ZR-W

ZR-W system switchgears are designed for energy distribution at each level, as well as control and protection of electrical devices against short-circuit and overload effects.

Technical description

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ZR-W system switchgears are designed for energy distribution at each level, as well as control and protection of electrical devices against short-circuit and overload effects. They can be used as primary or sectional switchgears, or as control cabinets.

Thanks to the configuration universality, the ZR-W switchgear can be applied to the following industrial branches:

  • chemical / petrochemical,
  • pharmaceutical,
  • power plants and thermal-electric power stations,
  • heavy industry: mines, steel plants, coking plants,
  • light industry: paper, textile, production of household appliances.

As well as for infrastructure needs:

  • server facilities,
  • airports,
  • offices,
  • shopping centres,
  • hospitals.

Characteristics

  • Simple assembly system, which does not require complicated manufacturing processes and tools, that considerably shorten the production time,
  • Well thought-out construction composed of repeatable elements, which enables serial production of the switchgear ‘s components,
  • Easy to modify (reconstructions and expansions), which makes it possible to adapt the device to changing needs, 
  • Depending on the requirements, it is possible to manufacture switchgears with primary busbars located at the top or at the back of the cubicle, which enables cables to be conducted both from the top and the bottom side of the switchgear,
  • Withdrawable module technology assures quick device replacement without the need to switch off the whole switchgear,
  • Easier service operations and maintenance, possibility to install various function modules in the cubicle,
  • The switchgear has been completely examined according to the newest PN-EN 61439-1/2 standard, which focuses on operator safety,
  • 25 years of experience in designing and developing switchgears has resulted in the introduction of a wide range of safety improvements,
  • The switchgear is equipped only with high-quality materials and apparatus, which meet European requirements.

Technical data

Compliance with standards:

The ZR-W type switchgear meets the requirements of the following standards:

  • PN-EN 61439-1 - “Low Voltage Switchgear and Control gear – Part 1: Common specifications”,
  • PN-EN 61439-2 -“Low Voltage Switchgear and Control gear – Part2: Low voltage switchgear and control gear for power distribution”,
  • PN-EN 60529 – “Degrees of protection provided by enclosures (IP code)”,
  • PN-EN 50102 – “Degrees of protection against mechanical damages provided by the enclosures of the electrical devices (IK code)”.
Electrical data:
Rated voltage of the isolation 690 V / 1000 V / 1500 V1)
AC up to1500 V DC
Rated connection voltage 400 V / 500 V / 690 V / 1000 V2)
AC up to1200 V DC
Rated test impulse withstand voltage 8 kV / 12 kV
Rated frequency 50 Hz
Rated current rozdzielnicy from 1000 up to 6300 A
Rated short-time withstand current from 105 kA (1s)
Rated peak current strength from 231 kA

1) In special design up to 1500 V AC.
2) In special design up to 1000 V AC.


Mechanical data:
Dimensions Width from 400 up to1200 mm
Height 1900 / 2200 mm
Depth 600 / 800 / 1000 mm
Protection degree IP from IP20 up toIP54
Protection degree IK up to IK 10
Compartment division from 2A up to4B
Surface protection Zinc and galvanized steel constructions- 2,5 mm
Door covers from metal painted- 1,5 / 2 mm3)
Covers from metal painted- 1,5 mm
Paint (powder technology): standard - RAL 7035
or another colour – on request
Plastic components Halogen-free, self-extinguishing, fire-resistant, do not contain CFC

3) Different construction technology, after prior consultation with the manufacturer.


Service conditions:
Ambient temperature
    - Lower limit of the ambient temperature
    - upper limit of the ambient temperature
    - daily average ambient temperatures

-5°C (- 25°C)4)
+ 40°C
-5°C up to35°C
Relative humidity up to 50% (at temperature. 40°C)
Installation altitude up to 1000 meters above sea level
Atmosphere in installation place Free from chemically aggressive dust, steam and gases

4) Depend on apparatus used.

