on the vacuum contactor are performed with
the front door closed.

Figure 2 : Cable connection area

7
2. Air insulated switchgear

One of the main characteristics of the UniGear MCC is the

new automatic earthing switch that it is operated by the
movement of the vacuum contactor.
This device is a patented switch with rectilinear movement.
This earthing switch has been dimensioned to conduct the
rated short circuit making current of the contactor on cable
side; this means 6 kA.
The earthing switch is equipped with three pins which
connects the three phases of the cable connection system.
The earthing pins are electrically connected to earth by a
stranded copper conductor.
The speed of the snap action closing operation is indipendent
of controls.
The closure of the earthing switch is drive by the movement of
the vacuum contactor truck.
When the vacuum contactor will move from “test”
to “removed” position the earthing switch will close
automatically.
With the clousure of the earthing switch it will be unlocked the
possibility to open the front door and get access to the power
cables.
The UniGear MCC panel is fitted with a front inspection
window to verify the open or closed position of the earthing
switch.

Figure 4 : Automatic earthing switch

The earthing switch has been tested at two closing operations

at 100% of the rated short-circuit making current (6 kA).

The device is provided with auxiliary switches for signalling the

open and closed positions, operated by the rod mechanism.
The following are available on request:
• locking magnet
• key locks for open and closed positions
• padlock

Figure 3: Earthing switch front indication

8
IEC electrical characteristics
Switchgear UniGear MCC
Type of construction – Internal arc classification IAC AFLR
Rated voltage [kV] 7.2
Insulation levels / power frequency / lightning impulse [kV] 7.2/20/60
Rated frequency [Hz] 50/60
Rated main busbar current (40 °C) (3)
[A] ... 4000
Rated feeder current (40 °C) [A] ... 400
Rated short-time current (1)
[kA x 3 s] .... 50
Arc proof withstand current (IEC 62271-200) (2)
[kA x 1 s] ... 50
Tested according to IEC
(1) Limited by the fuses.
(2) The internal arc withstand values are guaranteed on the busbar compartment; the supply side. The fault in contactor and cable compartment is limited by the fuses.
(3) 4000 A is achieved with UniGear ZS1 combination.

Standards Degrees of protection

The switchgear and main apparatus contained in it comply The degrees of protection of the switchgear conform with
with the following Standards: IEC 60529 Standards.
• IEC 62271-1 for general purposes UniGear MCC switchgear is normally supplied with the
• IEC 62271-200 for the switchgear following standard degrees of protection:
• IEC 62271-102 for the earthing switch • IP4X for the enclosure
• IEC 60071-2 for the insulation coordination • IP2X for the partitions between the compartments.
• IEC 60470 for the contactor On request, the external housing can be supplied with higher
• IEC 60529 for degree of protections degrees of protection; in this case, please contact your ABB
sales representative.
Normal service conditions The electrical characteristics of the switchgear can vary for
ambient conditions other than those described in the previous
The rated characteristics of the switchgear are section and also if a higher degree of protection is used.
guaranteed under the following ambient conditions:
• minimum ambient temperature: – 5 °C
• maximum ambient temperature: + 40 °C
For different temperature ranges, please contact your ABB
Colour of the external surfaces
sales representative RAL7035 - light grey. (Front doors and side sheets). Other
• ambient humidity: colours available on request.
- maximum 24 h average of relative humidity 95% RH
- maximum 24 h average of water vapour pressure 2,2 kPa
- maximum monthly average of relative humidity 90% RH
- maximum monthly average of water vapour pressure
1.8 kPa
• the normal operational altitude is up to 1000 m above sea
level. For higher altitude applications, please contact your
ABB sales representative
• presence of normal, non-corrosive and uncontaminated
atmosphere

9
3. IEC Classification

With the release of the IEC 62271-200 standard, new defi- Partition Metallic - PM
nitions and classifications of Medium Voltage switchgear
have been introduced. With regard to the type of partitions or shutters between
One of the most significant changes is that classification live parts and an open compartment, a distinction is made
of switchgear into metal-clad, compartmented and cubi- between two partition classes:
cle types has been abandoned. •  Class PM (Partition made of Metal)
The revision of switchgear classification rules has been •  Class PI (Partition made of Insulating material).
based on the user’s point of view, in particular on aspects UniGear MCC is defined with PM partition class having the
like service and maintenance of the switchgear, according segregation between compartments made of metallic sheets/
to the requirements and expectations for proper manage- shutters.
ment, from installation to dismantling.
In this context, Loss of Service Continuity (LSC) has been Interlock-controlled accessible
selected as a fundamental parameter for the user.
compartment
According to the IEC 62271-200, UniGear MCC switchge-
ar can be defined as follows. The front side of UniGear MCC is classified interlock-
controlled because the access of the compartments
containing high-voltage parts, intended to be opened for
normal operation and/or normal maintenance, is controlled by
Loss of service continuity - LSC-2A the integral design of the switchgear.
The various LSC categories describe the possibility of
keeping other compartments and/or panels energized while Tool-based accessible compartment
a compartment in the main circuit is opened. The defined
categories are: The rear part of the UniGear MCC is classified tool-based
•  LSC-1: the whole switchgear shall be put outof service for because it is possible to open the compartment containing
opening a main circuitcompartment for normal operation high-voltage parts, that may be opened, but not for normal
and/ornormal maintenance or for gaining access toany operation and maintenance, only using a tool. Special
switchgear components procedures are required.
•  LSC-2A: the same as LSC-1 with the exception that the
main busbars and the functional unitsadjacent to the one Internal arc classification – IAC AFLR
under maintenance can remain energized
UniGear MCC switchgear is classified IAC AFLR
•  LSC-2B: the same as LSC-2A with the exceptionthat the
When the switchgear is specified and installed, some
cable compartment can remainenergized.
fundamental points must be taken into consideration:
UniGear MCC is classified as LSC-2A because the busbar
• level of the fault current (16...50 kA)
and contactor cable compartments are physically and
• duration of the fault (0.1...1s)
electrically segregated. This is the category that defines the
• escape routes for the hot and toxic gases produced by
possibility of accessing the contactor/cable compartment with
combustion of materials
the busbars and cables energized.
• dimensions of the room, with special attention to the height.
Please consult your ABB representatives for detailed
information.

