ABB POLIM-D User manual

ABB
Operating instructions Surge arrester
Type POLIM®-D
Publication No. 1HC0010173 AB
With ABB metal-oxide resistors and
silicone housing
Without gaps
For indoor and outdoor use
Mounting and installation, maintenance,
transportation, storage and disposal
Issued by: Contact information:
ABB Switzerland Ltd.
High Voltage Products
Surge Arresters
Jurastrasse 45
CH-5430 Wettingen 1
Phone: [phone]
Telefax: [phone]
E-Mail: [email protected]
Internet: www.abb.com/arrestersonline
We reserve the right to make changes.
We reserve all rights to this document and the object presented within. Reproduction, passing on to third parties or utilisa-
tion of the contents is not permitted without our express consent.
© ABB Schweiz AG

Operating instructions for POLIM©-D surge arrester ABB
2 EN Doc. 1HC0010173 AB
Table of contents
1. ABOUT THIS DOCUMENT 3
1.1. Validity 3
1.2. Target group 3
1.3. Copyright 3
2. SAFETY 4
2.1. Symbols and advices 4
2.2. Basic safety precautions 5
2.2.1. Product safety 5
2.2.2. Personnel-related measures 5
2.2.3. Organisational measures 5
3. DESCRIPTION 6
3.1. Intended use 6
3.2. Structure and function 6
3.3. Technical data 7
3.3.1. Technical data on the surge arrester 7
3.3.2. Application guidelines 8
3.3.3. Recommended torques and screw-in depths 8
3.3.4. Behaviour in fire 8
4. TRANSPORTATION, UNPACKING AND STORAGE 9
5. COMMISSIONING 10
5.1. Safety 10
5.2. Electrical check before commissioning 10
5.3. Installation location and protective distance 10
5.4. Mounting 11
5.4.1. System voltage 11
5.4.2. Installation position 11
5.4.3. Minimum distances between surge arresters and earth 12
5.4.4. Connections 12
5.5. Earthing 13
6. MAINTENANCE, UPKEEP 14
6.1. Disconnecting device 14
6.2. Replacement after overloading or damages caused by animals 15
6.3. Cleaning in case of heavy pollution 15
7. DISPOSAL 16

ABB Operating instructions for POLIM©-D surge arrester
Doc. 1HC0010173 AB EN 3
1. ABOUT THIS DOCUMENT
These operating instructions are part of the POLIM®-D surge arrester and describe
safe and proper use for all phases of operation.
We reserve the right to make changes in the interest of further development.
1.1. Validity
These operating instructions are valid only for the POLIM®-D surge arrester.
1.2. Target group
The target group of these operating instructions is professionals in the field of high-
voltage technology.
The POLIM®-D may only be commissioned and maintained by persons instructed
in proper use and handling.
1.3. Copyright
The copyright of these operating instructions belongs to ABB Switzerland Ltd.
These operating instructions are to be handled confidentially and are intended
solely for mounting, operating and monitoring personnel. They contain regulations
and illustrations of a technical nature which may neither be utilized for competitive
purposes nor passed on to others. Handing over to third parties is impermissible
and liable for compensation.
All rights, including those regarding the translation, are reserved.
Language of original document: German

Operating instructions for POLIM©-D surge arrester ABB
4 EN Doc. 1HC0010173 AB
2. SAFETY
2.1. Symbols and advices
This is a safety sign. It warns you of the danger of injury and material damage.
Follow all measures marked with the safety sign to avoid injuries, death and da-
mage to materials.
This safety sign warns you of the danger of death or serious injury from electric
shocks. Follow all measures marked with the safety sign to avoid injuries and
death.
XThis mark indicates that an action is to be performed.
Warnings in these operating instructions indicate special dangers and list meas-
ures for prevention of the danger. There are three levels of warning:
Warning
word Meaning
DANGER Immediate, impending endangerment of your life and health
WARNING Possible impending endangerment of your life and health
CAUTION Possible impending danger of light injuries or damage to materials
Warnings are structured as follows:
WARNING
WORD
The type and source of danger appear here
Possible consequences, which could occur if the measures are not followed,
appear here.
:Impermissible actions appear here.
XMeasures for avoiding the danger appear here.

