ZCW Series 72.5kV / 126.5kV Outdoor SF6 Hybrid Switchgear (Open-Type)
The ZCW Series Outdoor SF6 Hybrid Switchgear (Open-Type) is an advanced high-voltage switchgear solution developed for 72.5kV and 126.5kV three-phase AC transmission and distribution applications. By using air as the external insulation medium and SF6 gas for arc extinguishing, it integrates multiple primary switching devices into a compact outdoor assembly, providing reliable control, protection, and efficient operation for modern power systems.
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The ZCW Series Outdoor SF6 Hybrid Switchgear (Open-Type) is an advanced high-voltage switchgear solution designed for 72.5kV and 126.5kV three-phase AC transmission and distribution systems. By using air as the external insulation medium and SF6 gas for arc extinguishing, this compact outdoor switchgear integrates multiple primary electrical components into a reliable and efficient power switching system.
The ZCW Series combines an SF6 circuit breaker, disconnect switch, earthing switch, current transformer (CT), busbar, and supporting structure into a complete integrated switching bay. Compared with traditional air-insulated switchgear (AIS) solutions, it offers a more compact footprint, simplified installation, and improved operational flexibility while maintaining high reliability and easy maintenance access.
Designed for modern power grid applications, the ZCW Series Outdoor SF6 Hybrid Switchgear is widely used for transmission line switching, transformer protection, busbar coupling, capacitor bank switching, and substation automation systems. It is an ideal high-voltage switchgear solution for compact urban substations, industrial power networks, renewable energy projects, and remote mountain substations where space optimization and reliable operation are essential.
Model and meaning
Features
Highly Integrated Hybrid Switchgear Structure
The ZCW Series integrates multiple primary high-voltage electrical components into a compact and complete switching bay, including:
- SF6 Circuit Breaker
- Disconnect Switch
- Earthing Switch
- Current Transformer (CT)
- Busbar System
- Steel Support Frame
Compared with traditional AIS (Air Insulated Switchgear) configurations, the integrated hybrid switchgear design can reduce substation installation space by 30–50%. It helps minimize civil construction requirements, optimize equipment layout, and improve overall project efficiency.
Factory-Assembled Modular Switchgear Solution
Each ZCW Series switching bay is fully assembled, tested, SF6 gas-filled, and factory commissioned before delivery.
Key benefits include:
- Strict factory quality inspection
- Reduced on-site installation work
- Simplified commissioning process
- Shorter construction periods
- Lower project installation costs
After transportation, only foundation installation, cable termination, and secondary control wiring are required at the project site, significantly improving installation efficiency.
Advanced SF6 Switching and Arc Extinguishing Technology
The integrated SF6 circuit breaker adopts advanced gas arc-extinguishing technology to ensure reliable performance in high-voltage transmission and distribution systems.
Main advantages include:
- Excellent insulation performance
- High short-circuit breaking capacity
- Stable switching operation
- Long electrical service life
- Reliable capacitor bank switching capability
- No restrike during capacitive current interruption
The optimized interrupter structure provides dependable switching performance even under demanding power grid operating conditions.
Low-Maintenance Primary Components
The circuit breaker interrupter and disconnect switch contacts are engineered for long-term reliable operation with minimal maintenance requirements.
Additional reliability features include:
- Factory-installed self-supporting busbar design
- Fully sealed SF6 gas compartment
- Annual SF6 leakage rate below 0.5%
- Real-time gas density monitoring system
- Reduced routine maintenance workload
Flexible Hybrid Switchgear Configuration
The modular design of the ZCW Series supports various substation configurations, including:
- Single busbar arrangements
- Double busbar arrangements
- Bus coupler applications
- Transformer feeder bays
- Transmission line feeder bays
The circuit breaker can be removed as a complete unit, allowing maintenance or replacement within approximately three hours. This greatly reduces equipment downtime and improves substation availability.
