ABB HVL 120-0.3 User manual

Operating manual HVL 120-0.3
Operating Manual
Publication number 1HC0023892
Low Voltage Limiter
Type HVL 120-0.3
With metal oxide varistor and thyristors
from ABB
Silicon housing material for indoor and
outdoor applications
Transport, storage, operation, assembly,
installation and maintenance
Low Voltage Limiter HVL 120-0.3
with accessories
Table of contents
1GENERAL ........................................................2
2DESCRIPTION AND FUNCTION ................2
3TRANSPORT AND STORAGE .....................3
4TECHNICAL DATA / DESIGN .....................4
5OPERATION AND STRUCTURE ................6
6ASSEMBLY AND INSTALLATION.............7
7MAINTENANCE / SERVICING ...................9
8SQS CERTIFICATE......................................11
9EU DECLARATION OF CONFORMITY..11
Published by: Contact details:
ABB Switzerland Ltd Phone [phone]
Surge arresters Telefax: [phone]
Jurastrasse 45 E-mail: [email protected]
CH-5430 Wettingen 1 www.abb.com/arrestersonline
Switzerland
Subject to change without notice
We reserve all rights to this document and the subject matter presented herein. Reproduction, disclosure to
third parties or utilization of its content are prohibited without our express permission. © ABB Schweiz.
1HC0023892 AA EN Page 1 / 12

Operating manual HVL 120-0.3
1 GENERAL
This document is applicable to the ABB low voltage limiter, type HVL 120-0.3
The data in this operating manual describes the product, but does not establish the right to a guarantee
claim. In the interest of our customers, we continually strive to improve our products and adapt them to the
latest technological standards. Consequently, it is possible that small differences may occur between the
supplied product and the product description or the operating manual.
This document was written for qualified service personnel working in the field of railway engineering
technology. All safety regulations of the railway operator and the national safety authorities must be
observed and complied with, and only qualified and instructed personnel who have the required experience
of safety practices may install and maintain these devices. This manual does not in any way replace the
required training and experience with regard to safety regulations. Precautionary measures and warnings
must be strictly followed where there is a danger to persons or where the installation may be damaged.
The information contained here is intended to ensure that this product is installed correctly. As in all work
situations, ABB has no control over the conditions present in the electrical network of the railway operator,
which can have a marked effect on the installation of the product. It remains the responsibility of the product
user to choose the most suitable methods of installation. ABB accepts no liability for direct or indirect
damage arising from the use or misuse of this product.
2 DESCRIPTION AND FUNCTION
Stationary installations for the supply of railway traction current employ the rails, amongst other means, as
the return path for the traction current. In the case of DC current railways, electrically conductive parts or
structures located in the area of the overhead line and the current collector are not simultaneously
connected to the return current path and the earth potential. This simultaneous connection is not allowed to
be of long duration, owing to the stray current diffusion in the ground and the associated effects. Electrically
conductive parts that are not connected to the earth potential can become live with unacceptable shock-
hazard voltages.
The low voltage limiter HVL 120-0.3 is used in the case of DC current railways, to provide effective
protection for personnel and equipment. It fulfils the tasks of a voltage limiting device in accordance with EN
50122-1, and limits the occurring shock-hazard voltages to safe values. The resulting values are distinctly
below the limit values defined for these voltages in the EN 50122-1 standard.
An important benefit of the low voltage limiter is its resetting capability under certain operating conditions.
Tests must be carried out to establish whether the requirements for the protection of personnel and
equipment can still be guaranteed, not just in the case of new structures, but also where structural
modifications are made to existing systems. If these requirements are no longer fulfilled, the use of the low
voltage limiter HVL 120-0.3 should be examined.
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Operating manual HVL 120-0.3
Area of application for the low voltage limiter
Protection of personnel Protection of equipment
At all locations where dangers can occur from the
rail potential
On fully-conductive or semi-conductive components
which are not part of the operating electrical circuit
and which are located in the area of the overhead
line or current collector and which are not earthed
On parts which can become live in the event of a
fault
As overvoltage protection
On further high-current systems, telecommunications and other electrical systems which are at risk, or
which could be at risk, from the railway’s electrical power supply
3 TRANSPORT AND STORAGE
The low voltage limiter is supplied ex works, packed in a cardboard box. The accessories (fixing brackets,
fixing bolts and tension washers) are supplied separately from the low voltage limiter. Each consignment is
accompanied by final inspection record.
Scope of supply
Low voltage limiter Fixing bracket for the low
voltage limiter
T-bracket for cable
connection
Bolts and tension
washers
Final inspection
record
1 x 1 x 1 x 4 x 1 x
Following delivery, each consignment must be checked for completeness and correctness (compare against
the order and delivery documents). In the case of incompleteness or deviations from the delivery documents,
the supplier and the carrier must be notified immediately.
The supplied goods must be examined for transport damage immediately on receipt. In the event of
transport damage, this must be reported immediately to the insurance agent, the carrier and the supplier,
and a damage report must be completed. Low voltage limiters which show any signs of damage must not be
installed in the system or be put into service.
The supplied equipment must be stored in a well-ventilated room and must be protected from dirt or
damage. The original transport package can be used for storage purposes.
1HC0023892 AA EN Page 3 / 12

