UniPack compact secondary substations

(CSS) upto 36 kV
For safe, reliable and space saving power
distribution solutions
ABB – a global leader

ABB is a global leader in power and automation technologies Commitment to quality and sustainability
that enable utility and industry customers to improve ABB manufacturing facilities conform to the highest
performance while lowering environmental impact. The ABB quality and environmental standards. The facilities are
Group of companies operates in around 100 countries. ISO 9001 and ISO 14001 compliant and certified by
In India, ABB has a vast installed base, extensive leading international authorities.
manufacturing facilities and a countrywide marketing and
ISO 9001 - 2008 Quality Systems
service presence.

The power technologies business offers electric, gas and

water utilities as well as industrial and commercial customers
a wide range of products, systems and services for power
generation, transmission and distribution. ABB’s turnkey
solution capabilities in the sector range from bulk power
transmission, turnkey substations and complete electrification
to utility automation and distribution systems.

Our product offering covers a wide spectrum of technologies

across the entire voltage range including indoor and outdoor
circuit breakers, air and gas insulated switchgear, instrument
transformers, disconnectors, capacitor banks, reactive power
compensators, power and distribution transformers and a
range of power distribution products like compact secondary
substations (CSS) and ring main units (RMU).

Typical distribution network

Primary distribution Secondary distribution

MV switchboard
Compact secondary substation

HV/MV transformer

MV network LV network

MV/LV transformer

2 Compact Secondary Substations (CSS) | Product brochure

Technology advantage

CSS is a prefabricated substation, factory-designed, tested Product portfolio

and ready-to-install and is fully compliant with IEC 62271-202 Outdoor CSS for secondary distribution up to 36kV
(IEC 61330). Our compact substations are engineered to
configuration
the highest possible standards for personnel safety and
aesthetics, designed to help solve problems of footprint and – MV switchgear
space limitations experienced within dense urban load centers. – Step-down distribution transformer

ABB’s CSS has the highest installation base in India as well as – LV switchgear
around the world.
Outdoor CSS for wind power evacuation at 36kV
Salient features configuration

– Modular construction of enclosure provides high degree of – LV switchgear

flexibility to meet specific site requirements – Step-up distribution transformer
– Fully compartmentalized construction for MV switchgear, – MV switchgear
transformer and LV switchgear
– Specially designed ventilation system to suit local climatic Indoor frame mounted CSS for secondary distribution
conditions up to 24kV configuration

– Appealing aesthetics – MV switchgear

– Safety ensured for operator, public and environment – Step-down dry type distribution transformer

– Low life-cycle cost – LV switchgear

– Transformer enclosure type-tested for IP2X and enclosure
class k10
– Customized design to suit site conditions
– Factory-designed and tested interconnections

CSS for outdoor application Frame mounted CSS for indoor application

Product brochure | Compact Secondary Substations (CSS) 3

Advanced construction for CSS enclosure

The enclosure of the outdoor CSS is manufactured using Painting

high quality pre-galvanized sheet steel.This provides Enclosure is painted with polyurethane paint.
high resistance to corrosion, which is paramount in
outdoor applications. CSS is typically divided into three Advantages:
compartments for - medium voltage switchgear, low voltage – Aesthetic, glossy finish
switchboard and distribution transformer. The detachable roof
– Outdoor durability
with ventilation opening is beam supported and secured at
– Resistant to corrosion
each corner with bolts.
– Resistant to chemicals and stains
Modular construction
– Abrasion resistant
The enclosure’s wall units, roof and doors are constructed
using standard modules. Its limiting dimensions are
Ventilation
3830 x 2330 x 2415 mm (L x W x H)
Ventilation is achieved
Advantages: by means of natural
– High mechanical strength air circulation from the
louvers of wall/door to
– Flexibility in design, different layout possible
the top of the roof using
– Appealing aesthetics
thermo siphon effect.
Sufficient cooling of
Clinching technology distribution transformers
Self-interlocking modules are inter-connected using clinching is achieved by means
technology. All load bearing members are of 2 mm thickness of ventilation openings
and non-load bearing members are 1.5 mm thick. in the transformer compartment, which is designed taking
into consideration the transformer rating, losses and climatic
Bolting is used only for the base frame and lifting fittings.
conditions. A standard CSS is classified and type-tested in
accordance with enclosure class requirement.
Advantages:
– New-age technology, free from rivets and screws
– Piercing of sheet metal is eliminated Doors and locking system

– Enhances mechanical strength of CSS enclosure All compartment doors are fixed with stainless steel hinges,
which provide high mechanical strength. Press-fit type
– Water and air-tight joints
gaskets ensure IP protection. Locks are equipped with
concealed shooting bolt arrangement and complete with a
magnetic flap. A padlock is also provided to protect against
vandalism.

