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1. ABB Australia Pty Ltd
1VGA671004 – Rev. D
August 12, 2023 | Slide 1
UniGear ZVC
Standard Product
January 2010

2. © ABB Group
August 12, 2023 | Slide 2
Contents
Air Insulated Switchgear
Certifications 3
Internal Arc Containment 4
Loss of Service Continuity 5
Partition Class 6
Current Ratings 7
Electrical Characteristics 8
Wall Standing Solution 9
Panel Dimension 10
Cable Entry 11
Flexible Applications 12
Basic Structure 13
Contactor and Cable
Compartments 14
The Heart of the Switchgear 15
Contactor 16
HRC Fuses 17
Earth Switch 20
Control Power Transformer 21
Instrument Transformer 22
Compulsory Tools 23
UniGear Platform 24
Product Value 25
Comparisons 26
Project Savings 28
The SLD of Typical Motor Starting
Options 30
Typical Configuration of Unigear ZVC
Panels 31
Contact 32

3. © ABB Group
August 12, 2023 | Slide 3
Air Insulated Switchgear
Motor Control Centre
Certifications:
 Quality System: ISO 9001
Standards
 Environmental
Management System: ISO
14001 Standards
Complies with:
 IEC Standards
 Australian Standards
 Chinese GB Standards
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4. © ABB Group
August 12, 2023 | Slide 4
Air Insulated Switchgear
Internal Arc Containment
 Arc Flash safe according to
IEC 62271-200
 Classification AFLR ...50kA
(...1sec)
 For all the five criteria
 Front, rear and sides arc
resistance
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5. © ABB Group
August 12, 2023 | Slide 5
Air Insulated Switchgear
Loss of Service Continuity
 LSC2A according to IEC
62271-200
 Busbar, cable and fused
contactor compartments
physically and electrically
segregated (Metal-Clad)
A. Circuit Breaker
Compartment
B. Busbar Compartment
C. Feeder Compartment
D. Low Voltage Control
Compartment
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6. © ABB Group
August 12, 2023 | Slide 6
Air Insulated Switchgear
Partition Class
 Partition class PM to IEC
62271-200
 Metallic shutters operated
by the apparatus movement
 Metallic segregation of all
the compartments
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7. © ABB Group
August 12, 2023 | Slide 7
Air Insulated Switchgear
Current Ratings
50kA
50kA
0 1000 2000 3000 4000 5000
3.6kV
7.2kV
Rated Voltage [kV]
Rated Busbar Current [A]
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8. © ABB Group
August 12, 2023 | Slide 8
Air Insulated Switchgear
Electrical Characteristics
Rated Voltage kV 3.6 7.2
Test Voltage (50-60Hz/1 min) kV 16 20
Impulse Withstand Voltage kV 40 60
Rated Frequency Hz 50/60 50/60
Rated Short-time Withstand Current kA …50 …50
Peak Withstand Current kA …125 …125
Internal Arc Fault Containment kA …50 …50
Rated Current of the Main Busbars A 4000 4000
Rated Normal Load Current A 200 400 200 400
Fused Drawout Contactor Type VSC7/ZVC
V7/ZVC
 -  -
-  - 
Motor Switching kW 1000 2000 2000 4000
Capacitors Switching kVAR - 1000 - 2000
Transformers Switching kVA 1000 2000 2000 4000
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9. © ABB Group
August 12, 2023 | Slide 9
Air Insulated Switchgear
Wall Standing Solution
 All operations behind
closed compartment doors
 Maintenance and service
operations performed from
the front
 Front access to all the
compartments (apparatus,
busbars, cables)
 Comfortable front cables
access
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10. © ABB Group
August 12, 2023 | Slide 10
Air Insulated Switchgear
Panel Dimension
Width (mm) 325
Height (mm) 2200 2400 2595
LV Box Height (mm) 665 865 1060
Height with Gas Duct (mm) 2530 / 2680
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11. © ABB Group
August 12, 2023 | Slide 11
Air Insulated Switchgear
Cable Entry
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12. © ABB Group
August 12, 2023 | Slide 12
Air Insulated Switchgear
Designed for Flexible Applications
 Direct coupling with
UniGear platform
 Vacuum contactor
technology
 Two fuses in parallel for
each phase for high load
current ≥ 400A
 Withdrawable truck
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13. © ABB Group
August 12, 2023 | Slide 13
Air Insulated Switchgear
Basic Structure
Compartments:
A. Busbar compartment
B. Contactor and HRC fuses
compartment
C. Cable compartment
D. Low voltage compartment
Main Components
1. Busbars
2. Withdrawable fused contactor’s
contacts
3. Vacuum contactor
4. HRC fuses
5. Instruments current transformer
6. Earthing switch
7. Auxiliary voltage transformer
8. Cable connection terminals
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14. © ABB Group
August 12, 2023 | Slide 14
Air Insulated Switchgear
Contactor and Cable Compartments
Internal view detailing:
1. Metal shutter – Bus
2. Metal shutter – Circuit
3. Fixed auxiliary control
connection
4. Earth switch operating
slot
5. Power cables
connections
6. Earth switch
1
2
4
5
3
6
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15. © ABB Group
August 12, 2023 | Slide 15
Air Insulated Switchgear
The Heart of the Switchgear
 Busbar Moulding
 Contactor Moulding
 BS Fuses
 Metallic Shutters
 Current Transformers
 Auxiliary control connection