ABB Operating instructions for POLIM©-D surge arrester
Doc. 1HC0010173 AB EN 5
2.2. Basic safety precautions
2.2.1. Product safety
The POLIM®-D has been constructed using state-of-the-art technology and offi-
cially recognised safety-related rules. Danger to life and health of the user or third
parties could arise or damage of the POLIM®-D and other property could occur
while the POLIM®-D is in use, however.
XThe POLIM®-D is only to be used when it is in technically sound condition, for
the intended purpose, and with safety and the possible dangers in mind while
observing the operating instructions.
XKeep the operating instructions intact and fully readable, and store them in
such a way that they are accessible to operating personnel at all times.
XDecommission and replace overloaded or damaged POLIM®-D units.
2.2.2. Personnel-related measures
XTrain personnel in professional and safe working with high-voltage technology.
XTrain and instruct personnel in working on the POLIM®-D using the operating
instructions.
XPersonnel being trained, instructed or provided with general education may
only work with the POLIM®-D under constant supervision by an experienced
high-voltage technology professional.
2.2.3. Organisational measures
XObserve all safety- and danger-related information regarding the POLIM®-D.
XThe safety rules of the owner of the high- and medium-voltage system and all
regulations of the respective national safety authorities are to be observed.
XOnly trained and instructed professionals may be authorised.
XClearly assign areas of responsibility for working with the POLIM®-D. Make
them known and adhere to them.
XOnly personnel who have read and understood the operating instructions, es-
pecially the "Basic safety precautions" section may be allowed to carry out ac-
tivities with the POLIM®-D.
XCheck to ensure that work is being performed in a safety-conscious way with
awareness of possible dangers and while observing the operating instructions.

Operating instructions for POLIM©-D surge arrester ABB
6 EN Doc. 1HC0010173 AB
3. DESCRIPTION
3.1. Intended use
The POLIM®-D is a surge arrester intended for use in high- and medium-voltage
applications. Surge arresters protect the insulation of high voltage and medium
voltage devices against unacceptable overvoltages which are caused by lightning
or switching operations.
The manufacturer is not liable for resulting damages from further, unintended use.
The operator accepts all responsibility for using the POLIM®-D outside of its in-
tended application range as specified in this document.
3.2. Structure and function
The POLIM®-D surge arrester is constructed from serially connected, non-linear
metal-oxide (MO) resistors. These MO resistors have an extremely non-linear re-
sistance property. At the maximum operating voltage of Uc, only a small capacitive
current will flow in the mA range. With an increase in voltage, the MO resistors en-
ter a highly-conductive state practically without delay. Thus any further increase in
voltage is limited to the specified residual voltage values. After the decline of the
overvoltage the arrester immediately turns back to the non- or slightly-conductive
state. The MO arrester converts the energy of the surge into heat, which it trans-
fers to the surrounding air.
The stack of MO resistors and connection equipment is held together with loops
made of fiberglass-reinforced plastic. The directly molded silicone housing protects
it from all environmental and weather influences. This design has proven to be the
best solution in every environment for years.
The POLIM®-D surge arrester is optionally equipped with a disconnecting device
(disconnector). This device disconnects the POLIM®-D surge arrester from the
power network, when it has been overloaded and destroyed. Disconnecting is
done by firing of a small propellant charge in the disconnecting device.
The POLIM®-D is especially suited for overvoltage protection of:
•transformers
•cables
•other medium-voltage apparatuses and systems

ABB Operating instructions for POLIM©-D surge arrester
Doc. 1HC0010173 AB EN 7
3.3. Technical data
The technical data, dimensions, weights and installation distances are specified in
the following documents:
•surge arrester POLIM®-D for applications in a.c. systems in the pamphlet
1HC0075866
•POLIM®-D dimensional drawings
•Drawings of accessories
3.3.1. Technical data on the surge arrester
The rating plate molded into the silicone housing contains the following data:
Data Meaning
POLIM®-D Type designation
In = .. kA Nominal discharge current In
IEC-P-CL .. kA Rated short-circuit current Isfor 0.2 sec.
Additional data is engraved .
Data Meaning
Uc = .. kV maximum permissible continuous operating voltage Uc
Ur = .. kV Rated voltage Ur
xxxxxxxx Serial number
xx/20xx Date of manufacture, month/year