Technical Data
Electrical Ratings
| Item | Unit | Parameter |
| Rated Voltage | kV | 72.5/126.5 |
| Rated Current | A | 3150 |
| Rated Frequence | Hz | 50 |
| Rated Short-Circuit Breaking Current | kA | 31.5/40 |
| Rated Short-Circuit Making Current (Peak) | 80 | |
| Rated Peak Withstand Current | 80 | |
| Rated 4s Short-Time Withstand Current | 31.5 | |
| First-Pole-to-Clear Factor | / | 1.5 |
| Rated operating sequence | / | O–0.3s–CO–180s–CO |
| Out-of-Phase Breaking Current | kA | 8 |
| Line Charging Switching Current | A | 10 |
| Main Circuit Resistance | / | Factory Tested |
| Mechanical Life | Times | 10000 |
| Radio Interference Voltage | μV | ≤500 |
Insulation Performance
| Item | Specification |
| Power Frequency Withstand Voltage (to Ground) | K × 160kV |
| Power Frequency Withstand Voltage (Across Open Contacts) | K × 200kV |
| Lightning Impulse Withstand Voltage (to Ground) | K × 350kV |
| Lightning Impulse Withstand Voltage (Across Open Contacts) | K × 410kV |
| Power Frequency Withstand Voltage at Zero SF6 Pressure | K × 84kV |
| Creepage Distance (Across Contacts) | 2585mm |
| Creepage Distance (to Ground) | 2248mm |
Altitude Correction Factor
| Installation Altitude | K Factor |
| 2000m | 1.13 |
| 3000m | 1.28 |
SF6 Gas Characteristics
| Item | Specification |
| Auxiliary Voltage | DC110V / DC220V |
| Closing & Trip Coil Voltage | DC110V / DC220V |
| Energy Storage Motor | AC110V / AC220V / DC110V / DC220V |
| Motor Operating Voltage | 85–110% Rated Voltage |
| Motor Power | 600W |
| Charging Time | ≤15s |
| Heater Voltage | AC220V |
| Auxiliary Contact Rating | 10A |
| Auxiliary Contacts | 10 NO + 10 NC |
CT26 Spring Operating Mechanism
| Item | Specification |
| Auxiliary Voltage | DC110V / DC220V |
| Closing & Trip Coil Voltage | DC110V / DC220V |
| Energy Storage Motor | AC110V / AC220V / DC110V / DC220V |
| Motor Operating Voltage | 85–110% Rated Voltage |
| Motor Power | 600W |
| Charging Time | ≤15s |
| Heater Voltage | AC220V |
| Auxiliary Contact Rating | 10A |
| Auxiliary Contacts | 10 NO + 10 NC |
Mechanical Performance
| Item | Specification |
| Pole Spacing | 1200mm |
| Contact Stroke | 120±3mm |
| Contact Travel | 25±2mm |
| Opening Speed | 4.2–5.0m/s |
| Closing Speed | 2.2–3.0m/s |
| Opening Time | ≤40ms |
| Closing Time | ≤100ms |
| Total Breaking Time | ≤60ms |
| Close-Open Time | ≤80ms |
| Open-Close Interval | 300ms |
| Three-Phase Opening Synchronism | ≤2ms |
| Three-Phase Closing Synchronism | ≤3ms |
Installation Data
| Item | Specification |
| Total Assembly Weight | 1500kg |
| Wind Load Area | 4.5m² |
| Pole Spacing | 1200mm |
| Mounting Holes | 4 × Φ18mm |
| Foundation | Standard Reinforced Concrete Base |
Overall and mounting dimensions(mm)
Typical Applications
The ZCW Series Outdoor SF6 Hybrid Switchgear is widely applied in modern high-voltage power systems and is suitable for various substation and grid infrastructure projects, including:
- Compact urban substations
- Utility transmission and distribution substations
- Industrial power substations
- Renewable energy substations
- Wind power and solar power plants
- Mountainous and remote-area substations
- Bus coupler applications
- Transformer feeder bays
- Capacitor bank switching systems
- Grid modernization and substation expansion projects
With its compact design, high reliability, and flexible configuration, the ZCW Series provides an optimized solution for applications where installation space, operational stability, and maintenance efficiency are critical.
Why Choose the ZCW Series Outdoor SF6 Hybrid Switchgear?
The ZCW Series offers advanced performance advantages for modern high-voltage transmission and distribution applications:
- Integrated SF6 hybrid switchgear combining circuit breaker, disconnect switch, earthing switch, CT, and busbar system in one compact bay
- 30–50% smaller installation footprint compared with conventional AIS switchgear solutions
- Factory-assembled modular construction for simplified installation and faster project completion
- Available voltage ratings of 72.5kV and 126.5kV
- Rated current capability up to 3150A
- Short-circuit breaking capacity up to 40kA
- Mechanical endurance of up to 10,000 operating cycles
- Annual SF6 leakage rate lower than 0.5%
- Complete circuit breaker replacement possible within approximately 3 hours
- Flexible layouts supporting single busbar, double busbar, and transformer feeder configurations
- Suitable for compact substations, utility projects, and modern power grid upgrades
Customization Services
To meet different utility, EPC, and industrial project requirements, Dxellence provides comprehensive customization options, including:
- 72.5kV and 126.5kV voltage class configurations
- Customized rated current and short-circuit breaking capacity
- CT transformation ratios and accuracy class selection
- Auxiliary power and control voltage configurations
- Single busbar and double busbar system arrangements
- Enhanced anti-pollution insulation solutions
- OEM and private labeling services
- Factory Acceptance Testing (FAT) and complete technical documentation
- Engineering support according to IEC, ANSI, and project-specific standards
The ZCW Series Outdoor SF6 Hybrid Switchgear delivers a compact, reliable, and economical solution for modern high-voltage substations. By combining advanced SF6 switching technology, modular construction, and flexible system integration, it helps power utilities and industrial users achieve reduced installation space, simplified maintenance, and improved grid reliability.