10
11
4. Design features

Compartments Earthing switch

Each switchgear unit consists of two power compartments Each contactor/cable compartment can be fitted with an
busbars [A], contactor/cables [B]; please refer to Figure 5. earthing switch for cable earthing.
The closing of the contactor/cables compartment doors is The earthing switch has short-circuit making capacity limited
with handle. by the presence of the fuses.
Each unit is fitted with a low voltage compartment [C], where Control of the earthing switch is from the movement of the
all the auxiliary instruments are housed. contactor with automatic operation.
Arc-proof switchgear is normally provided with a duct [D] for The position of the earthing switch can be seen from the front
evacuation of the gases produced by an arc; different types of of the switchgear by means of a mechanical coupled indicator
gas ducts are available. and via front inspection window.
All the compartments are accessible from the front and
maintenance operations can properly carried out with the Earthing busbar
switchgear installed up against a wall. The compartments are
segregated from each other by metallic partitions. The earthing busbar is made of electrolytic copper and it runs
longitudinally throughout the switchgear, thereby guaranteeing
maximum personnel and installation safety.
Main busbars
The busbar compartment contains the main busbar system Insulating bushings and shutters
connected to the upper isolating contacts of the contactor by
means of branch connections. The insulating bushings in the busbar compartment contain
The main busbars are made of electrolytic copper. the contacts for connection of the contactor with the busbar
For ratings up to 2500A, the busbars are made of flat bars; compartment.
while for currents between 3150A and 4000A, a special D- The insulating bushings are of three-pole type and are made
shape busbar is used. of epoxy resin. The shutter is metallic type and it is activated
The busbars are covered with insulating material. automatically during the movement of the contactor from the
There is a single busbar compartment along the whole length test position to the inserted position and vice versa.
of the switchgear, which optionally can be dividing into com-
partments.

Cable connections
The contactor/cable compartment contains the branch sys-
tem for connection of the power cables to the lower contacts
of the contactor.
The feeder connections are made of electrolytic copper and
they are flat bars for the whole range of current.

12
Cables
Single and three-core cables up to a maximum of two cables
per phase can be used depending on the rated voltage and
the cable cross section (please refer to page 28).
The switchgear can be back to wall installed as cables are
D
easily accessible from the front.

Gas exhaust duct

The gas exhaust duct is positioned above the switchgear and
runs along its whole length.
Each power compartment is fitted with a flap on its top
surface. The pressure generated by the fault makes it open, C
allowing the gas to pass into the duct. A
Evacuation from the room of the hot gases and incandescent
particles produced by the internal arc must normally be
carried out. The UniGear MCC switchgear can be fitted with
a complete range of solutions to satisfy with all requirements,
either in the case where evacuation is possible directly at the
end of the switchgear, or when solutions from the front or rear
are requested.
Some installations, such as marine applications, do not
allow evaquation of the gases to the outside of the room and
therefore a dedicated solution has been realised to guarantee
personnel safety and conformity with the Standards, such as
longitudinal evacuation chimneys. Please contact ABB sales
representative for more informations.

Unit compartments
A Busbar compartments
B Contactor/cable compartment
C Low voltage compartment
D Compact gas duct channel

Figure 5 : UniGear MCC section view

13
5. Fully type-tested

The UniGear MCC switchgear has undergone all the tests IEC type tests
required by the international (IEC) Standards and local
Standards organizations (for example, the Chinese GB/DL •  Short-time and peak withstand current
and Russian GOST standards). •  Temperature rise
As indicated in these standards, the tests were carried •  Internal arc capability
out on the switchgear units considered most sensitive •  Dielectric test
to the effects of the tests and therefore the results were •  Making and breaking capacity of contactors
extended across the whole range. •  Earthing switch making capacity
Each switchgear unit is subjected to routine tests in the •  Mechanical operations of contactor and earthing switch
factory before delivery. •  IP degree
These tests are intended to provide a functional check of
the switchgear based on the specific characteristics of IEC routine factory tests
each installation.
•  Visual inspection and check
•  Mechanical sequence operations
•  Cabling check
•  Electrical sequence operations
•  Power frequency withstand voltage
•  Measurement of the resistance of the main circuits
•  Secondary insulation test

Special type tests required by shipping

registers for marine application
•  High ambient temperatures (+ 45 °C)
•  Inclination
•  Vibration

Description of IEC type tests

•  Short-time and peak withstand current
The test shows that the main power and the earthing circuits
resist the stresses caused by the passage of the short-circuit
current without any damage.
It should also be noted that both the earthing system of the
withdrawable circuit-breaker and the earthing busbar of the
switchgear are subjected to the test.
Figure 6: UniGear MCC panel after internal arc test The mechanical and electrical properties of the main busbar
system and of the top and bottom branch connections remain
unchanged even in the case of a short-circuit.

•  Temperature rise
The temperature rise test is carried out at the rated current
value of the switchgear unit and shows that the temperature
does not become excessive in any part of the switchgear unit.
During the test, both the switchgear and the circuit-breaker or
contactor it may be fitted with are checked.

•  Internal arc capability

Please refer to page 16.

14
• Dielectric test
These tests verify that the switchgear has sufficient
Capability to withstand the lightning impulse and the power
frequency voltage.
The power frequency withstand voltage test is carried out as
a type test, but it is also routine test on every switchgear unit
manufactured.

• Contactor making and breaking capacity

The contactor is subjected to the rated current and short-
circuit current breaking tests.
Furthermore, it is also subjected to the opening and closing of
capacitive and inductive loads, capacitor banks and/or cable
lines.

• Earthing switch making capacity

The earthing switch of the UniGear MCC switchgear can be
closed under short-circuit. Although, the earthing switch is
normally interlocked to avoid being operated on circuits which
are still live.
However, should this happen for any one of several reasons,
safety of the personnel would be fully safeguarded.

• Mechanical operations
The mechanical endurance tests of all the operating parts
ensures the reliability of the apparatus.
General experience in the electro-technical sector shows that
mechanical faults are one of the most common causes of a
fault in an installation.
Contactor is tested by carrying out a high number of
operations - higher than those which are normally carried out
in installations in operation.
Moreover, the switchgear components are part of a quality
program and are regularly taken from the production lines
and subjected to mechanical life tests to verify that the quality
is identical to that of the components subjected to the type
tests.

• IP degree
The IP protection degree is the resistance offered by the
UniGear MCC against penetration of solid objects and liquids.
This degree of resistance is indicated by the prefix IP followed
by two numbers.
The first number identifying the protection degree against the
entrance of solid objects, the second one is related to liquids.

