Product Details of ZGS Series Combined Substation (American-Style Box Substation)

1. Product Introduction

ZGS eries combined substation (American-style box substation) is an integrated, fully sealed and fully insulated complete power supply equipment designed specifically for outdoor compact power distribution needs, in accordance with GB/T 17467-2018 and IEC 62271-200 international standards. The product highly integrates the high-voltage switch unit, transformer unit and low-voltage distribution unit into a single sealed corrugated oil tank structure, eliminating the traditional independent cabinet, and achieving miniaturization, integration and maintenance-free operation.

Compared with traditional civil substations and European-style box substations, the ZGS American-style box substation has significant advantages such as smaller footprint, faster installation, stronger protection, lower cost, higher overload capacity and longer service life. It can be directly used in various distribution network modes such as terminal power supply, ring network power supply and dual-power supply.

The entire equipment adopts fully sealed oil-immersed heat dissipation and anti-corrosion metal enclosure, which can operate outdoors for a long time without the need to build a power distribution room. It can be energized after on-site hoisting and wiring. It is especially suitable for urban old community renovation, industrial park power supply, temporary construction site power supply, photovoltaic and wind power new energy grid connection, rural power grid upgrading and other scenarios. With high reliability, minimal operation and maintenance, and ultra-high cost performance, ZGS has become the mainstream solution for compact, economical and rapid power supply in the construction of a new generation of urban and rural power grids.

2. Technical Parameters（Customizable）

2.1 Standard Electrical Parameters

• Model: ZGS-12/0.4-□ (□ is capacity in kVA)

• Rated Voltage: HV 10kV (6kV, 35kV customizable); LV 0.4kV

• Rated Frequency: 50Hz

• Rated Capacity: 50, 80, 100, 125, 160, 200, 250, 315, 400, 500, 630, 800, 1000, 1250, 1600, 2000kVA

• Transformer Type: Fully sealed oil-immersed transformer

• Energy Efficiency Class: S13, S20, S22 (Level 1 / Level 2)

• High-Voltage System:

• Switch Type: Oil-immersed two-position / three-position load switch

• Protection Configuration: Plug-in dual-sensitive fuse + backup current-limiting fuse

• Incoming Line Mode: Fully insulated, live pluggable elbow cable joint

• Power Supply Mode: Terminal power supply / Ring network power supply

• Low-Voltage System:

• Incoming Line: Molded case circuit breaker (MCCB)

• Outgoing Line: 4～12 circuits (customizable)

• Function Configuration: Metering, reactive power compensation, lightning protection, leakage protection, intelligent monitoring

• Connection Group: D,yn11

• Tap Regulation: Off-circuit tap adjustment ±2×2.5%

• Short-Circuit Impedance: 4%～6% (according to capacity)

• Protection Degree: IP54

• Ambient Temperature: -40℃ ～ +45℃

• Applicable Altitude: ≤3000m

• Relative Humidity: ≤95% (no condensation)

• Enclosure Material: Cold-rolled steel plate with spray coating / 304 stainless steel anti-corrosion type

• Installation Mode: Outdoor floor-mounted, pole-mounted, foundation-fixed

• Design Life: ≥25 years

• Maintenance-Free Period: 15～20 years

3. Main Features

1. Ultra-Compact with Minimal Footprint

   Integrated HV, LV and transformer in one tank, with a volume only 1/3～1/5 of European-style box substations. Compact structure and low profile, it can be directly installed in narrow spaces such as roadsides, green belts, community corners and construction site edges, greatly saving land acquisition and civil engineering costs.

2. Fully Sealed & Fully Insulated, High Safety Level

   All high-voltage live parts are immersed in transformer oil, with no exposed live parts, eliminating the risk of electric shock, accidental contact and electric arc. High-voltage adopts elbow-type fully insulated cable joints, which can be operated with live plugging and unplugging, and also has the function of isolating switch, making operation safe and simple.