 Voltage Transformer
 Contactor
 Chassis
 Earth Switch
 Cable connection Moulding
 Front Plate
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16. © ABB Group
August 12, 2023 | Slide 16
Air Insulated Switchgear
Contactor
Rear View
Upper line side disconnect
contacts
Lower load side disconnect
contacts
Moving auxiliary
control connection
Front View
Rating plate
Mechanical Position Indicator
Truck Interlock
Contactor ON/OFF Indicator
Truck Racking Point
Left Side View.
Right Side View
Power fuses
Control VT fuses
Vacuum interrupters
Electronic controller
Control VT
Operation Counter
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17. © ABB Group
August 12, 2023 | Slide 17
Air Insulated Switchgear
HRC Fuses
Fuse selection. Service voltage 3300V
Fuse Rating (A)
Transformers Motors Capacitors
F.L.C. kVA F.L.C. kW F.L.C. kVAR
63 40A 200 45A 200 40A 250
80 50A 250 60A 280 60A 300
100 65A 325 75A 350 75A 400
125 80A 400 90A 425 90A 500
160 100A 500 120A 550 120A 600
200 130A 700 150A 700 150A 800
225 150A 800 165A 750 165A 900
250 165A 900 185A 800 185A 1000
315 210A 1000 225A 1100 225A 1000
350 230A 1250 270A 1300 225A 1000
400 (2x225) 260A 1400 - - - -
400 (2x225) 300A 1500 300A 1500 - -
450 (2x250) 360A 2000 335A 1650 - -
550 (2x315) 400A 2200 400A 2000 - -
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18. © ABB Group
August 12, 2023 | Slide 18
Air Insulated Switchgear
HRC Fuses
Fuse selection. Service voltage 6600V
Fuse Rating (A)
Transformers Motors Capacitors
F.L.C. kVA F.L.C. kW F.L.C. kVAR
63 40A 400 45A 400 40A 500
80 50A 500 60A 550 60A 600
100 65A 750 75A 710 75A 800
125 80A 800 90A 850 90A 1000
160 100A 1000 120A 1100 120A 1200
200 130A 1250 150A 1400 150A 1600
225 150A 1600 165A 1500 165A 1800
250 165A 1750 185A 1750 185A 2000
315 210A 2000 225A 2100 225A 2000
400 (2x225) 260A 2750 - - - -
400 (2x225) 300A 3050 300A 3000 - -
450 (2x250) 360A 4000 335A 3300 - -
550 (2x315) 400A 4400 400A 4000 - -
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19. © ABB Group
August 12, 2023 | Slide 19
Air Insulated Switchgear
HRC Fuses
Fuse Options for ZVC
Manufacturer
Order
Code/Part
No.
Size
Rated
Voltage (kV)
Current
Range (A)
Maximum
Breaking
Current (kA)
SIBA 30 269 56 TA2 3.6 50…315 50
SIBA 30 271 56 TA4 7.2 50…315 50
GEC ALSTHOM K81PEX TA2 3.6 100…350 40
GEC ALSTHOM K81SDX TA4 7.2 50…315 45
Cooper Bussman 3.6WDFHO TA2 3.6 50…125 50
Cooper Bussman 3.6WFFHO TA2 3.6 160…200 50
Cooper Bussman 3.6WKFHO TA2 3.6 250…400 50
Cooper Bussman 7.2WFNHO TA4 7.2 25…315 40
Cooper Bussman 7.2MROSA TA4 7.2 50…315 50
XiRong WFNDF TA2 3.6 50…400 50
XiRong WFNDF TA4 7.2 25…315 50
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20. © ABB Group
August 12, 2023 | Slide 20
Air Insulated Switchgear
Earth Switch
 With full making capacity
 Short time withstand
current for 3 seconds
 Operated from the front
 Provided with secure
position indicators
 Visible identification of
Earth Switch Position
 Visible through window in
front door
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21. © ABB Group
August 12, 2023 | Slide 21
Air Insulated Switchgear
Control Power Transformer
 2 pole Power
Transformer,
withdrawable HV fused
Control PT
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22. © ABB Group
August 12, 2023 | Slide 22
Air Insulated Switchgear
Instrument Transformers
 Ring type Current Transformers
 Multi ratio 2-core resin
encapsulated toroids. Three
versions cover the full range:
 400-300-200/1/1A
 150-100-75/1/1A
 50/1/1A
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23. © ABB Group
August 12, 2023 | Slide 23
Air Insulated Switchgear
Compulsory Tools
 Contactor Transport Trolley
 Handles and Key
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24. © ABB Group
August 12, 2023 | Slide 24
Air Insulated Switchgear
UniGear Platform
 UniGear ZVC can be directly
coupled to:
 UniGear ZS1
 UniGear 550
 UniGear 500R
 UniGear ZVC standard
design utilises REM 615, but
can easily integrate IEDs:
 REF542 plus
 REF5xx series
 REM5xx series
 RET5xx series
 Others including 3rd
party manufacture
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25. © ABB Group
August 12, 2023 | Slide 25
Air Insulated Switchgear
Product Value
 How can a product add
value?
1. By reducing the total
cost
2. Or by increasing
revenues
 UniGear ZVC adds value by:
1. Occupying minimum
floor space
2. Reduced size of
motor cables
3. Higher performance
and availability
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26. © ABB Group
August 12, 2023 | Slide 26
Air Insulated Switchgear
Comparisons
Comparison of performance
Evaluating UniGear ZVC Fused Vacuum Contactor technology to conventional
Circuit Breaker technology for switching applications:
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UniGear ZVC
Fault current limited due to HRC fuses.
Fault clearing time is typically <5ms at full fault current.
Reduced let through energy allows reduced cable size.
Reduced thermal stresses on motor and rapid fault
clearing time minimise damage.
Up to 1,000,000 op. provides extended service life.
Small footprint totalling 0.42 sq m.