15
6. Safety

When developing modern medium voltage switchgear, The test also ensure that no holes are produced in external
personnel safety must necessarily take priority. This is accessible parts of the housing, and finally, that all the
why the UniGear MCC switchgear has been designed and connections to the earthing circuit remain intact, hence
tested to withstand an internal arc due to a short-circuit guaranteeing the safety of personnel who may access the
current of the same current level as the maximum short- switchgear after the fault.
time withstand level. The IEC 62271-200 Standard describes the methods to
The tests show that the metal housing of UniGear MCC be used for carrying out the test and the criteria which the
switchgear is able to protect personnel near the switchge- switchgear must conform to.
ar in the case of a fault which evolves as far as striking an The UniGear MCC switchgear fully conforms to all the five
internal arc. criteria indicated by the IEC standards.

An internal arc is a highly unlikely fault, although it can The IAC classification is proved by the test according to the
theoretically be caused by various factors, such as: following designations:
•  insulation defects due to quality deterioration of the •  general: classification IAC (Internal Arc Classified)
components. The reasons can be adverse environmental •  accessibility: A, B or C (switchgear accessible to authorized
conditions and a highly polluted atmosphere personnel only (A), to all (B), not accessible due to
•  overvoltages of atmospheric origin or generated by the installation (C)
operation of a component •  F, L, R: access from the front (F – Front), from the sides (L –
•  inadequate training of the personnel in charge of the Lateral) and from the rear (R – rear)
installation •  test values: test current in kiloamperes (kA), and duration in
•  breakage or tampering of the safety interlocks seconds (s)
•  overheating of the contact area, due to the presence
of corrosive agents or when the connections are not The parameters of each specific plant mean that evacuation
sufficiently tightened of the hot gases and incandescent particles must be checked
•  entry of small animals into the switchgear (i.e. through cable very carefully in order to ensure and maintain personnel safety.
entrance)
•  material left behind inside the switchgear during Fault limiting systems
maintenance activities
The structure of the UniGear MCC switchgear offers complete
The characteristics of the UniGear MCC switchgear notably passive type protection against the effects of a fault due to an
reduce the incidence of these causes for faults, but some of internal arc for a time of 1 second up to 50 kA.
them may not be eliminated completely. ABB has also developed excellent active protection systems
The energy produced by the internal arc causes the following which allow very important objectives to be achieved:
phenomena: •  detection and extinction of the fault, normally in less than
•  increase in the internal pressure 100 ms, which improves network stability
•  increase in temperature •  limitation of damage on the apparatus
•  visual and acoustic effects •  limitation of outage time for the switchgear unit.
•  mechanical stresses on the switchgear structure For active protection against an internal arc, devices
•  melting, decomposition and evaporation of materials consisting of various types of sensors can be installed in the
various compartments, which detect the immediate outburst
Unless suitably protected, these phenomena have very of the fault and carry out selective tripping of the contactor.
serious consequences for the personnel, such as wounds The fault limiting systems are based on sensors which use the
(due to the shock wave, flying parts and the doors opening) pressure or light generated by the arc fault as trigger for fault
and burns (due to emission of hot gases). disconnection.
The internal arc test verifies that the compartment doors
remain closed and that no components are ejected from the
switchgear even when subjected to very high pressures, and
that no flames or incandescent gases penetrate, thereby
ensuring safety of the personnel near the switchgear.

16
ITH REA
The ITH sensors consist of micro-switches positioned on the This system offers the same functionality as TVOC. The REA
top of the switchgear near the gas exhaust flaps of the two system consists of the main unit (REA 101) and optional
power compartments (busbars and contactor/cables). extension units (REA 103, 105, 107) which make it possible to
The shock wave makes the flaps open and operate the create customized solutions with selective tripping. For more
micro-switches connected to the shunt opening release of the information, please see the dedicated chapter at page 38.
contactor. Total tripping time is 32,5 ms (2,5 ms REA + 30 ms
Total tripping time is 45 ms (15 ms ITH + 30 ms contactor). contactor).

FRD (Fast Recovery Device) Arc protection in IED

This system consists of pressure sensors located in the low The REF615, RET615, REM615 and REF610 IEDs (Intelligent
voltage compartment and connected to the three power Electronic Device) can optionally be fitted with a fast and
compartments by means of small tubes. selective arc flash protection. It offers a two-to three-channel
The sensors detect the rising front of the pressure wave which arc-fault protection system for arc flash supervision of the
develops on the outburst of the arc and react by making the circuit breaker, cable and busbar compartment of switchgear
circuit-breakers open. panels.
The sensors are protected against the external environment Total tripping time is 42 ms (12 ms IED + 30 ms contactor).
and they can be checked even with the switchgear in
operation.
Total tripping time is 45 ms (15 ms FRD + 30 ms contactor).

TVOC
This system consists of an electronic monitoring device located
in the low voltage compartment which is connected to optic
sensors. These are distributed in the power compartments and
are connected to the device by means of optic fibres.
When a certain pre-set light level is exceeded, the device
opens the circuit-breakers. kA2 s

To prevent the system from intervening due to light occasionally

generated by external phenomena (flash of a camera,
reflections of external lights, etc.), current transformers can also
be connected to the monitoring device.
The protection module only sends the opening command to the
circuit-breaker if it receives the light and short-circuit current
signal simultaneously.
Total tripping time is 32 ms (2 ms TVOC + 30 ms contactor).

Melting of steel

Melting of copper

Melting of cables

0 100 200 500 ms

Figure 7: Arc duration and damage caused

17
6. Safety

The UniGear MCC switchgear is fitted with all the interlocks

and accessories needed to guarantee the highest level of
safety and reliability for both installation and personnel.

Interlocks
The safety mechanical interlocks are standard ones [1÷4],
please see the dedicated table at page 19.
They are stated by the IEC standards and are therefore
necessary to guarantee the correct operation sequence.
ABB safety interlocks guarantees the highest level of reliability,
even in the case of an accidental error, and enables highest
operator safety system of interlocks.

Keys
The use of key interlocks is very important in realising the
interlocking logics between panels of the same switchgear, or
of other medium, low and high voltage switchgear. The logics
are realised by means of distributors or by ringing the keys.
The contactor truck [5] can be locked in the removed
position and the relevant lock key can only be removed with,
the contactor in this position.
In this position the earthing switch is automatically closed, the
same key [5] can use also for this lock.
The earthing switch opening [6] operation can be locked by
means of key.
The latter can only be removed with the earthing switch in an
opposed position to the lock to be made. Figure 8 : Front view of the panel key system

Padlocks
Locking magnets
The contactor/cables [7] compartment door can be locked in
the closed position by means of padlock. The locking magnets are used to make automatic interlock
This can be applied to both door closing versions – with logics without human intervention.
central handle (standard) or screws (optional). The contactor racking-in/out [9] operation can be interlocked.
The metallic segregation shutters [8] between contactor The magnets operate with active logics and therefore the lack
and busbars compartments can be locked by means of two of auxiliary voltage leaves interlocking system active (in safety
independent padlocks in both the open and closed positions. conditions).
Padlocks from 4 to 8 mm diameter can be accomodated.

