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.

Introduction

Low Voltage switchgear ZR-W

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

Their universal configuration enables the use of ZR-W switchgears in the following branches of industry:

  • chemical / petrochemical,
  • pharmaceutical,
  • power plants and CHP plants,,
  • heavy industry: mines, steel plants, coking plants,
  • light industry: paper, textile, domestic appliances manufacturing.

And in infrastructure:

  • data centres,
  • airports,
  • office buildings,
  • shopping centres,
  • hospitals.

Characteristics

  • Simple installation system, which does not require the use of complicated manufacturing processes and tools, which significantly shortens manufacturing time,
  • thoughtful design composed of repeatable elements, which enables mass manufacturing of switchgear components,
  • ease of modification (reconstruction and expansion), which allows the adaptation of the device to changing needs,
  • depending on the requirements, it is possible to manufacture switchgears with primary busbars at the top or in the rear of the cabinets, which enables the feeding of cables both from the top and from the bottom of the switchgear,
  • withdrawable module technology ensures rapid replacement of devices without having to shut down entire switchgear,
  • easy servicing and maintenance, possibility of placing various functional modules in the cabinet,
  • the switchgear has been thoroughly tested according to the newest PN-EN 61439-1/2 standard, which focuses on operator safety,
  • 30 years of experience in switchgear design and development has resulted in the introduction of a wide range of safety improvements,
  • only high-quality materials and devices (meeting the requirements of European standards) are used.

Basic 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 controlgear assemblies. General rules”,
  • PN-EN 61439-2 - „Low-voltage switchgear and controlgear assemblies. Power switchgear and controlgear assemblies.”,
  • PN-EN 60529 - „Degrees of protection provided by enclosures (IP Code)”,
  • PN-EN 62262 - „Degrees of protection provided by enclosures for electrical equipment against external mechanical impacts (IK code)”
Electrical data:
Rated insulation voltage 690 V / 1000 V / 1500 V1)
AC up to 1500 V DC
Rated connection voltage 400 V / 500 V / 690 V / 1000 V2)
AC up to 1200 V DC
Test impulse withstand voltage 8 kV
Rated frequency 50 Hz
Rated current of the switchgear from 1000 to 6300 A
Rated short-time withstand current up tp 105 kA (1s)
Rated peak withstand current up to 231 kA
Resistance to internal arcing 105 kA / 1s

1) Up to 1500 V AC in custom design.
2) Up to 1000 V AC in custom design.


Mechanical data:
Dimensions Width from 400 to 1200 mm
Height 1900 / 2200 mm
Depth 600 / 800 / 1000 mm
IP degree of protection from IP20 up to IP54
IK degree of protection up to IK 10
Form of compartments
(depending on bay type)
from 2A to 4B
Surface protection Framework: 2.5 mm zinc and galvanized steel sheet
Covers (doors): 1.5/2 mm painted sheet 3)
Font panels: 1.5 mm painted steel sheet
Powder painting RAL 7035 as standard,
other colours on request
Plastic components Halogen-free, self-extinguishing,
fire-resistant, CFC-free

3) Other design technology to be agreed with the manufacturer.


Service conditions:
Ambient temperature
    - Lower limit of ambient temperature
    - Upper limit of ambient temperature
    - Average daily temperatures over 24 hours

-5°C (- 25°C)4)
+ 40°C
from -5°C to 35°C
Relative humidity up to 50% (at a temp. 40°C)
Installation altitude up tp 1000 m a.s.l.
Atmosphere at the place of installation free from chemically aggressive and
conducting dust, fumes and gases

4) Depending on the devices used.

At the customer's request it is possible to design a switchgear adapted to other conditions.

Switchgear design

Main mechanical design of the switchgear consists of:

  • framework made of zinc-coated profiles,
  • functional compartment divider elements, such as vertical and horizontal partitions,
  • external covers (doors/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 multi-layered glass or plastics.

Framework
Framework
Internal partitions
Internal partitions
External covers
External covers
Depending on the requirements and switchgear design cells are divided into three functional compartments.
podzial

Bay dimensions

szkielet

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

Busbars

Classification of busbars in the ZR-W switchgear according to their function:

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

Primary busbars

Primary busbars located at the top of the cabinet

Primary phase busbars and primary neutral N busbars (protective earth-neutral PEN for 4-wire system) are located in the busbar compartment at the top of the switchgear. Primary protective earth PE busbars (for 5-wire system) are located in the front in the lower part of the cabinet along its face.

Primary busbars in a top mounted system
Primary busbars in a top mounted system

Primary busbars in a top mounted system

Primary busbars located at the rear of the cabinet

Primary phase busbars and primary neutral N busbars (protective earth-neutral PEN for 4-wire system) are located in the busbar compartment at the rear of the switchgear.