On the customer’s request it is possible to design a switchgear adapted to other conditions.

Switchgear construction

The main mechanical construction of the switchgear is composed of:

  • a structure made from zinc profiles,
  • elements that divide functional compartments, such as: horizontal and vertical partitions,
  • external covers (door/ side and back walls /  roof / floor).

Depending on the method of production, cells can be partially or entirely covered .The door, front covers and back walls can be equipped with ventilation grilles. Inspection windows installed on the door are made from multiple-walled glass or plastic.

Structure
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Internal partitions
przegrody wewnetrzne
External covers
oslony zewnetrzne
Cells are divided into three functional compartments depending on the switchgear requirements and design.
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Bays size

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Construction dimensions
Height
(mm)
Width
(mm)
Depth
(mm)
1900 / 2200 400 600 / 800 / 1000
500
600
700
800
900
1000
1100
1200

Busbars

In the ZR-W type switchgear the following types of busbar systems are applied:

  • primary busbars,
  • distribution busbars,
  • protective earth and neutral busbars (PE+N/PEN)

Primary busbars

Primary busbars located at the top of the switchgear cubicle

Phase and neutral N primary busbars (protective earth-neutral PEN applied for 4-wire cable) are located at the top of the switchgear in the busbar compartment. For 6300 A current, the upper busbar compartment is expanded with an extension with primary busbars, which increases the volume of the switchgear. Protective earth primary PE busbars (for 5-wire cable system) are located in the front at the lower part of the cubicle along its head.

Primary busbars installed at the top
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Busbars located at the back of the switchgear cubicle

Phase and neutral N primary busbars (protective earth neutral PEN applied for 4-wire cable) are located at the back of the switchgear in the busbar compartment. They are led on the lower or upper part depending on the configuration. Protective earth primary PE busbars (for 5-wire cable system) are located in the front at the lower part of the cubicle along its head.

Distribution busbars

szyny dystrybucyjne 01

Vertical distribution busbars are located in the busbar compartment, on the left side of the switchgear cubicle. They are used for connecting fixed, plug-in and withdrawable outgoing blocks. A neutral N busbar and protective earth PE busbar (for 5-wire cable system) or a protective earth neutral  PEN (for 4-wire cable system) are then arranged vertically in the connection compartment.

szyny dystrybucyjne 02

Busbars adapted to strip-type fuse disconnectors installation

Busbars located at the front of the switchgear cubicle are used for strip-type fuse disconnectors installation.

Bays types

The ZR-W type switchgear is composed of a combination of 9 bay types:

  • Bay with circuit breaker,
  • Coupler bay,
  • Bay with vertical fuse switch disconnectors,
  • Bay with horizontal fuse switch disconnectors,
  • Receiving bay
  • Free installation bay,
  • Cassette bay,
  • Capacitor banks bay,
  • Corner bay.

Bay with circuit breaker

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pole z wylacznikiem 02
Technical data of the bay with circuit breaker
Field of application

Power supply
Outgoing

Protection degree Ventilated for IP41
Non-ventilated for IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
400*) / 500 / 600 / 700 / 800 / 900/ 1000 / 1100 / 1200 mm
600 / 800 / 1000 mm
Possibility to install the apparatus Air circuit breaker up to 6300 A
Compact circuit breaker up to 1600 A
Form 2B / 3A / 4B
Compartment division Form 2B / 3A / 4B
Bay manner of performance  
Upper location of the primary busbar Bay depth 600 Terminal:
- side / back / bottom busbar
- bottom busbar system
- cable at the bottom, up to 12 cables of 240 mm2
Upper location of the primary busbar Bay depth 800 / 1000 Terminal:
- side / back / bottom busbar
- bottom busbar system
- cable at the top / bottom, up to 12 cables of 240 mm2
Back location of the primary busbar Bay depth 600 Terminal:
- top / bottom busbar
- top / bottom busbar system
- cable at the top / bottom, up to 12 cables of 240 mm2
Back location of the primary busbar Bay depth 800 / 1000 Terminal:
- side / top / bottom busbar
- top / bottom busbar system
- cable at the top / bottom, up to 12 cables of 240 mm2

*) Solution applied only to bays with a back busbar system.