Operating instructions for POLIM©-D surge arrester ABB
8 EN Doc. 1HC0010173 AB
3.3.2. Application guidelines
The following guidelines apply for the use of POLIM®-D surge arresters:
•“Application guidelines Overvoltage protection”
Dimensioning, testing and application of metal oxide surge arresters in me-
dium voltage systems, pamphlet 1HC0075561
Additionally for surge arresters equipped with disconnecing devices applies:
XUse POLIM®-D surge arrester equipped with a disconnecting device in out-
door installations, only.
XUse the disconnecting device with POLIM®-D surge arrester, only.
3.3.3. Recommended torques and screw-in depths
The specified values in the table below apply for steel bolts of strength class 8.8 in
aluminum nut threads.
Thread Position Torque
[Nm] Minimum screw-in depth
[mm]
Maximum
screw-in depth
[mm]
M12 top connection 48 18 25
M12 top connection
without socket 48 18 20.5
M12 bottom
connection 48 18 20.5
M12 bottom connection
without socket 48 12 12.5
The specified values in the table below apply for POLIM®-D surge arrester equip-
ped with a disconnecting device
Thread Position Torque
[Nm]
M12 bolt between disconnecting device and bottom con-
nection of surge arrester 20
M10 bolt of the disconnecting device 20
3.3.4. Behaviour in fire
The silicone housing of the surge arrester is self-extinguishing.

ABB Operating instructions for POLIM©-D surge arrester
Doc. 1HC0010173 AB EN 9
4. TRANSPORTATION, UNPACKING AND STORAGE
Transportation
CAUTION
Surge arresters not secured during transportation
Damage to surge arresters that have fallen during transport.
XSecure surge arresters against sliding or falling before transportation.
XObserve safety precautions printed on the packaging for proper handling
during transportation and storage.
XDon’t expose disconnectors or surge arresters with equipped disconnecting
devices to temperatures above +60°C .
Unpacking
The surge arresters provided are packaged in stable cardboard boxes or wooden
crates. The accessories, packaged in plastic bags, are either included in the carton
or wooden crate or supplied separately in case of large quantities.
The surge arresters are supplied with accessories installed, unless specifically or-
dered otherwise. The routine test reports for the final electrical inspection are in-
cluded in the packaging material.
XAfter receiving the shipment, compare the order and delivery documents im-
mediately to check for completeness and accuracy of the shipment. In case of
incompleteness or deviations, inform the supplier and shipper immediately.
WARNING
Damaged surge arresters
Material damage and personal injury due to the installation and commissioning of
damaged surge arresters.
:Do not use damaged surge arresters.
XExamine shipment immediately to check for damage.
XNotify the insurance company, the shipper and the supplier of the damage
immediately and create a damage log.
Storage
The original packaging materials can be used for storage.
XStore surge arresters in a well-ventilated, clean room.
XRemove plastic film to prevent the formation of condensation water.
XStorage temperature: -40 .. 70°C
XDon’t expose disconnectors or surge arresters with equipped disconnecting
devices to temperatures above +60°C.

Operating instructions for POLIM©-D surge arrester ABB
10 EN Doc. 1HC0010173 AB
5. COMMISSIONING
5.1. Safety
DANGER
System uses high voltage
Death, serious bodily harm and damage to the switching gear may result from an
electric shock.
XAllow only authorised professionals to perform work on the surge arrester.
XObserve the safety rules of EN 50110-1 before working on the system:
– Disconnect the system from the power supply.
– Secure the system against being switched on again.
– Ensure that the system is de-energised.
– Earth the system and short-circuit it.
– Cover or cordon off neighbouring energised parts.
5.2. Electrical check before commissioning
Each surge arrester is tested by the manufacturer. The routine test report is in-
cluded with the packaging. Additional electrical testing before commissioning is not
necessary.
5.3. Installation location and protective distance
DANGER
Danger of fire and injury via arc with overloading of the surge ar-
rester and when disconnecting device is disconnecting the surge
arrester
Ignition of flammable materials by an arc and flying burning parts.
XDo not store flammable materials near the surge arrester.
XWhen working near the surge arrester, do not wear easily flammable clothing.
Surge arresters only protect medium-voltage apparatuses when they are located
within the protective distance The protective distance is only a few meters.
XAlways mount surge arresters as close as possible to the apparatus to be pro-
tected within the protective distance. The length of the connecting cables are
decisive here.
XIn cases of doubt, calculate the protective distance according to the formulas
in the "Application guidelines".
XUse POLIM®-D surge arrester equipped with a disconnecting device in out-
door installations, only.