18
Standard safety interlocks (mandatory)
Lock Description Condition to be fulfilled
A Contactor racking-in/out Contactor open
1
B Contactor closing Defined contactor position
A Contactor racking-in Contactor multi-contact plug plugged
2
B Contactor multi-contact plug unplugging Contactor remove position
A Earthing switch closing Contactor remove position
3
B Contactor racking-in Earthing switch open
A Contactor/cables compartment door opening Contactor in remove position
4
B Contactor racking-in Contactor/cables compartment door closed

Keys
5 Earthing switch closing Can only be removed with the contactor in removed position
6 Earthing switch open Can only be removed with the contactor in inserted position

Padlocks
Lock
7 Contactor/cables compartment door opening
8 Shutters opening or closing

Locking magnets
Lock Condition to be fulfilled
9 Contactor racking-in/out Magnet energized

19
7. VSC vacuum contactor

V-Contact VSC medium voltage contactors are apparatus The V-Contact contactors are provided in the following
suitable for operating in alternating current and are usually versions:
used to control feeders which require a high number of • VSC7/P for voltages up to 7.2 kV in UniGear ZS1
operations per hour. • VSC12/P for voltages up to 12 kV in Ungear ZS1
They are suitable for operating and protecting motors, • VSC7/PN for voltages up to 7.2 kV in UniGear MCC
transformers and power factor correction banks. Fitted with Both versions are available with the operating mechanism with
appropriate fuses, they can be used in circuits with fault levels sco or DCO configuration.
up to 1000 MVA.
The electrical life of V-Contact VSC contactors is defined
as being in category AC3 with 100,000 operations (closing-
Operative mechanism
opening), 400A interrupted current. Due to the Magnetic actuator V-Contact VSC contactors have
a negligible auxiliary power requirement in all configurations
The contactors consist of a monobloc of resin containing the
(15W inrush - 5W continuous for all configurations).
following components:
V-Contact VSC is available in three differents configurations.
• vacuum interrupters
• moving equipment
SCO (single command operation). The contactor close
• magnetic actuator
supplyng auxiliary voltage to the multivoltage feeder input,
• multivoltage feeder
when auxiliary is cut the contactor opens.
• accessories and auxiliary contacts
DCO (double command operation). The contactor close
supplyng auxiliary voltage to the multivoltege feeder closing
input and opens when opening input is supplied; anti pumping
function is supplied as a standard.
DCO configuration is also available, on request, with a
delayed undervoltage function. This function allow to
automatically open the contactor when auxiliary voltge level
drops below IEC defined levels.
Opening can be delayed from 0 to 5 seconds (customer
setting by dipswitches).

All configurations are suitable for 1.000.000 of mechanical

operations.

Fuses
The contactor is fitted with medium voltage fuses for
protection of the operated feeders.
Coordination between the contactor, fuses and protection unit
is guaranteed in accordance with the IEC 60470 Standards
for apparatus in class C.
The fuse-holder frame is usually preset for installation of a set
of three fuses according to the following Standards:
• DIN 43625
• BS 2692
VSC/PN is also suitable to install two BS 2692 fuses in
parallel per phase.
VSC contactors cannot be used with ABB CEF-BS and ABB
CMF-BS fuses.

Figure 9 : V-Contact VSC on the service trolley

20
The following fuses can be applied:
• DIN type with a length of 192, 292 and 442 mm
• BS type with a length of 235, 305, 410, 454 and 553 mm

The fuse-holder frames are fitted with a device for automatic

opening when even just one fuse blows. This same device
does not allow contactor closing when even a single fuse is
missing.
The ABB range of DIN fuses for transformer protection
is called CEF, whereas CMF is the one for motors and
capacitors.

Standards
• IEC 60470 for the contactor
• IEC 60282-1 for the fuses Figure 10: Double fuse according to BS standard

Electrical characteristics
VSC7/PN
Rated voltage [kV] 7.2
Rated insulation voltage [kV] 7.2
Rated power frequency withstand voltage [kV] 20
Rated lighning impulse withstand voltage [kV] 60
Rated frequency [Hz] 50-60
Rated short-time withstand current [kA] ...50 (1)
Peak current [kA] ...125
Internal arc withstand current [kA x 1 sec] ...50 (2)

Maximum rated current of the contactor [A] 400

(1) Limited by the fuses.
(2) The internal arc withstand values are guaranteed on the busbar compartment; the supply side. The fault in contactor and cable compartment is limited by the fuses.

Maximum performances of the contactor with fuses

3.6 kV 7,2 kV
Motors [kW] 1000 1800
Transformers [kVA] 2000 2800
Capacitors (single bank) [kVAR] 1000 1800

Motors Transformer Capacitors (single bank)

Fuse brand
Rated Contactor Contactor Contactor
Contactor type and international Fuse rated Fuse rated Fuse rated
voltage operational operational operational
standard current current current
rated current rated current rated current
[A] [A] [A] [A] [A] [A]
7.2 kV VSC7/PN ABB (DIN type) 315 250 200 160 315 220
SIBA (BS type) 250 200 250 160 250 125

21
8. Instrument transformers

Ring core current transformers accuracy class, burden, short-circuit current and overcurrent
factor) and have the posibility to be reconnectable on the
Low voltage current instrument transformer, without primary secondary side.
conductor. KORI 071 DF 12 current transformers can
be assembled on the bushing with their own insulation. Assembly procedure of the transformers on the bushings in
Transformers of this type series enable the measuring and Unigear MCC is exactly specified (triangle position).
protection and are designed for use in indoor installations.
The number of secondary windings (1 or 2) depends on These transformers comply with IEC 60044-1 standard
the combination of the technical parameters (such as the

Figure 11: KORI ring core current transformer with CT Rod Figure 12: Application example of KORI ring core current transformer in
UniGear MCC

Terminal marking

Terminals Ratio Burden Class

S1-S2 150/1A/A 0.5 VA 0.5/5P40
S1 S2 S3
S1-S3 400/1A/A 0.5 VA 0.5/5P40

P1 P2

S1 S2 S3

22
Technical data
Type (low voltage current transformer for medium voltage application) KORI
Highest voltage for equipment Um [kV] 0.72
Power frequency test voltage 1min [kV] 3
Rated insulation level [kV] 0.72 / 3 / -
Rated frequency fn [Hz] 50 / 60
Rated primary current [A] 10 - 400
Rated secondary current [A] 1 or 5
Rating short-time thermal current I th 3s [kA] 50.0
Rating peak current I dyn [kA] 125.0
Accuracy classes [kA] 0.2, 0.2S, 0.5, 0.5S, 1, 5P, 10P
Burden [VA] 1 - 20
Highest voltage of a system [kV] 12 kV by using CT ROD
Flammability class B

KORI 072 GH 8 current transformers are designed for ABB switchgear type UniGear 550
and have the following dimensions.