Minimum bay dimensions depending on installed apparatus:
Apparatus type Rated current Bay width (3-pole apparatus) Bay width (4-pole apparatus) Bay depth
Stationary or withdrawable compact circuit breaker Up to 1600 A 400*) / 500 mm 600 mm 600 mm
Stationary or withdrawable power circuit breaker Up to 1600 A 600 mm 800 mm 600 mm
Stationary power circuit breaker From 2000 up to 3200 A 600*) / 700 mm 800 mm 600 mm
Withdrawable power circuit breaker From 2000 up to2500 A 600*) / 700 mm 800 mm 600 mm
Stationary power circuit breaker 4000 A 800 mm 900 mm 800 mm
Withdrawable power circuit breaker From 3200 up to 4000 A 800 mm 900 mm 800 mm
Stationary or withdrawable power circuit breaker From 5000 up to 6300 A 1000 mm 1200 mm 1000 mm

*) Solution applied only to bays with a back busbar system.

Coupler bay

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pole sprzeglowe 02
Coupler bay technical data:
Field of application Coupler between sections
Protection degree Ventilated for IP41
Non-ventilated for IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
600*) / 700*) / 800 / 900 / 1000 / 1100 / 1200 mm
600 / 800 / 1000 mm
Possibility to install the apparatus Air circuit breaker up to 6300 A
Compact circuit breaker up to 1600 A
Compartment division Form 2B / 3A / 4B
Upper location of the primary busbar Bay depth depends on the power supply bay depth Busbar connection of two upper tracks using a riser compartment
Back location of the primary busbar Bay depth depends on the power supply bay depth Upper busbars connection with down busbars

*) Solution applied only to bays with a back busbar system.


Minimum bay dimensions depending on installed apparatus:
Apparatus type Rated current Bay width
(3-pole apparatus)
Bay width
(4-pole apparatus)
Bay depth
Stationary or withdrawable compact circuit breaker Up to 1600 A 600 mm 700 mm 600 mm
Stationary or withdrawable power circuit breaker Up to 1600 A 700*) / 800 mm 800 mm 600 mm
Stationary power circuit breaker From 2000 up to 3200 A 900 mm 1000 mm 600 mm
Withdrawable power circuit breaker From 2000 up to 2500 A 900 mm 1000 mm 600 mm
Stationary power circuit breaker 4000 A 1100 mm 1200 mm 800 mm
Withdrawable power circuit breaker From 3200 up to 4000 A 1100 mm 1200 mm 800 mm
Stationary or withdrawable power circuit breaker From 5000 up to 6300 A 1200 mm ---------------- 1000 mm

*) Solution applied only to bays with a back busbar system.

Bay with vertical fuse switch disconnectors

pole z rozlacznikami bezpiecznikowymi pionowymi 01
pole z rozlacznikami bezpiecznikowymi pionowymi 02
Technical data of the bay with vertical fuse switch disconnectors:
Field of application Outgoings on the fuse switch disconnectors
Protection degree Ventilated for IP2X
Non-ventilated for IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
400*) / 500 / 600 / 700 / 800 / 900/ 1000 / 1100 / 1200 mm
600 / 800 / 1000 mm
Possibility to install the apparatus Strip-type fuse switch disconnectorssize 00 up to 3
Twin switch disconnector installation (size3) 800 A / 1000 A / 1250 A
Compartment division Form 2B
Bay manner of performance  
Upper location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom, up to 3 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue
Back location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom or top, up to 3 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue
Primary busbar positions Bay depth 800 / 1000 Terminal:
- cables from the bottom or top, up to 3 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue

*) Solution applied only to bays with a back busbar system.