Circuit Breaker
No fault current limiting capability.
CB fault break at first natural current zero 200ms.
Cable needs to be sized to maximum system short
circuit level.
Thermal stresses consistent with system short circuit
level and clearing time result in severe damage.
Up to 30,000 operations service life.
Average footprint 1.05 sq m.

27. © ABB Group
August 12, 2023 | Slide 27
Air Insulated Switchgear
Comparisons
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TYPICAL CABLE COST COMPARISON
Motor FLC
(A)
31.5kA 50kA
Fused Contactor Panel Circuit Breaker Panel Fused Contactor Panel Circuit Breaker Panel
Cable
csa sq mm
Cable Cost
100m
Cable
csa sq mm
Cable Cost [1]
100m
Cable
csa sq mm
Cable Cost
100m
Cable
csa sq mm
Cable Cost [1]
100m
45 35 €1,600 185 €4,800 35 €1,600 300 €7,500
60 35 €1,600 185 €4,800 50 €2,000 300 €7,500
75 35 €1,600 185 €4,800 50 €2,000 300 €7,500
90 50 €2,000 185 €4,800 50 €2,000 300 €7,500
120 50 €2,000 185 €4,800 70 €2,900 300 €7,500
150 50 €2,000 185 €4,800 70 €2,900 300 €7,500
165 50 €2,000 185 €4,800 70 €2,900 300 €7,500
185 50 €2,000 185 €4,800 70 €2,900 300 €7,500
225 70 €3,800 185 €4,800 95 €3,800 300 €7,500
[1] Cable cost in yr. 2008.
TYPICAL FLOOR SPACE COMPARISON
Panel Width (mm) Panel Depth (mm) Area (sq m) Construction cost
325 1300 0.42 €1,268
400 1300 0.52 €1,560
500 1300 0.65 €1,950
600 1300 0.78 €2,340
700 1300 0.91 €2,730
800 1300 1.04 €3,120
900 1300 1.17 €3,510
1000 1300 1.30 €3,900
1200 1300 1.56 €4,680