Depending on the configuration, they are placed in its bottom or its top part. Primary protective earth PE busbars (for 5-wire system) are located in the front in the lower part of the cabinet along its face.

Distribution busbars

Distribution busbars

Vertical distribution busbars are located in the busbar compartment, on the left side of the switchgear cabinet. They are used for connecting fixed, plug-in and withdrawable outgoing units. 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.

Distribution busbars

Busbars adapted to strip-type fuse switch disconnectors installation

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

Types of bays

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

  • Circuit breaker bay,
  • Bus coupler bay,
  • Bay with vertical fuse switch disconnectors,
  • Bay with horizontal fuse switch disconnectors,
  • Outgoing bay,
  • Free installation bay,
  • MCC type cassette bay,
  • Capacitor bank bay,
  • Corner bay.

Circuit breaker bay

Circuit breaker bay
Circuit breaker bay
Technical data of the circuit breaker bay
Area of application

Incoming feeder
Outgoing feeder

Ingress protection rating Ventilated up to IP41
Non-ventilated up to IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
400*) / 500 / 600 / 700 / 800 / 900/ 1000 / 1100 / 1200 mm
600 / 800 / 1000 mm
Possibility of installing devices Air circuit breaker up to 6300 A
Compact circuit breaker up to 1600 A
Form of compartments Form 2B / 3A / 4B
Bay construction method
Primary busbars
placed at the top
Bay depth 600 Connection:
- busbar: side / rear / bottom
- bus duct: bottomm
- cable: bottom, up to 12 cables of 240 mm2
Primary busbars
placed at the top
Bay depth 800 / 1000 Connection:
- busbar: side / rear / bottom
- bus duct: bottom
- cable: top, up to 12 cables of 240 mm2
Primary busbars
placed at the back
Bay depth 600 Connection:
- busbar: side / bottom
- bus duct: bottom
- cable: top, up to 12 cables of 240 mm2
Primary busbars
placed at the back
Bay depth 800 / 1000 Connection:
- busbar: side / top / bottom
- bus duct: bottom
- cable: top, up to 12 cables of 240 mm2

*) Solution only for bays with busbars at the back.


Minimum bay dimensions depending on the installed devices
Device type Rated current Bay width
(3-pole devices)
Bay width
Device type (4-pole devices)
Bay depth
Fixed or withdrawable
compact circuit breaker
Up to 1600 A 400*) / 500 mm 600 mm 600 mm
Fixed or withdrawable
power circuit breaker
Up to 1600 A 600 mm 800 mm 600 mm
Stationary compact circuit breaker From 2000 to 3200 A 600*) / 700 mm 800 mm 600 mm
Withdrawable compact circuit breaker From 2000 to 2500 A 600*) / 700 mm 800 mm 600 mm
Stationary compact circuit breaker 4000 A 800 mm 900 mm 800 mm
Withdrawable compact circuit breaker From 3200 to 4000 A 800 mm 900 mm 800 mm
Fixed or withdrawable
power circuit breaker
From 5000 to 6300 A 1000 mm 1200 mm 1000 mm

*) Solution only for bays with busbars at the back.

Bus coupler bay

Bus coupler bay
Bus coupler bay
Technical data of the bus coupler bay
Area of application Coupler between sections
Ingress protection rating Ventilated up to IP41
Non-ventilated up to IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
600*) / 700*) / 800 / 900 / 1000 / 1100 / 1200 mm
600 / 800 / 1000 mm
Possibility of installing
devices
Air circuit breaker up to 6300 A
Compact circuit breaker up to 1600 A
Form of compartments Form 2B / 3A / 4B
Bay construction method
Primary busbars
placed at the top
Bay depth depends on
the incoming bay depth
Busbar connection of two upper circuits using
a riser compartment
Primary busbars
placed at the back
Bay depth depends on
the incoming bay depth
Connection of the upper busbar circuit with
the bottom busbar circuit

*) Solution only for bays with busbars at the back.


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

*) Solution only for bays with busbars at the back.

Bay with vertical fuse switch disconnectors

Bay with vertical fuse switch disconnectors
Bay with vertical fuse switch disconnectors
Technical data of the bay with vertical fuse switch disconnectors:
Area of application Outgoing on fuse switch disconnectors
Protection rating Ventilated up to IP2X
Non-ventilated up to IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
400*) / 500 / 600 / 700 / 800 / 900/ 1000 / 1100 / 1200 mm
600 / 800 / 1000 mm
Possibility of installing
devices
Strip-type fuse switch disconnectors, size 00 up to 3
Twin switch disconnector installation (size 3) 800 A / 1000 A / 1250 A
Form of compartments Form 2B
Bay construction method
Primary busbars placed at the top Bay depth 600 Connection:
- cables from the bottom, up to 3 cables to each
switch disconnector, cable cross-sections according to the manufacturer's catalogue
Primary busbars placed at the back Bay depth 600 Connection:
- cables from the bottom or top, up to 3 cables to each
switch disconnector, cable cross-sections according to the manufacturer's catalogue
Every placement of primary busbars Bay depth 800 / 1000 Connection:
- cables from the bottom or top, up to 3 cables to each
switch disconnector, cable cross-sections according to the manufacturer's catalogue

*) Solution only for bays with busbars at the back.