Minimum bay dimensions depending on installed apparatus:
Bay width 400*) 500 600 700 800 900 1000 1100 1120
Number of 00 size apparatus 6 8 10 12 14 16 18 20 22
Number of 1 size apparatus 3 4 5 6 7 8 9 10 11
Number of2 size apparatus 3 4 5 6 7 8 9 10 ----
Number of 3 size apparatus 3 4 5 6 7 ---- ---- ---- ----

*) Solution applied only to bays with a back busbar system.

Bay with horizontal fuse switch disconnectors

pole z rozlacznikami bezpiecznikowymi poziomymi 01
pole z rozlacznikami bezpiecznikowymi poziomymi 02
Technical data of the bay with horizontal fuse switch disconnectors:
Field of application Outgoings on the fuse switch disconnectors
Protection degree Ventilated for IP2X
Non-ventilated for IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
1100 / 1200 mm
600 / 800 / 1000 mm
Possibility to install the apparatus Strip-type fuse switch disconnectorssize 00 up to 3
Compartment division Form 2B / 3B / 4B
Bay manner of performance  
Upper location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom, up to 3 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue
Back location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom or top, up to 3 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue
Primary busbar positions Bay depth 800 / 1000 Terminal:
- cables from the bottom or top, up to 3 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue

Minimum bay dimensions depending on installed apparatus:
Bay width 1000 mm 1200 mm
Number of 00 size apparatus up to 15 up to 19
Number of 1 size apparatus up to 10 up to 15
Number of 2 size apparatus up to 9 up to 11
Number of 3 size apparatus up to 6 up to 7

Receiving bay

pole odbiorcze 01
pole odbiorcze 02
Receiving bay technical data:
Field of application Outgoings on the box fuse switch disconnectors, compact circuit breakers or motor modules
Protection degree Ventilated for IP41
Non-ventilated for IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
1100 / 1200 mm
600 / 800 / 1000 mm
Possibility to install the apparatus Box fuse switch disconnectors
Compact circuit breakers up to 800 A motor power suppliers (protection/ contactor)
Modular apparatus
Compartment division Form 2B / 3B / 4B
Bay manner of performance  
Upper location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom, up to 2 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue
Back location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom or top, up to 2 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue
Primary busbar positions Bay depth 800 / 1000 Terminal:
- cables from the bottom or top, up to 2 cables for each switch disconnector, cable cross-sections according to the manufacturer’s catalogue

pole odbiorcze 03
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Possibility to install the apparatus:
Height bloku Possibility to install the apparatus in the block
150 mm Stationary compact circuit breaker up to 160 A Box fuse switch disconnector up to 160 A Modular apparatus
200 mm Plug compact circuit breaker up to 160 A
Stationary compact circuit breaker up to 250 A
250 mm 3- pole stationary compact circuit breaker up to 630 A
3- pole plug or withdrawable compact circuit breaker up to 400 A
3-pole box fuse switch disconnector up to 400 A
300 mm Four fuse switch disconnectors or compact circuit breakers installed vertically (current ≤ 160 A )
3- pole stationary compact circuit breaker up to 800 A
3- pole plug or withdrawable compact circuit breaker up to 630 A
Meters for electrical energy
Various apparatus

In a cubicle with height 2200 the field for apparatus application is 1900 mm
In a cubicle with height 1900 the field for apparatus application is 1500 mm

Free installation bay

pole swobodnej zabudowy 01
pole swobodnej zabudowy 02
Free installation bay technical data:
Field of application Bay for customer’s specific configurations
Protection degree Ventilated for IP41
Non-ventilated for IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
400*) / 500 / 600 / 700 / 800 / 900 / 1000 / 1100 / 1200 mm
600 / 800 / 1000 mm
Possibility to install the apparatus Bay designed to install customer’s apparatus, such as: frequency changers, softstarts, non-typical control apparatus, etc.
Compartment division Form 2A
Bay manner of performance  
Upper location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom, cable cross-sections according to customer’s specifications
Back location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom or top, cable cross-sections according to customer’s specification
Primary busbar positions Bay depth 800 / 1000 Terminal:
- cables from the bottom or top, cable cross-sections according to customer’s specification

*) Solution applied only to bays with a back busbar system.