90
29

S1 S2

P1
59

180
180
156

0
8,5
4X 156
180
120
15
40

Rating Plate

23
9. Measurement sensors

Electronic instrument transformers Characteristics of the sensors

Future for measuring currents and voltages in intelligent Construction of current sensors is done without the use of
UniGear is a low-power instrument transformer (according to ferromagnetic core. This fact results in several important
present IEC standards they belong to the group of Electronic benefits for the user and the application:
instrument transformers) called a “sensor” for short. These – sensor behavior is not influenced by non-linearity and
products replace conventional instrument transformers. width of hysteresis curve; that results in accurate and
The characteristic feature of advanced ABB sensors is linear response over a wide dynamic range of measured
the level of output signal, which is fully adapted to fit new quantitites
microprocessor-based equipment without the need of having – single device/sensor could be used for both protection and
unnecessary power. for measurement purposes (no need for a separate design/
The analogue output signal level depends on the principle product)
used and can be in the range of mV for current sensor (typical – there are no hysteresis losses, so sensors are having
value is 150 mV at rated primary current). excellent frequency response also at frequencies different
The UniGear MCC can be fitted with one KECA ring type from the rated one, thus providing very precise input to
current sensor. protection functions, allowing more precise fault analysis
and efficient fault location.

Secondary
ABB sensor
output
Us

Saturation level

Standard CT

is

10A 100A 1000A 10 000A Primary current

Figure 13: Linearity of advanced ABB sensors and example of output signal waveforms compared to conventional saturated CT

24
– sensors do not have dangerous states in operation (no Benefits of the sensors
problem to keep output short-circuited or left open),
resulting in high safety for surrounding devices and Due to the linear response and wide dynamic range, sensors
personell. The output signal remains very low even in fault are much more standardized devices (compared to a number
situations of the network. of different designs of CTs). Therefore, it is much easier to
– the use of sensors disable the possibility of related select the appropriate design (it simplify engineering tasks)
ferroresonance phenomena, thus even more increasing the and there could be also reduction in spare parts on user side.
safety and reliability of the power network; furthermore, Significantly decreased power consumption during operation
there is no need for additional protection equipment, special of sensors due to negligible losses introduced by sensors
burden or wiring. (no iron = no hysteresis losses; less winding and negligible
ABB sensors are connected to the measurement and output current = small losses in sensor winding) results in
protection evaluation devices by means of shielded cables huge savings for lost energy and minimized temperature rise
and connectors, providing a high degree of immunity to (thus improving temperature conditions and ageing within
electromagnetic disturbances. application). It also results in significantly lighter devices,
Accuracy of these sensors is verified and tested including the having weight only a fraction of that provided by conventional
cabling, so precise information is assured up to the evaluation CTs. Therefore, no special machines/tools are needed to cary
device. Furthermore, the use of ABB sensors and ABB relays them and transport costs can be smaller.
enables to guarantee the overal system accuracy, i.e. to Fast connection of sensors to IEDs without any tools and
guarantee the accuracy of full measurement chain = sensors material needed simplify and reduce assembly effort.
together with IED, to be better than 1%.

Figure 14: KECA ring core type sensor

25
9. Measurement sensors

Current sensor Output voltage is phase shifted of 90° from the primary
current waveform.
The current sensor is based on Rogowski Coil principle.
Rogowski Coil work in the same manner as conventional iron- Therefore, for simple and rough information about the
core current transformers (CTs). The main difference between measured current signal, it is possible to use voltmeters with
Rogowski Coils and CTs is that Rogowski Coil windings are high input impedance. Nevertheless, more exact and precise
wound over a non-magnetic core, instead of over an iron information under transient conditions, content of different
core. As a result, Rogowski Coils are linear since the non- frequency components or current waveform distortions
magnetic core cannot saturate. Rogowski Coils produce that appears in electric power network requires integration
output voltage (US) that is a scaled time derivative of the of voltage signal comming out of Rogowski Coil. This
measured primary current (I P). functionality is already available inside of IEDs provided by
ABB, so very precise measurement of the primary current is
available.

Output voltage of Rogowski Coil linearly depends on

frequency, therefore rated value of output voltage is 150mV
at 50Hz and 180mV at 60Hz. Once the rated frequency is
set in the IED, sensor provides precise information about the
measured primary current signal even for different harmonics
(no hysteresis losses and no saturation applies) and thus
correct performance for all protection functions is assured.
In theory, response of Rogowski coil output is linear in
unlimited dynamic range of the measured primary current.
Constraints in their use originates from other limitations, e.g.
application size, fixations etc. Only single coil is sufficient to
cover whole range of primary currents needed, e.g. KECA
250B1 type has been successfully tested up to 2000A
continuous thermal current.
They conform to the IEC 60044-8 standard.
Figure 15: Working principle of Rogowski Coil

Integration of the current sensor output signal is performed

within the connected IED in order to obtain the information
about actual current value.

In case of purely sinusoidal primary current (I ) at rated

frequency defined as:

ip (t) = √2Ip sin(ωt)

the output voltage from the Rogowski Coil is

us (t) = √2Ip Mωcos(ωt)

For this case, r.m.s. value of the output signal could be
easily measured even without integrator, using a voltmeter or
oscilloscope, observing a phase shift of 90° from the primary
current waveform.