Operating manual HVL 120-0.3
4 TECHNICAL DATA / DESIGN
Technical data in accordance with EN 50123-5: 1997
Area of application: For DC current railway networks
for indoor and outdoor
applications
Rated voltage Ur: 50 V (DC)
Highest withstand voltage Uw: 60 V (DC)
Limiting voltage Us: 120 V (DC)
High-current strength: 20 kA for 0.1 s 1)
Current according to the resetting capability test Irev: 300 A for 60 s 2)
Long-time current strength Iwwithout guarantee of resetting
capability:
500 A for 1800 s 1)
LVL classification: LVLa
Temperature range: -20°C to +45°C
Height without accessories: 123 mm
Diameter without accessories: 130 mm
Weight without accessories: 3.8 kg
1) After responding, the resetting capability cannot be guaranteed. The protective function has been verified
up to the specified values. The low voltage limiter then represents a low-impedance connection (short
circuit).
2) Up to this current value in the stated time period, the low voltage limiter resets itself back to its starting
condition after responding. If the current is higher than this or if the time period is greater than that stated,
the resetting capability cannot be guaranteed. If the low voltage limiter does not reset to its starting condition,
it becomes permanently conductive. In this way, the protective function continues to be fulfilled up to
parameters as stated at 1).
Technical data for the integrated metal oxide varistor in accordance with IEC 60099-4: 2001
Nominal discharge current In: 20 kA 8/20 µs
High-current impulse Ihc: 100 kA 4/10 µs
Residual voltage at nominal discharge current Up: 380 V
Type plate
Name of manufacturer
abb
1HC0023892 AA EN Page 4 / 12
HVL Type designation (HVL = Hybrid Voltage Limiter)
Low Voltage Limiter U
sLimiting voltage
HVL 120-0.3 I
rev Current according to the resetting capability test
acc. EN 50123-5 IwLong-time current strength without guarantee
of resetting capability
U
s120 V In20 kA 8/20 µs
I
rev 300 A Up380 V InNominal discharge current
I
w500 A

Operating manual HVL 120-0.3
U
pResidual voltage at nominal discharge current In:
No. HA ……... Serial number
Dimensions
Low voltage limiter
T-bracket for cable connection
Fixing bracket for the low voltage limiter
1HC0023892 AA EN Page 5 / 12

Operating manual HVL 120-0.3
5 OPERATION AND STRUCTURE
Basic circuit diagram
U Trigger
electronics
Metal oxide varistor Th
y
ristors
Operation
The low voltage limiter consists of a parallel metal oxide varistor circuit, with two anti-parallel thyristors,
which are fired through a trigger electronics system. This hybrid design allows optimum protection against
short-time overvoltages and against overvoltages that continue for very long periods of time.
The metal oxide varistor changes its resistance depending on the input voltage U. This occurs without any
appreciable delay (in the region of several nanoseconds). In this way, the metal oxide varistor provides
protection against short-time overvoltages such as those that can occur, e.g. from the effects of lightning or
switching operations in the electricity network. Longer-lasting overvoltages in the range from milliseconds up
to hours cannot be limited by the metal oxide varistor for reasons related to the energy involved. Here, the
thyristors are employed which, after a time delay, short out the metal oxide varistor and consequently
provide protection against thermal loads. The delay is itself dependent on the input voltage U applied to the
low voltage limiter and typically lies in the region of several hundred microseconds.
The duration of the overvoltage is therefore the controlling factor for the value of the voltage limitation. If the
duration lies in the region of several hundred microseconds, then the characteristic curve of the metal oxide
varistor alone defines the voltage limitation (for example, 380 V at 20 kA pulse current peak value of the
pulse waveform 8/20 µs). If the overvoltage is applied for longer than the stated value, then one of the two
thyristors is fired (depending the polarity of the overvoltage) and accommodates the flow of current. By this
means, the voltage is limited to values less than 3 V. This condition remains in existence until the minimum
thyristor holding current is no longer met (between 10mA and 500mA, depending on the application).
In a very short space of time, the resulting shock-hazard voltage lies distinctly below the value permitted by
the EN 50122-1 standard for short-time conditions.
Resetting capability after possible loads
Current through the low voltage limiter Possible cause Resetting capability
guaranteed?
100 kA 4/10 µs Extreme lightning strike Yes
20 kA 8/20 µs Normal lightning strike Yes
300 A for 60 s Operating current Yes
20 kA for 0.1 s Short circuit No
500 A for 1800 s Fault in the network No
1HC0023892 AA EN Page 6 / 12