ABB Operating instructions for POLIM©-D surge arrester
Doc. 1HC0010173 AB EN 11
5.4. Mounting
5.4.1. System voltage
CAUTION
Incorrect system voltage
Damage to the switching gear and the surge arrester.
:Do not use surge arresters intended for a.c. systems in d.c. systems.
XObserve the "Application guidelines" from ABB Switzerland Ltd.
XBefore mounting, ensure that the characteristic data on the rating plate of the
surge arrester matches the requirements of the power system.
XEnsure that system voltage applied at the terminals of the arrester does not
exceed the maximum permissible continuous operating voltage of the surge
arrester.
5.4.2. Installation position
CAUTION
Deposits on the undersides of sheds
Conductivity of deposits hinders protective function of the POLIM-D .
XAlways mount surge arresters in such a way that the sheds point downward.

Operating instructions for POLIM©-D surge arrester ABB
12 EN Doc. 1HC0010173 AB
5.4.3. Minimum distances between surge arresters and earth
The minimum permissible distances between the surge arresters and the earth are
specified on the data sheets supplied with the offer or order confirmation. The val-
ues are based on calculations for unfavourable conditions and include safety mar-
gins.
XObserve national regulations and the rules of the system owner.
XThe mounting position of a surge arrester with equipped disconnecting device
shall be such, that disconnected earth wire can swing freely and in this case
no flash over will occur between the bottom connection and earth.
5.4.4. Connections
The base or foundation for the surge arrester must be flat, clean and suitable for
the loads that arise.
The following materials made of stainless or galvanised steel are to be provided by
the customer depending on the application:
•bolts
•nuts
•bolt locks
•any required balancing washers
The ordered mounting accessory is already mounted to the surge arrester in most
cases. If the mounting accessory hase been ordered and delivered separately, it
shall be mounted according to the enclosed instruction, drawing, data sheet or di-
mensional drawing.
XSurge arrester with disconnecting device:
Mount insulating bracket at vertical surface (wall, column, tower). Connect
earth wire to the stud of the disconnecting device. Use a stranded cable.
XSurge arrester without disconnecting device:
Mount the ground plate of the surge arresters directly to the frame or by
means of a metalllic mounting bracket. Connect earth wire to the ground plate
of the surge arrester.
XConnect the high voltage connection cable to the head end terminal of the
surge arrester. Use a stranded cable.
XObserve recommended torques (Clause 3.3.3).
XWhen tightening the bolt, the torque shall be countered by a spanner at the
same terminal.
XCarefully clean contact surfaces before mounting and lubricate with acid-free
contact grease.
XEnsure selection of suitable material pairs.

ABB Operating instructions for POLIM©-D surge arrester
Doc. 1HC0010173 AB EN 13
5.5. Earthing
XObserve national regulations and the requirements of the system owner.
XConnect surge arresters to the system ground via the shortest path.
XSurge arresters equipped with disconnecting device shall be connected to
earth by a stranded wire. One side of the earth wire shall be connected to the
disconnecting device the other side shall be connected to earth nearby the
mounting position of the insulating bracket.
XObserve recommended minimum diameters for POLIM®-D:
Copper dia. 20 mm2
Aluminum dia. 40 mm2