26
Outer dimensions of KECA

8.5
Ø

L=5000±50

69
Ø
147

P1
123

P2

70
90

20 123 29
37.5 176

27
10. Cable terminations

Terminations for polymeric insulated Applications and features

cables 1 – 7.2 kV Depending on cable design, it is necessary to use the

correct type of cable accessory. When single core cables are
designed with copper wire screen only, it is sufficient to use
General just a cable lug and a termination that fits the actual size of
It is crucial that power cables connecting the switchgear the cable.
are terminated properly, and for this purpose, ABB have The benefit with Cold Applied accessories means that no
developed an excellent range of easy-to-use products for heat or open flame is necessary for the installation (except for
preparation and termination of cables. branch seals on 3-core cables). After the cable is prepared,
the termination is simply slid on without any tools. If a three
MV power cables are normally designed with a conductor of core cable is used, or a cable with copper tape screen,
aluminium or copper, an insulation of polymeric material, an or aluminium foil screen, or a cable with armouring; then
extruded insulation screen, a metallic screen, an armouring additional material is required.
(optional) and a polymeric outer jacket. Another very important factor is to prepare the cable in a
proper way, and ABB also offer excellent cable preparation
To enable safe and reliable current carrying properties, it tools.
is necessary to achieve sufficient mechanical connection
between the cable conductor and the bus bar. ABB offer
mechanical cable lugs designed to fit the cable conductor by Recommended cable termination products
means of bolting technique. The pre-moulded cable termination type Kabeldon SOT can
It is also essential to guide the electrical field of the cable in a be used on any polymeric cable irrespective of design or
proper way, and ABB offer Cold Applied terminations, made conductor size. Type SOT 10 is designed for 7.2 kV cables.
of rubber, that create an active pressure around the cable. A few variants of terminations fit a wide range of cable sizes.
Furthermore, if the cable is designed with another type of Extra material such as earthing kits, crutch seals for 3-core
metallic screen than copper wires, special earthing kits must cables and screen potential material for cable armouring is
be used to achieve proper handling of possible fault currents. also within the ABB range of products.
The armouring of the cable shall have the same earth Kindly contact ABB Sales Representative for more
potential as the cable screen, why it might be necessary to information.
use additional connection material that also can be offered.
Detailed information can be found in separate technical
information for cable accessories.

28
Figure 16: Kabeldon cable termination type SOT 10 with bi-metallic cable Figure 17: Kabeldon cable termination type SOT 24 with bi-metallic cable
lug type SKSB lug type SKSB

Designaton and sizes

Voltage level Designation Diameter Conductor size

Kabeldon over insulation mm²
kV mm 7.2 kV
1 – 7.2 SOT 101 10.5 – 15 10 – 35
1 – 7.2 SOT 102 12.9 – 25.8 50 – 150
1 – 7.2 SOT 103 21.4 – 34.9 185 – 300

29
11. Distribution automation

ABB’s Power Protection Philosophy return the power system to its normal operating state, or,
isolate the fault to limit damage to the power system and
With deliveries of protection IEDs (Intelligent Electronic injury to personnel. This provides a safe environment for all.
Devices) to more than 70 countries, ABB best understands Power protection systems do not prevent power network
the requirements of diverse protection needs as a result faults from arising, but it will be activated only when an
of wide ranging local legislation, safety requirements and abnormality has occurred in the power system. However,
engineering practices. Therefore, ABB has developed a power carefully matching the available protection functionality offered
protection philosophy that not only serves the specific needs by ABB IEDs to the specific power protection requirements
and requirements of diverse power systems, but also creates of the power system and its components not only provides
a feeling of confidence and peace of mind for both power the best power protection for the power system, but also
system owners and users alike. improves the performance and the reliability of the power
The main purpose of an ABB IED power protection system protection system within it, thus minimizing the effects of
is to recognize any abnormal power system conditions, or power network faults and preventing the abnormalities or
abnormally operating components within the power system. disturbances from spreading to the healthy parts of the power
Then, based on the information gathered by the IED, the network.
power protection system will initiate corrective actions to

30
Advantages of a complete power power protection must be adequate to detect relatively high
resistance earth faults and short circuits in the most distant
protection system parts of the power network. Reliable selectivity is essential
Operating speed, sensitivity, selectivity and reliability are in order to limit the loss of power supply to as small an area
the integral elements of the power protection system and as possible, and to allow the abnormal or faulted part of the
need mentioning. There is a strong correlation between power network to be reliably located.
the operating speed of the power protection system and Corrective actions can then be directed to the abnormal or
the damage and danger caused by a power network faulty part of the network, and the supply can be restored as
fault. Substation automation provides remote control and rapidly as possible.
monitoring capabilities, which speeds up the location of The power protection system must also have a high degree
faults, and therefore the restoration of the power supply of reliability. This also means that if for example a CB (circuit-
after a fault.Fast operation of the power protection IEDs also breaker) fails to operate, the backup power protection will
minimizes post-fault load peaks, which together with voltage identify the fault and react.
dips increase the risk of the power disturbance spreading Substation Automation (SA) puts the operator in perfect
to healthy parts of the power network. The sensitivity of the control of the substation. In addition to the SA system
improving the power quality of the power transmission
and distribution network under normal operation, it
especially improves the quality of the power transmission
and distribution network’s available power in a situation of
disturbance and during substation maintenance. A SA system
or SCADA (supervisory control and data acquisition) system
brings the full benefits of numerical technology into protection
and control of power networks. The terminals are easily set
High requirement and power protection parameters configured to the specific
needs of the power system through easy and safe access via
the operator’s workplace.
Infeed from both ends

Single-function and multi-function

Ring main feeders
terminals
Distance
protection Correct power protection methods and comprehensive
Parallel feeders
functionality increase the performance of the power protection
system.
Single line The definition of comprehensive functionality varies with the
Feeders with
diagram HMI* requirements of the protected power network or system.
distributed
IED Features

generation
Feeder type

While single-function power protection IEDs are sufficient for

some network applications, more complex power networks
Fault locator
and systems need advanced multi-functional power protection
Radial feeders
with reclosers/ IEDs. Single-function Power protection IEDs include a set of
sectionalizers Power quality
monitoring
power protection functions for, for instance, a specific feeder
application type.
The main advantages of these power protection IEDs are
Radial Communication redundancy and price. One or more single-function power
feeders
protection IEDs would provide sufficient protection in most
Auto re-closure power protection application areas.

Single function * Human Machine

Interface

Standard requirement

Figure 18: Comparison between standard and high requirement feeders

31
11. Distribution automation

Transformer protection Recommended products

The power transformer is one of the most important The recommended products for transformer protection are
components, as well as one of the most valuable individual part of ABB’s Relion® product family of power protection
units in the power distribution network. IEDs. These IEDs have been developed after many years
Therefore, the particular importance of preventing of experience gathered from wide ranging application and
disturbances in the power distribution system is almost functionality requirements of ABB customers globally.
completely dependent on a functioning power transformer. The popular RE500 series IEDs also played a big part in
Although high-quality power transformers are highly reliable, ABB’s success in this area.
insulation breakdown faults occasionally occur. These faults, Relion® products have been designed to implement the
appearing as short circuits and/or earth faults generally cause core values of the IEC 61850 standard. The genuine
severe damage to the windings and transformer core. The implementation of the IEC 61850 substation communication
damage is proportional to the fault clearing time so the power standard covers vertical as well as horizontal communication
transformer must be disconnected as quickly as possible. between IEDs.
The power transformer has to be transported to a workshop
for repair, which is a very time-consuming process. The
operation of a power network where the power transformer
is out of service is always cumbersome. Therefore, a power
transformer fault often constitutes a more severe power
system fault than a line fault, which usually can be rectified
rather quickly. It is extremely important that fast and reliable
protection IEDs are used to detect transformer faults and
initiate tripping.
The size, voltage level and importance of the power
transformer determine the extent and choice of monitoring
and protection devices to be used to limit the damage at a
possible fault. When compared to the total cost of the power
transformer and the damages caused by a power transformer
fault, the cost of the power protection system is negligible.