Operating manual HVL 120-0.3
6 ASSEMBLY AND INSTALLATION
Safety instructions
On stationary railway installations in the vicinity of overhead line and current collector areas, voltages occur
which can be dangerous to the human body.
To ensure successful and safe operation, assembly and maintenance of the low voltage limiter, the following
fundamental safety instructions must be observed and followed:
o Installation and assembly of the low voltage limiter must only be carried out by qualified personnel
who by reason of their knowledge, abilities and experience, can carry out the work in the technically
correct manner, and who can independently evaluate the dangers involved.
o Before beginning the work, all members of the workforce must be sufficiently informed of the
possible dangers which arise through operation of the railway. For their personal protection, all
members of the workforce must carry out precautionary and/or safety measures.
o Depending on the local conditions, the measures to establish and to secure the de-energised
condition must be carried out on installations or installation components, where necessary.
o The low voltage limiter must only be assembled, installed and operated with the supplied
accessories for its intended purpose and in accordance with its specifications.
o Modifications and repairs to the low voltage limiter itself and to its mounting parts are prohibited.
o If special problems arise which were not covered or were insufficiently covered in this operating
manual, please contact ABB Schweiz.
Before beginning any electrical installation work, the following 5 safety rules for establishing and
securing the de-energised condition must be strictly observed.
o Isolate the installation
o Secure against switching on again
o Check the de-energised state
o Earth and short-circuit
o Safely cover up or fix barriers around adjacent and live parts
Compliance with these safety measures will assist in preventing personal injury and material damage.
Signs used in this operating manual:
Warning of electrical voltage: This sign is used in the individual chapters and sections
of this manual and means that death or severe personal injury can occur, if the safety
measures are not followed.
Warning of dangers: This sign is used in the individual chapters and sections of this
manual and means that death or severe personal injury can occur during assembly
work at high level and as a consequence of traffic, if the safety measures are not
followed.
1HC0023892 AA EN Page 7 / 12

Operating manual HVL 120-0.3
Assembly
o Assemble the fixing bracket for the low voltage limiter and the T-bracket
for the cable connection according to the illustration.
o For this purpose, use the supplied M12x20 stainless steel bolts and
tension washers.
o Tighten the bolts to a torque of 25 Nm. Use a suitable torque wrench for
this purpose.
o The low voltage limiter is now pre-assembled and can be installed at
the intended position in the network.
Installation
Before beginning the work, check the safety distance to adjacent live parts or
equipment. If there is a danger of inadvertent touching, the 5 safety rules for
establishing and securing the de-energised condition at the work location must be
carried out (see the section entitled Safety instructions).
Secure yourself against falling, if the intended mounting position is on a mast or on a
high-level structure. For this purpose, use a secure working platform and wear your
personal protective equipment.
The contact surface, to which the low voltage limiter is to be fitted by means of the fixing bracket, must be flat
and clean.
The mounting position of the low voltage limiter can be freely chosen. It must be noted, however, that the
type plate and serial number should remain easily readable without removing the low voltage limiter. Polarity
reversal is not possible owing to the bipolar design.
The cable connection should be maintained as short as possible, since the protective effect of the low
voltage limiter (especially in the case of fast-acting processes which can occur, for example, from the effects
of lightning) is greatly influenced by this length dimension.
The cross section of the cable connection must be constructed in compliance with the national regulations
and the requirements of the railway network operator.
Putting into service
No further action or work is required at the installation location to put the equipment into service.
1HC0023892 AA EN Page 8 / 12