3. Dual Fuse Full-Range Protection, Stable and Reliable

   Adopting plug-in thermal + current-sensitive dual-sensitive fuse + backup current-limiting fuse double protection, covering full-range faults such as overload, short circuit and overheating. It has sensitive action and low failure rate, without complex maintenance.

4. Super Strong Overload Capacity, Adapt to Peak Load

   Oil-immersed natural heat dissipation structure, with heat dissipation efficiency much higher than dry-type / European-style box substations, which can realize:

• 1.6 times rated capacity long-term overload operation

• 2 times rated capacity short-term overload (2 hours)

  It can easily cope with summer peaks, construction site startup and sudden increase of holiday load.

5. Fully Sealed Structure, Truly Maintenance-Free

   Adopting corrugated oil tank self-expansion structure, no oil conservator, no capsule, no leakage, completely isolated from air inside, no water intake, no condensation, no oxidation. It can operate normally for 15～20 years without oil refueling, leakage inspection and major maintenance, and the operation and maintenance cost is almost zero.

6. Super Strong Environmental Adaptability, Weather and Corrosion Resistant

   The whole machine is rainproof, dustproof, rustproof, anti-condensation, anti-salt fog and anti-acid-base corrosion. It can operate stably for a long time in coastal areas, chemical zones, mining areas, severe cold areas and high humidity areas, and can be placed outdoors without additional protection.

7. Extremely Fast Installation, Ready-to-Use

   Fully prefabricated, debugged and delivered as a whole in the factory. On site, it only needs simple foundation, hoisting in place, cable connection and grounding to be energized. It can be put into operation in 1～3 days at the fastest, and the construction period is shortened by more than 80% compared with traditional substations.

8. Low Comprehensive Cost, Ultra-High Cost Performance

   Saving civil engineering, land occupation, cables, labor and maintenance, the overall investment is 20%～40% lower than that of European-style box substations. It is the best choice for projects pursuing low cost, fast implementation and high reliability.

9. Low Noise, Low Loss, Environmentally Friendly

   The iron core adopts high-permeability grain-oriented silicon steel sheet, with low excitation and low noise. The operating noise is ≤50dB, which can be installed in areas with high environmental requirements such as communities, schools, hospitals and parks, without disturbing residents or damaging the landscape.

10. Convenient Intelligent Expansion

    Intelligent temperature control, remote monitoring, telemetry, remote signaling, remote control and energy management modules can be added, which can be easily connected to the distribution network automation system to realize unattended operation and remote operation and maintenance.

4. Application Scenarios

1. Urban residential communities, old community renovation

   Small footprint, simple appearance and low noise, which can integrate into the community landscape without damaging the environment or affecting residents' lives, and the power supply is stable and reliable.

2. Outdoor power supply for industrial parks, factories and enterprises

   Strong overload capacity and high protection level, suitable for high-load, continuous production and harsh environment scenarios.

3. Temporary power supply for construction sites, mines and temporary construction

   It can be hoisted as a whole, quickly moved and reused, meeting the needs of temporary power supply, short-term power supply and relocation reuse of construction sites.

4. Municipal public facilities

   Outdoor power supply scenarios such as road lighting, parks, scenic spots, squares, sewage treatment plants, garbage transfer stations, airports, high-speed railway stations and subway supporting facilities.

5. New energy supporting (photovoltaic, wind power, energy storage)

   Suitable for outdoor open-air, desert, mountain and roof photovoltaic projects, with small volume, wind and sand resistance and strong weather resistance, it can be used as a grid-connected step-up / power distribution device.

6. Rural power grids, mountainous areas and remote areas

   Simple installation, minimal maintenance and high reliability, suitable for scattered load, long-distance power supply and unattended rural, breeding and irrigation power supply.

7. Coastal, chemical and high-corrosion areas

   Stainless steel enclosure + anti-corrosion coating, salt fog resistance, corrosion resistance, waterproof and moisture-proof, with service life far exceeding that of ordinary box substations.

8. Supporting power supply for commercial complexes, parking lots and data centers

   Stable power supply, complete protection and ring network power supply, meeting the needs of high-power and high-reliability commercial power consumption.