Figure 19: Transformer protection and control RET630

32
•  Transformer Protection and Control RET630 is a •  Transformer Protection and Control RET615 is a
comprehensive transformer management IED for protection, dedicated transformer protection and control IED for two-
control, measuring and supervision of power transformers, winding power transformers, unit and step-up transformers
unit and step-up transformers including power generator- including power generator-transformer blocks in utility and
transformer blocks in utility and industry power distribution industrial power distribution systems.
networks. It provides main protection for two-winding power RET615 offers eight standard configurations to match applied
transformers and power generator-transformer blocks. transformer neutral earthing principles with either high
Two predefined configurations to match your typical impedance or numerical low impedance restricted earth-fault
transformer protection and control specifications are available. protection schemes. CT ratio differences and phase shifts of
The pre-defined configurations can be used as such, or the all commonly employed power transformer vector groups are
IED can easily be modified or functionally extended with freely numerically compensated for. RET615 features also local or
selectable add-on functions to help fine-tune the IED to meet remote control of the transformer HV side circui-breaker.
even the most demanding individual application requirements
-exactly.

Figure 20: Transformer protection and control RET615

33
11. Distribution automation

Motor protection Recommended products

Motor protection is generally expected to provide overcurrent, The recommended products for motor protection are part of
unbalance, earth-fault and short-circuit protection. However, ABB’s Relion® product family of power protection IEDs.
the fundamental issue for motors is thermal protection, as These IEDs have been developed after many years of
overheating is the worst threat to the motor. experience gathered from wide ranging application and
Motors need to be protected not only against electrical faults functionality requirements of ABB customers globally.
but also against any improper usage. ABB’s solutions focus The popular RE500 series IEDs also played a big part in
on advanced thermal protection that prevents improper use ABB’s success in this area.
of the motors. The thermal overload protection is needed Relion® products have been designed to implement the
to protect the motor against both short-time and long-time core values of the IEC 61850 standard. The genuine
overload and so it is of great importance for the performance implementation of the IEC 61850 substation communication
of the motor. Overload conditions of short duration mainly standard covers vertical as well as horizontal communication
occur during motor start-up. between IEDs.
Improper use of a running motor does not necessarily damage
the equipment but shortens its lifespan. Therefore, a reliable •  Motor Protection and Control REM630 is a
and versatile motor protection system not only protects comprehensive motor management IED for protection,
the motor but it also prolongs the motor’s life-cycle, which control, measuring and supervision of medium and large
contributes to improving the return on investment of your asynchronous motors in medium voltage industrial power
motor drive. systems.
REM630 is a member of ABB’s Relion® product family and
a part of its 630 product series characterized by functional
scalability and flexible configurability. It also features
necessary control functions required for the management of
industrial motor feeder bays.

Figure 21: Motor protection and control REM630 Figure 22: Motor protection and control REM615

34
REM630 provides main protection for asynchronous motors •  Motor Protection Relay REM610 is a motor IED for the
and the associated drives. The motor management IED protection, measuring and supervision of medium sized and
is intended for circuit-breaker and contactor controlled large asynchronous LV motors and small and medium-sized
medium sized and large asynchronous motors in a variety asynchronous HV motors in manufacturing and process
of drive applications, such as motor drives for pumps, industry.
fans, compressors, mills, crushers, etc. The pre-defined The REM610 IED can be used with both circuit-breaker and
configuration can be used as such or easily customized or contactor-controlled motor drives in a variety of applications.
extended with add-on functions, by means of which the motor Enhanced with an optional add-on card for RTD sensors
management IED can be fine-tuned to exactly satisfy the or thermistor elements, the IED can be used for direct
specific requirements of your present application. temperature measurement of critical motor items, such as
bearings and windings. It is also used for the protection of
•  Motor Protection and Control REM615 is a dedicated cable feeders and distribution transformers benefiting from
motor IED perfectly aligned for the protection, control, thermal overload protection besides phase overcurrent
measurement and supervision of asynchronous motors in protection, earth-fault protection and phase unbalance
manufacturing and process industry. Typically, REM615 is protection.
used with circuit-breaker or contactor controlled HV motors,
and contactor controlled medium sized and large LV motors
in a variety of drives. REM615 is available in three standard
configurations including all the basic motor protection
functions, voltage protection functions and power and energy
measurements. Local or remote start/stop control of the
motor is also facilitated.

Figure 23: Motor protection REM610

35
11. Distribution automation

Station automation COM600 Product

COM600, ABB’s station automation device, is an all-in- The Station Automation COM600 offers web server
one communication gateway, automation platform and functionality, providing a human machine interface (HMI) for
user interface solution for utility and industrial distribution local substation monitoring and control. Secure communication
substations. enables the access of the substation HMI over the internet
The gateway functionality provides seamless IEC61850 or LAN/WAN for any authorized user with a standard PC and
connectivity between substation IEDs and network-level control a web browser. By connecting a laptop computer to the unit
and management systems. locally, an HMI for full monitoring and control functionality is
The automation platform with its logic processor makes obtained on the substation level.
COM600 a flexible implementation platform for substation The Station Automation COM600 also provides gateway
level automation tasks. As a user interface solution COM600 functions for mapping data and signals between substation and
accommodates web technology based functionalities providing higher-level systems such as SCADA, DSC.
access to substation devices and processes via a web browser The COM600 is designed for smooth system integration and
based human machine interface (HMI). interoperability based on pre-configured solutions utilizing
connectivity packages for ABB IEDs.