Minimum bay dimensions depending on the installed devices:
Bay width 400*) 500 600 700 800 900 1000 1100 1200
Number of 00 size devices 6 8 10 12 14 16 18 20 22
Number of 1 size devices 3 4 5 6 7 8 9 10 11
Number of 2 size devices 3 4 5 6 7 8 9 10 ----
Number of 3 size devices 3 4 5 6 7 ---- ---- ---- ----

*) Minimum bay dimensions depending on the installed devices.

Bay with horizontal fuse switch disconnectors

Bay with horizontal fuse switch disconnectors
Bay with horizontal fuse switch disconnectors
Technical data of the bay with vertical fuse switch disconnectors:
Area of application Outgoing on fuse switch disconnectors
Ingress protection rating Ventilated up to IP2X
Non-ventilated up to Ip54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
1100 / 1200 mm
600 / 800 / 1000 mm
Possibility of installing
devices
Strip-type fuse switch disconnectors, size 00 up to 3
Form of compartments Form 2B / 3B / 4B
Bay construction method
Primary busbars placed at the top Bay depth 600 Connection:
- cables from the bottom, up to 3 cables to each
switch disconnector, cable cross-sections according to the manufacturer's catalogue
Primary busbars placed at the back Bay depth 600 Connection:
- cables from the bottom or top, up to 3 cables to each
switch disconnector, cable cross-sections according to the manufacturer's catalogue
Every placement of primary busbars Bay depth 800 / 1000 Connection:
- cables from the bottom or top, up to 3 cables to each
switch disconnector, cable cross-sections according to the manufacturer's catalogue

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

Outgoing bay

Outgoing bay
Outgoing bay
Technical data of the outgoing bay:
Area of application Outgoings on box fuse switch disconnectors,
compact circuit breakers or motor modules
Protection rating Ventilated up to IP2X
Non-ventilated up to IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
1000 / 1200 mm
600 / 800 / 1000 mm
Possibility of installing
devices
Box fuse switch disconnectors
Compact circuit breakers up to 800 A
Motor power supply systems (protection/contactor)
Modular device
Form of compartments Form 2B / 3B / 4B
Bay construction method
Primary busbars placed at the top Bay depth 600 Connection:
- cables from the bottom, up to 2 cables to each device,
cable cross-sections according to the manufacturer's catalogue
Primary busbars placed at the back Bay depth 600 Connection:
- cables from the bottom or top, up to 2 cables to each switch disconnector,
cable cross-sections according to the manufacturer's catalogue
Every placement of primary busbars Bay depth 800 / 1000 Connection:
- cables from the bottom or top, up to 2 cables to each switch disconnector,
cable cross-sections according to the manufacturer's catalogue

pole odbiorcze 03
pole odbiorcze 04
Possibility of installing devices:
Bay height The device may be installed in a unit
150 mm Stationary compact circuit breaker up to 160 A
Box fuse switch disconnector up to 160 A
Modular device
200 mm Plug-in compact circuit breaker up to 160 A
Plug-in stationary compact circuit breaker up to 250 A
250 mm 3-pole stationary compact circuit breaker up to 630 A
3-pole plug-in 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)
Plug-in stationary compact circuit breaker up to 800 A
3-pole plug-in or withdrawable compact circuit breaker up to 630 A
Electrical energy meters
Various devices

In a cabinet with a height of 2200 mm the device installation area is 1900 mm
In a cabinet with a height of 1900 mm the device installation area is 1500 mm

Free installation bay

Free installation bay
Free installation bay
Technical data of the free instalation bay:
Area of application The bay to be equipped by the customer
Protection rating Ventilated up to Ip41
Non-ventilated up to IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
400*) / 500 / 600 / 700 / 800 / 900 / 1000 / 1100 / 1200 mm
600 / 800 / 1000 mm
Possibility of installing
devices
The bay is designed for the installation of customer's devices, such as: frequency converters, softstarts,
non-typical control instrumentation, etc.
Form of compartments Form 2A
Bay construction method
Primary busbars placed at the top Bay depth 600 Connection:
- cables from the bottom, cable cross-sections according
to the client specification
Primary busbars placed at the back Bay depth 600 Connection:
- cables from the bottom or top, cable cross-sections according
to the client specification
Every placement of primary busbars Bay depth 800 / 1000 Connection:
- cables from the bottom or top, cable cross-sections according
to the client specification

*) Solution only for bays with busbars at the back.