Example of different CSS layouts

4 Compact Secondary Substations (CSS) | Product brochure

Flexible electrical composition

Medium voltage switchgear Distribution transformer

The MV compartment can be equipped with SF6 insulated
Oil-type transformer
compact Switchgear Type Safe Ring upto 36kV.
Oil-insulated transformer can be provided with CSS up to
For 36kV Compact Secondary Substation, air insulated 36kV. Fully hermetically sealed transformer with low losses
switchgear with vacuum circuit breaker can also be offered. and low temperature rise are used in CSS.
– Corrugated-wall type design without conservator
– Leak-proof design due to elimination of conservator
– Eliminates routine maintenance activities such as breather-
checking, periodical oil-testing and filtration.
– High efficiency design with low loss and low temperature rise

DV CCV

CCVV

Dry-type transformer
– Dry-type transformers can be provided with CSS
up to 24kV

Advantages of dry-type transformer:

– Resin is used as the
insulating medium for
longer life
– Maintenance-free
– No fire hazards
– Enhanced safety
– Environment-friendly

SafeRing switchgear is available with vacuum circuit-breaker

and fuse protection

Product brochure | Compact Secondary Substations (CSS) 5

Low voltage switchboard Connection between equipment
A fully customized solution type-tested as per IS/IEC Personnel and equipment safety is the major concern. In
standards is provided as per customer requirements. The order to ensure complete safety of equipment used in a CSS,
low voltage switchboard can be designed in different especially the transformer bushings, the connection between
arrangements and configurations in order to suit a specific the transformer and the RMU is made with XLPE insulated
application with required equipment such as: cables. The connection between the transformer and LVDB is
– Air circuit-breaker (ACB) made with cable / busbar.

– Moulded case circuit-breaker (MCCB)

– LV fuse switches / fuse ways
– Instrumentation and metering
– Automatic transfer schemes (ATS)
– Street lighting systems

Optional features
– Tariff metering for MV in a separate compartment
– Automatic Power Factor Correction Panel on LV side
– Smoke detector and fire alarm system for transformer
compartment
– Motor operation of LV and MV equipment for SCADA
connectivity
– Special enclosure colour options for outdoor CSS
– Touch-proof plug-in MV terminations for transformers

Internal earthing
The earthing of the CSS is made by 50 x 6 mm GI strip. The
continuity of earth system is ensured taking into account the
thermal and mechanical stresses.

6 Compact Secondary Substations (CSS) | Product brochure

CSS electrical characteristics

Outdoor CSS Outdoor CSS Indoor frame mounted CSS

up to 24kV for 36kV up to 24kV

Standard applicable IEC 62271 – 202 IEC 62271 – 202 MV Switchgear – IEC 62271 -
(IEC 61330) (IEC 61330) 200 / 60265 / 60694
Transformer - IEC 60076 / 60726
LV Switchgear – IEC 60439
Normal ambient temperature 40 ° C 40 ° C 40 ° C
Maximum ambient temperature 50 ° C 50 ° C 50 ° C
Enclosure construction Modular Modular Modular for Transformer compartment
Ventilation Natural Natural Natural
Temperature class (Std.) K 10 K 10 K 10
Degree of protection
MV and LV compartment IP 54 IP 54 NA
Transformer compartment IP 23 IP 23 IP 2X
MV Switchgear
Rated voltage (kV) 12/24kV 36kV 12 / 24kV
Rated insulation level
Power frequency (kV rms) 28/50 70 28 / 50
Impulse (kV p) 75/125 170 75 / 125
Rated frequency (Hz) 50 50 50
Isolator
Rated normal current (A) 630 630 630
Breaking capacity (A) 630 630 630
Making capacity (kA) 52.5 / 40 50 52.5 / 40
Vacuum circuit breaker
Rated normal current (A) 630 630 630
Breaking capacity (kA) 21/16 20 21 / 16
Making capacity (kA) 52.5 / 40 50 52.5 / 40
Transformer
Rated power (kVA) – oil type 1600 2000 NA
Rated power (kVA) – Dry type 2000 2000 2000
Rated secondary voltage (V) 433 433 433
Vector group Dyn 11 Dyn 11 Dyn 11
Tapping range + 5 in steps of 2.5% + 5 in steps of 2.5% + 5 in steps of 2.5%
Type test
IP Yes Yes Yes (For transformer compartment)
Internal arc Yes Yes NA
Enclosure class Yes Yes Yes
Impact test Yes Yes NA
Short circuit test on earthing Yes Yes NA

Product brochure | Compact Secondary Substations (CSS) 7

Contact us
ABB Limited operates a process of continuous
product development. We therefore reserve the
right to change designs, dimensions and data
without prior notice.