Cassette bay

pole kasetowe 01
pole kasetowe 02
Cassette bay technical data:
Field of application Cassette outgoings
Protection degree Ventilated for IP41
Bay dimensions Height
Width
Depth
1900 / 2200 mm
1000 / 1200 mm
600 / 800 / 1000 mm
Possibility to install the apparatus       Cassettes (withdrawable module from 8M/2 to 24M/1)
Cassette type Maximum current Maximum number of cassettes in the cubicle
8M/2 63 A 18
8M/1 160 A 9
14M/1 250 A 4
20M/1 400 A 3
24M/1 630 A 2
Compartment division Form 2B / 3B / 4B
Bay manner of performance  
Upper location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom in the cable duct
Back location of the primary busbar Bay depth 600 Terminal:
- cables from the bottom or top in the cable duct
Primary busbar positions Bay depth 800 / 1000 Terminal:
- cables from the bottom or top in the cable duct

*) Solution applied only to bays with a back busbar system.

Capacitor banks bay

pole baterii kondensatorow 01
pole baterii kondensatorow 02
pole baterii kondensatorow 03
Capacitor banks bay technical data:
Field of application Capacitor or choke type battery with power from 160 up to 600 kvar
- From 160 kvar to 460 kvar by increments of 20 kvar
- 500 / 550 / 600 kVA by increments of 25 kvar
Protection degree Ventilated for IP31
Bay dimensions Height
Width
Depth
1900 / 2200 mm
600 / 800 / 1000 / 1200 mm
600 / 800 / 1000 mm
Possibility to cover the capacitor steps or capacitor-choke steps Battery increment size used
Non-choke-type Choke
5 kvar 10 kvar
10 kvar 15 kvar
15 kvar 20 kvar
20 kvar 25 kvar
30 kvar 30 kvar
40 kvar 40 kvar
50 kvar 50 kvar
  60 kvar
Compartment division Form 2A
Bay manner of performance  
Battery connected in line with the main switchgear Busbar terminal from switchgear primary busbars
Cable connection from the top or bottom
Separate battery Cable connection from the top or bottom

Notice:
More information about capacitor banks can be found in chapter BK, BKD - Capacitor Banks

Corner bay

pole narozne 01
pole narozne 02
Corner bay technical data:
Field of application Bay connecting switchgear cubicles, which form a “L” shape
Protection degree Ventilated for IP41
Non-ventilated for IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
700 / 900 / 1100 mm
700 / 900 / 1100 mm
Busbar connection in top and back layout Top busbar track 1600 / 2000 / 2500 / 3200 /4000 / 5000 / 6300 A
Back busbar track 1600 / 2000 / 2500 / 3200 /4000 / 5000 / 6300 A
Compartment division Form 1
Cable connections Does not apply to

General conditions of positioning and setting of the switchgear

Instructions of positioning the switchgear
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posadowienie 02
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Setting
Flooring must be leveled, and the floor unevenness cannot exceed 1 mm / 1000 mm.
The switchgear cubicle can be installed directly on the ground, duct frame or steel construction of the facility.


External leads. Useable area to lead cables from the bottom side of the switchgear cubicle.
Fig. Switchgear cubicle with cable connection compartment
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Fig. Switchgear cubicle with cable connection compartment
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Fig. Duct width under the switchgear and holes arrangement to fix the cubicle on the duct frame required for transport sets.
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L - length of the transport set (400 - 3000)
Sk - duct width Sk =(G-100)
G - switchgear cubicle depth (600, 800, 1000)

Fig. Installation of the switchgear without supporting frame
On the floor
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On the duct
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Fig. Installation of the switchgear with supporting frame
On the floor
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On the duct
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