Figure 24: Station Automation COM600

36
Application and features The COM600 is fully compliant with the IEC 61850 standard
for distribution automation. Thus it provides full interoperability
With their compact and robust design, the COM600 is well with any IEC 61850 compliant IEDs, tools and systems, which
adapted for harsh environments. It meets the IP4x degree simplifies system design and commissioning.
of protection by enclosure and contains no moving parts The commissioning of ABB IEDs is straight forward due to the
subject to wear and tear. The COM600 is based on embedded support of ABB’s unique connectivity package concept, which
technology for durability and maximum availability. The features simplifies system configuration and reduces the risk of errors
and compact dimensions of the COM600 enable it to be easily in the system integration, minimizing device configuration and
installed in the Low Voltage Compartment of most UniGear set-up times.
ZS1 panels. COM600 is suitable for both industrial and utility
applications. For more detailed information, the technical and product guides
The COM600 incorporates OPC Server functionality, which for COM600 are available at:
provides one entry point to all the information of a substation, http://www.abb.com/substationautomation
and the IEC 61850 support enables connectivity and seamless
communication with application-specific equipment.

distributed Remote Ac-

EMS/ control cess-
scada system Engineering

OPC Client/Server wan

Ethernet switch
GPS

Serial protocols
(DNP3, IEC 60870-5-101)
LAN1

Ethernet switch
TCP/IC protocols Serial protocols
(IEC 61850, DNP3, (Modbus®)
Modbus®)

REF601 REF601
REF610 REF610 REF615 REF615 Secondary distribution switchgear

Figure 25: Overview of a system using Station Automation COM600

37
11. Distribution automation

Arc protection Applications and features

An electric arc short-circuit in a switchgear installation is Sources of arcing may be insulation faults, maloperating
normally caused by a foreign object entering the cubicle or a devices, defective bus or cable joints, overvoltage, corrosion,
component failure. The arc causes an explosion-like heat and pollution, moisture, ferro-resonance (instrument transformers)
pressure effect usually causing vast damage to the switchgear and even ageing due to electrical stress. Most of these arc
and the operation personnel. fault sources could be prevented by sufficient maintenance.
An adequate arc protection system protects your substation However, in spite of the precautions taken, human errors can
against arc faults by minimizing the burning time of the arc, lead to arc faults.
thus preventing excessive heat and damage. It minimizes Time is critical when it comes to detecting and minimizing
material damage and allows power distribution to be smoothly the effects of an electric arc. An arc fault lasting 500 ms may
and safely restored. The system can also bring cost benefits cause severe damage to the installation. If the burning time of
even before an arc fault occurs. As older switchgear is more the arc is less than 100 ms the damage is often smaller, but if
prone to arc faults, an arc protection system will effectively the arc is extinguished in less than 35 ms its effect is almost
extend the life of your switchgear and make more of your unnoticeable.
investment. But what is even more important, this technology Generally applied, protection IEDs are not fast enough to
can help save lives. ensure safe fault clearance times at arc faults.
The operation time of the overcurrent IED controlling the
incoming circuit breaker may, for instance, have to be delayed
hundreds of milliseconds for selectivity reasons.
This delay can be avoided by installing an arc protection
system. The total fault clearance time can be reduced to max
2.5 ms plus the circuit breaker’s contact travel time.
Furthermore, at cable compartment faults, auto-reclosures
can be eliminated by employing arc protection.

Figure 26: Arc protection REA 101 with extensions REA 103, REA 105
and REA 107

38
Recommended products
•  Arc protection system REA 101 with its extension units
REA 103, REA 105 and REA 107 are designed to be used
for the protection of medium and low-voltage air-insulated
switchgear.
The central unit type REA 101 operates independently or
together with other REA 101 units. REA is the fastest arc
protection system on the market, providing tripping times
down to 2.5 ms.
REA is equipped with a fast integrated overcurrent-sensing
element and is thus working independently from other feeder
protection units.
The REF615 and REF610 feeder protection IEDs include an
optional arc protection function for the feeder cubicle.

Figure 27: Typical setup with REA 101 and subunits 103

39
11. Distribution automation

Selection table of relays

REM RET REA

Application
610 615 630 54_ 615 630 54_ 10_
Voltage based protection • •
Feeder application (Incomming and/or Outgoing) s
High requirement feeder application
Transformer application s • • •
High requirement transformer application •
Motor protection • • • •
High requirement motor protection • •
Generator & synchronous motor protection • •
Distance protection
Line differential protection
Back-up Protection
Arc protection o o •

Communication Protocols
IEC61850-8-1 •* • • •* • • •*
IEC60870-5-103 • • • •
DNP 3.0 • • • • •
SPA • • •
LON •* • •
Modbus • • • • •
Profibus •* • •* •*

Additional Functionality
Fault locator
Auto re-closure 5 shots
On load tap changer control • •
Disturbance recording • • • • •
Withdrawable release mechanism • • •
Single line diagram HMI** • • • • • •
Local control • • • • • • •
Remote control • • • • • •
Condition monitoring • • • •
Power quality monitoring
Analog inputs (VT/CT) -/4 -/5 4/5 -/7 3/9 -/3
Sensor inputs • •
Binary Inputs / Outputs 5/8 12/10 32/27 14/13 32/27 1/3
RTD*** / mA inputs 6/- 6/2 8/- 6/2 8/-
mA outputs

* With interface protocol converter

** HMI - Human Machine Interface
*** RTD - Resistive Temperature Detector
**** 27 if outputs are static outputs
1) REU615 with A configuration, for voltage and frequency based protection
2) REU615 with B configuration, for tap changer control
o = optional
s = secondary application

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41
12. Typical units

Single-line diagram of typical units

M M

MF - Across the line motor starting TF - Transformer feeder CF - Capacitor bank feeder Reverse operation *)

M M M

Star-delta motor starting *) Reactor motor starting *) Auto-transformer motor starting *)

Note
*) Available in 2012

42
Graphical symbols

Circuit-breaker Contactor Switch-disconnector Switch Isolating bar Socket and plug

Voltage transformers Current transformers Fuse Earth Cable entry Busbar entry

Key to components Standard components Accessories Alternative solutions

43
13. Technical data

Units: …7.2 kV - …50 kA

Depth mm 1340
Height mm 2200 / 2595 (1)

Height with gas exhaust duct mm 2675 (2)

Width mm 400
Rated current A 400
MF
TF
CF

(1) The height of the unit is a function of the height of the low voltage compartment,
available in the 705 and 1100 mm versions.
(2) Other solutions are available, please contact your ABB representative.

Typical feeder unit

C C
Height with gas exhaust duct

B
Height (1)

A
Unit compartments
A - Contactor and cable compartment
A
B - Busbar compartment
C - Low voltage compartment
D - Gas duct channel

Width Depth

44
Notes

45
Notes

46
47
Contact us

1VCP000405 - Rev. C , en - Technical catalogue - 2012-09 - (UniGear MCC) gs

Your sales contact: www.abb.com/contacts
More product information: www.abb.com/productguide

The data and illustrations are not binding. We reserve the right to make changes
without notice in the course of technical development of the product.

© Copyright 2012 ABB. All rights reserved.