Operating instructions for POLIM©-D surge arrester ABB
14 EN Doc. 1HC0010173 AB
6. MAINTENANCE, UPKEEP
DANGER
System uses high voltage
Death, serious bodily harm and damage to the switching gear may result from an
electric shock.
XAllow only authorised professionals to perform work on the surge arrester.
XObserve the safety rules of EN 50110-1 before working on the system:
– Disconnect the system from the power supply.
– Secure the system against being switched on again.
– Ensure that the system is de-energised.
– Earth the system and short-circuit it.
– Cover or cordon off neighbouring energised parts.
The surge arresters do not contain wearing parts and are therefore maintenance-
free. Replacement parts are not needed.
6.1. Disconnecting device
DANGER
Tripping of disconnecting device
Risk of injury due to inappropriate handling.
:Do not expose the disconnecting device to temperatures above 60°C.
:Never try to open the disconnecting device.
:Do not connect any voltage/energy source to the terminals of the disconnec-
ting device.
The disconnecting device does not need any maintenance.

ABB Operating instructions for POLIM©-D surge arrester
Doc. 1HC0010173 AB EN 15
6.2. Replacement after overloading or damages caused by ani-
mals
Overloading during operation can lead to damaging (e.g. traces of fire, fractures) of
the surge arrester from arcs.
Minimal animal bites on the sheds of the silicone housing (e.g. by birds, martens,
mice etc.) do not hinder the functioning of the surge arrester. Heavy bites do re-
duce the insulation capacity of the silicone housing, however.
CAUTION
Damage to the surge arrester
Damaged surge arresters no longer protect the switchgear.
XCheck the surge arresters visually on a regular basis to ensure that they are
in sound condition.
XReplace surge arresters, when disconnecting device has operated.
XReplace damaged surge arresters.
XKeep a small percentage of installed surge arresters in reserve.
6.3. Cleaning in case of heavy pollution
Thanks to the hydrophobicity of the silicone housing, normal pollution does not af-
fect the insulation capacity of the housing. If pollution exceeding this is present
(heavy deposit layer) the surge arrester should be cleaned.
CAUTION
Solvents and abrasive equipment
Damage to the silicone housing.
:Do not use cleaning agents containing solvents besides isopropanol
:Do not use abrasive equipment for cleaning.
:Do not use silicone grease or silicone oil after the cleaning.
XClean surge arresters either with
– warm water and soft, lint-free cloths
– water spray with a maximum pressure of 10 bar
– soft, lint-free cloths moistened with isopropanol (isopropyl alcohol).
Apply on the whole silicone surface

Operating instructions for POLIM©-D surge arrester ABB
16 EN Doc. 1HC0010173 AB
7. DISPOSAL
POLIM®-D surge arresters are environmentally-friendly products which must be
disposed of based on the respective applicable regional regulations in an environ-
mentally-friendly manner. The materials should be given up for recycling.
Constituent components are:
•silicone rubber (not halogenated) for the external insulation
•mounting sections and other parts made of aluminium
•metal-oxide varistors
•fibreglass-reinforced plastic lugs
•steel mounting hardware
Constituent components of the disconnecting device:
•terminals and metallic parts from aluminium
•enclosure from thermoset material
•small propellant charge
If disconnecting device has not been damaged it can be assumed that the small
propellant charge had not been tripped. In this case disconnecting device shall be
disposed according to the local laws and regulations. Do not open disconnecting
device.
The remaining parts of a disconnecting device, which has tripped, can be recycled.
Silicone rubber (not halogenated)
The silicone rubber can break down into SiO2and CO2, thus uncovering the en-
cased metal-oxide varistors.
Metal-oxide varistors
The metal-oxide varistors are sintered ceramics consisting up to 90% of ZnO. The
following additions are also contained within:
•percent by weight over 1%: Bi2O3and Sb2O3, which are considered to be dan-
gerous substances according to EU ordinances
•percent by weight between 0.1 and 1%: NiO and Cr2O3, which are considered
poisonous and dangerous materials pursuant to EU guideline 91/689/EEC
Metal-oxide varistors are coated with a thin glass coating containing lead-oxide
(< 0.1% of the weight).
The substances are present as an oxide in metal-oxide varistors. A wash-out test
in accordance with an EPA specification (Federal Register/vol. 45, No 98 /Rules
and regulations) has shown that the sintered metal-oxide varistors can be dis-
posed of as industrial waste without infringing on EEC guidelines.
No danger to personal health or the environment is present during normal opera-
tion.