28. © ABB Group
August 12, 2023 | Slide 28
Air Insulated Switchgear
Project Savings
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Typical FPSO Switchboard
6.6kV, 3150A, 40kA
comprising:
- 2 off Incomer panel
- 1 off Bus Riser panel
- 1 off Bus Section (Tie)
panel
- 1 off Bus Metering panel
- 15 off Transformer Feeder
panel
- 15 off Motor Feeder panel

29. © ABB Group
August 12, 2023 | Slide 29
Air Insulated Switchgear
Project Savings
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ENGINEERING DESIGN ELEMENTS
MCC Switchboard Floor Area Cable[1]
Heat Loss[2] Weight Clear Fault
Circuit breaker solution 32 m2 300 mm2 5.1 kW 29 tonnes 60 ms
Compact UniGear ZVC solution 19 m2 95 mm2 4.8 kW 17 tonnes 20 ms
OVERALL PROJECT COST COMPARISON
MCC Switchboard
Cost
Floor Area[3] Cable[4]
Heat Loss Weight Clear Fault
Circuit breaker solution € 96,000 € 225,000 5.1 kWh 29 tonnes 60 ms
Compact UniGear ZVC solution € 57,000 € 114,000 4.8 kWh 17 tonnes 20 ms
Difference (Δ) with UniGear ZVC Less 41 % Less 50 % Less 6 % Less 70 % Good 300 %
Savings in plant purchasing cost € 39,000 € 52,500 Varies[5] Significant[7] Negligible[8]
Savings in plant running cost - - Varies[6] - -
Savings in plant spare part - - - - Significant[9]
[1] Power cables based on differences of motor and transformer feeder. Same power cable for Incomer.
[2] Heat loss based on motor load 1000 kW and transformer 1000 kVA.
[3] Floor space construction cost based on € 3000 /m2 (average for E-Houses – yr. 2008)
[4] Cable cost based on average length 100 m each.
[5] Depends on air conditioning system to cool switchgear heat loss generated.
[6] Depends on energy and greenhouse cost, plant specific.
[7] Depends on installations, i.e. on or off-shore, seismic (earthquake), vibration, wind loads, remoteness, etc
[8] Similar manufacturing cost for fused contactor and circuit breaker technology.
[9] Depends on operation and fault severity. Worst case – equipment replacement may be necessary.

30. © ABB Group
August 12, 2023 | Slide 30
Air Insulated Switchgear
The SLD of Typical Motor Starting Options
Key to components :
 Contactor with electrical
latching
 Contactor with
mechanical latching
 Two-poles voltage
transformer for
supplying the control
circuit
 Direct-on-line
1
2
3
A
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31. © ABB Group
August 12, 2023 | Slide 31
Air Insulated Switchgear
Typical configuration of UniGear ZVC panels
 Large number of motor starters
 Large number of transformer feeders
IF IF
IF BT R IF
IF IF IF
IF IF IF IF IF
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32. © ABB Group
August 12, 2023 | Slide 32
Air Insulated Switchgear
Enquiries?
Please send all enquiries to:
ZVC Team
ABB Australia Pty Limited
Bapaume Road
Moorebank NSW 2170
Australia
Ph: + 612 9821 0111
Fax: + 612 9602 2454
Email: abb.zvc@au.abb.com
Product library:
Internal link
External link
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33. © ABB Group
August 12, 2023 | Slide 33