Low voltage ZR-W type switchgears

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

Internal partitions

External covers

Depending on the requirements and switchgear design cells are divided into three functional compartments.

Bay dimensions

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 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

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.

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

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

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

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

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

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

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

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 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

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

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

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