Operating manual HVL 120-0.3
7 MAINTENANCE / SERVICING
The low voltage limiter HVL 120-0.3 contains no parts that are subject to wear, and therefore is
maintenance-free. Spare parts are not required.
We recommend that the following work is carried out at regular intervals (at the latest, however, every 5
years) on all low voltage limiters that are in service.
Before beginning the work, check the safety distance to adjacent live parts or
equipment. If there is a danger of inadvertent touching, the 5 safety rules for
establishing and securing the de-energised condition at the work location must be
carried out (see the section entitled Safety instructions).
Secure yourself against falling if the intended mounting position is on a mast or on a
high-level structure. For this purpose, use a secure working platform and wear your
personal protective equipment.
o Inspect the low voltage limiter for any kind of damage such as, for example, the effects of electrical
arcing or defects in the housing. Damaged low voltage limiters must be replaced by new ones.
o Inspect all screwed connections.
o In the event of exceptional contamination, the low voltage limiter should be cleaned. For this, we
recommend that a soft cloth is used with warm water and a mild household cleaner (do not use
solvents or abrasive cleaning agents).
Faults and reserve equipment
The low voltage limiter is a protective equipment element and therefore overloading can never be completely
excluded. Depending on the number of units in operation, it is recommended that a suitable number of spare
units is kept in reserve.
Note on behaviour in fire
The silicon housing of the low voltage limiter is self-extinguishing (Oxigene Index LOI equates to 26.9% in
accordance with ISO 4589/84).
Effects of animal damage
Slight mechanical damage to the silicon grouting (for example, from the bites of animals such as birds and
martens) does not impair the function of the low voltage limiter.
Function checks by means of resistance measuring
A complete function check of the low voltage limiter is not possible at the installed location. Overloading of
the low voltage limiter can lead to a breakdown (short circuiting) of one or both thyristors. If there are any
doubts about the function of the low voltage limiter, we recommend that a resistance measurement is carried
out with a standard Multimeter. Before carrying out this measurement, the low voltage limiter must be
removed from the electrical circuit.
1HC0023892 AA EN Page 9 / 12

Operating manual HVL 120-0.3
Before beginning the work, check the safety distance to adjacent live parts or
equipment. If there is a danger of inadvertent touching, the 5 safety rules for
establishing and securing the de-energised condition at the work location must be
carried out (see the section entitled Safety instructions).
Secure yourself against falling if the intended mounting position is on a mast or on a
high-level structure. For this purpose, use a secure working platform and wear your
personal protective equipment.
A low voltage limiter must not be removed from the electrical circuit until its operating condition has been
determined! For this, proceed as follows:
1. Measure the voltage via the connections of the HVL 120-0.3 with a measuring device suitable for DC
voltage.
2. Measure the current through the HVL 120-0.3 with a current probe suitable for DC current. During
this operation, never disconnect a connection! Otherwise, there is the danger of an electric
shock.
3. If the voltage measurement gives a value greater than 50 V or the current measurement gives a
value greater than 0.3 A, then first of all the cause must be determined. If the cause is found and
rectified, the checks under Point 1. and Point 2. must be repeated.
4. The HVL 120-0.3 must be shorted out with a conductor of sufficient dimensions (observe the
national regulations and the requirements of the railway network operator). This conductor must be
arranged to ensure that detachment of the connection during removal of the HVL 120-0.3 cannot
occur.
5. Take a further measurement of the voltage via the connections of the HVL 120-0.3 with a measuring
device suitable for DC voltage. The voltage measurement should now give a value less than 1 V. If
this is the case, then the HVL 120-0.3 can be removed. Otherwise, the current circuit must be
checked again.
6. The volume resistance of the HVL 120-0.3 can now be measured with a standard Multimeter 3). The
resistance value obtained must be at least 1 kΩ. If this is not the case, then the HVL 120-0.3 is
defective and must be replaced. If the resistance value is equal to, or greater than 1 kΩ, it can be
concluded that the thyristors are functional, and the HVL 120-0.3 can be re-fitted.
7. The conductor used for shorting-out, must only be removed when the HVL 120-0.3 has been
completely re-fitted.
3) For the resistance measurement, do not use an insulation resistance meter (Megger)! This could lead to a
false evaluation, since such measuring devices work at voltage levels which will cause the low voltage limiter
to change into its conductive state.
1HC0023892 AA EN Page 10 / 12

Operating manual HVL 120-0.3
8 SQS CERTIFICATE
The company ABB Switzerland Ltd has established a management system which complies with the
requirements of the international standards for quality management and quality assurance (ISO 9001) as
well as for environmental management (ISO 14001).
9 EU DECLARATION OF CONFORMITY
EU Declaration of Conformity
in accordance with the low voltage directives 73/23/EEC for
electrical equipment
The construction of the electrical equipment
product: low voltage limiter HVL 120-0.3
was developed, designed, manufactured and brought into service in conformity with the EC
directive 73/23/EEC
Company: ABB Switzerland Ltd
Surge arresters
Jurastrasse 45
CH-5430 Wettingen
Switzerland
The following EC directives and harmonised standards have been applied:
EC directive 73/23/EEC, low voltage electrical equipment
The following European standards have been applied:
Railway applications – stationary installations, DC current switchgear
EN 50123-5
The technical documentation is fully available
The operating manual relating to product is available
Xin the original edition•
• ... in the language of user's country
Place, date stamp / signature
Engineering manager Quality management
Wettingen, 01.09.2003
Bernhard Doser Werner Boenzli
signature signature
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Operating manual HVL 120-0.3
1HC0023892 AA EN Page 12 / 12