MCC type cassette bay

MCC type cassette bay
MCC type cassette bay electrical data:
Rated impulse
Rated insulation voltage Ui
- main circuits
- auxiliary circuits

1000 V AC
500 V
Rated connection voltage Ue do 690 V AC
Rated impulse withstand voltage Uimp 8 kV
Overvoltage category III / IV
Level of contamination 3
Rated frequency 50 / 60 Hz
Rated current
Distribution busbars Rated current Ie 1250 A
Rated short-time withstand current Icw 65 kA
Rated peak withstand current Ipk 150 kA
Resistance to electric arc effects
“Arc fault free” design prevents the occurrence of an arc fault.
MCC type cassette bay mechanical data:
Dimensions
Support cabinet and construction Height 2200 mm
Height of cassettes installation space 1650 mm
Widht 1000, 1100, 1200 mm
Depth 600, 800, 1000 mm
Surface protection
Supporting structures (profiles) Zinc or Aluzinc coated
Ingress protection rating
Depending on installation conditions up to IP30
Plastic components
Halogen-free, self-extinguishing, fire-resistant, CFC-free
Form of compartments
Depends on the solution adopted from 3B to 4B
Cable compartment
Cable connection right side of the bay
Cable outlet bottom or top

More details can be found in the Low voltage switchgears catalog in "Download" page

Capacitor bank bay

Capacitor bank bay
Capacitor bank bay
Capacitor bank bay
Technical data of the capacitor bank bay:
Area of application A capacitor or reactor bank with a power of 160 to 600 kvar
- from 160 kvar to 460 kvar adjusted every 20 kvar
- 500 / 550 / 600 kVA adjusted every 25 kvar
Ingress protection rating Ventilated up to IP31
Bay dimensions Height
Width
Depth
1900 / 2200 mm
600 / 800 / 1000 / 1200 mm
600 / 800 / 1000 mm
The possibility of installing capacitor stages
or capacitor and reactor stages.
Using various sizes of bank stages
Reactor-free Reactor-based
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
Form of compartments Form 2A
Bay construction method
The bank is connected in series
with the main switchgear
Busbar connection from the main busbars of the switchgear
Cable connection fed in from the top or from the bottom
Separately standing bank Cable connection fed in from the top or from the bottom

Note:
More information about capacitor bank bay can be found in chapter BK, BKD - Capacitor Banks

Corner bay

Corner bay
Corner bay
Technical data of the corner bay:
Area of application Connection bay of the switchgear cabinet in an L-shape
Ingress protection rating Ventilated up to IP31
Non-ventilated up to IP54
Bay dimensions Height
Width
Depth
1900 / 2200 mm
700 / 900 / 1100 mm
700 / 900 / 1100 mm
Connection of busbar circuits in a top-mounted
and rear-mounted system
Upper busbar circuit 1600 / 2000 / 2500 / 3200 /4000 / 5000 / 6300 A
Busbar circuit on the back 1600 / 2000 / 2500 / 3200 /4000 / 5000 / 6300 A
Form of compartments Form 1
Cable connection Not applicable

General conditions for location and placement of the switchgear

Guidelines for switchgear location
Guidelines for switchgear location
Guidelines for switchgear location
Guidelines for switchgear location

Placement
The foundation must be level, and its unevenness may not exceed 1 mm / 1000 mm.
The switchgear may be placed directly on the floor, on duct frame or on steel structure of the facility.


External feed-ins. Usable space for feeding the cables from the bottom of the cabinet
Fig. Cabinet without a connection compartment
Fig. Cabinet without a connection compartment
Fig. Cabinet with a connection compartment
Fig. Cabinet with a connection compartment

Fig. Required width of the duct under the switchgear and position of the switchgear mounting holes on the duct frame compared to the transport sets.
Fig. Required width of the duct under the switchgear and position of the switchgear mounting holes on the duct frame compared
to the transport sets.
Fig. Required width of the duct under the switchgear and position of the switchgear mounting holes on the duct frame compared
to the transport sets.
Fig. Required width of the duct under the switchgear and position of the switchgear mounting holes on the duct frame compared
to the transport sets.
 
L - length of the transport set (400 - 3000)
Sk - duct width Sk =(G-100)
G - depth of the switchgear cage (600, 800, 1000)

Fig. Switchgear placement without a load-bearing frame
On the floor
Switchgear placement without a load-bearing frame on the floor
On a duct
Switchgear placement without a load-bearing frame on a duct

Fig. Switchgear placement with a load-bearing frame
On the floor
Fig. Switchgear placement with a load-bearing frame on the floor
On a duct
Fig. Switchgear placement with a load-bearing frame on a duct

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