ABB POLIM 4.5 ID User manual

Operating instructions
Surge arrester
Type POLIM®4.5 ID

2 | Operating instructions | EN | 1HC0075079 AB
Content
1 About this document ..........................................................................................3
1.1 Validity ...........................................................................................................................3
1.2 Target group ...................................................................................................................3
2 Safety ................................................................................................................3
2.1 Symbols and advices ..................................................................................................... 3
2.2 Basic safety precautions ................................................................................................ 4
2.2.1 Product safety ................................................................................................................4
2.2.2 Personnel-related measures ........................................................................................... 4
2.2.3 Organisational measures ................................................................................................ 4
3 Description ........................................................................................................4
3.1 Intended use .................................................................................................................. 4
3.2 Structure and function .................................................................................................... 4
3.3 Technical data ................................................................................................................5
3.3.1 Technical data on the surge arrester ............................................................................... 5
3.3.2 Application guidelines .................................................................................................... 5
3.3.3 Recommended torques and screw-in depths .................................................................. 5
3.3.4 Behaviour in fire ............................................................................................................. 5
4 Transportation, unpacking and storage ..............................................................6
4.1 Transportation ................................................................................................................6
4.2 Unpacking ......................................................................................................................6
4.3 Storage ..........................................................................................................................6
5 Commissioning ..................................................................................................7
5.1 Safety ............................................................................................................................ 7
5.2 Electrical check before commissioning ........................................................................... 7
5.3 Installation location and protective distance ................................................................... 7
5.4 Mounting ........................................................................................................................8
5.4.1 Minimum distances between surge arresters and earth .................................................. 8
5.4.2 Connections ...................................................................................................................8
5.4.3 Earthing .........................................................................................................................9
6 Maintenance, upkeep ....................................................................................... 10
6.1 Safety .......................................................................................................................... 10
6.2 Replacement after overloading ..................................................................................... 10
7 Disposal........................................................................................................... 11

1HC0075079 AB | EN | Operating instructions | 3
1 About this document
These operating instructions are part of the POLIM®4.5 ID surge arrester and describe safe and pro-
per use for all phases of operation.
Language of the original operating instructions: German
1.1 Validity
These operating instructions are valid only for the POLIM®4.5 ID surge arrester.
1.2 Target group
The target group of these operating instructions is professionals in the field of high-voltage technolo-
gy.
The POLIM®4.5 ID may only be commissioned and maintained by persons instructed in proper use
and handling.
2 Safety
2.1 Symbols and advices
Important information and technical notes are emphasised in order to illustrate the correct operation.
Symbol Meaning
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 damage 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.
X This mark indicates that an action is to be performed.
Warnings in these operating instructions indicate special dangers and list measures 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.
XMeasures for avoiding the danger appear here.

4 | Operating instructions | EN | 1HC0075079 AB
2.2 Basic safety precautions
2.2.1 Product safety
The POLIM®4.5 ID has been constructed using state-of-the-art technology and officially recognised
safety-related rules. Danger to life and health of the user or third parties could arise or damage of
the POLIM®4.5 ID and other property could occur while the POLIM®4.5 ID is in use, however.
XThe POLIM®4.5 ID 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 instruc-
tions.
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®4.5 ID 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®4.5 ID using the operating instructions.
XPersonnel being trained, instructed or provided with general education may only work with the
POLIM®4.5 ID under constant supervision by an experienced high-voltage technology professio-
nal.
2.2.3 Organisational measures
XObserve all safety- and danger-related information regarding the POLIM®4.5 ID.
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®4.5 ID. Make them known and
adhere to them.
XOnly personnel who have read and understood the operating instructions, especially the „Basic
safety precautions“ section may be allowed to carry out activities with the POLIM®4.5 ID.
XCheck to ensure that work is being performed in a safety-conscious way with awareness of possi-
ble dangers and while observing the operating instructions.
3 Description
3.1 Intended use
The POLIM®4.5 ID is a surge arrester intended for use in medium-voltage applications. Surge arres-
ters protect the insulation of medium voltage devices against overvoltages which are caused by light-
ning or switching operations.
The manufacturer is not liable for resulting damages from further, unintended use. The operator
accepts all responsibility for using the POLIM®4.5 ID outside of its intended application range as
specified in this document.
3.2 Structure and function
The POLIM®4.5 ID surge arrester is constructed from two parallely connected, non-linear metal-
oxide (MO) resistors. These MO resistors have an extremely non-linear resistance 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 enter 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 transfers to the surrounding air.
The stack of MO resistors and connection equipment is held together with strong straps made of
fiberglass-reinforced plastic. The directly molded silicone housing protects it from all environmen-
tal and weather influences. This design has proven to be the best solution in every environment for
years.

1HC0075079 AB | EN | Operating instructions | 5
Thanks to its extra high energy absorbing capability, the POLIM®4.5 ID is especially suited for over-
voltage protection of
locomotives and other apparatuses in railway applications
The POLIM®4.5 ID is intended to be used indoors.
3.3 Technical data
The technical data, dimensions and weights are specified in the following documents:
Surge arrester POLIM®4.5 ID for applications in d.c. systems in the pamphlet 1HC0075852.
POLIM®4.5 ID dimensional drawing HAWA 380212
3.3.1 Technical data on the surge arrester
The rating plate contains the following data:
Data Meaning
POLIM®4.5 ID Complete type designation with specification of the maximum permissible
continuous operating voltage Uc
In = 40 kA Nominal discharge current
Uc = ... kVdc Maximum permissible continuous operating voltage (d.c. voltage)
Ur = ... kVdc Rated voltage (d.c. voltage)
HA … Serial number
xx-20xx Date of manufacture: month-year
3.3.2 Application guidelines
The following guidelines apply for the use of POLIM®4.5 ID surge arresters:
„Application guidelines“ for railway systems, pamphlet 1HC0075573
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
Maximum
torque
[Nm]
Minimum
screw-in depth
[mm]
Maximum
screw-in depth
[mm]
M12 Head end / High
voltage terminal
48 18 25
3.3.4 Behaviour in fire
The silicone housing of the surge arrester is self-extinguishing.

6 | Operating instructions | EN | 1HC0075079 AB
4 Transportation, unpacking and storage
4.1 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.
4.2 Unpacking
The surge arresters provided are packaged in stable cardboard boxes or wooden crates.
The routine test reports for the final electrical inspection are included in the packaging material.
XAfter receiving the shipment, compare the order and delivery documents immediately 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.
XDo 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.
4.3 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.

1HC0075079 AB | EN | Operating instructions | 7
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:
àDisconnect the system from the power supply.
àSecure the system against being switched on again.
àEnsure that the system is de-energised.
àEarth the system and short-circuit it.
àCover 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 included with the pack-
aging. 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 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 protecti-
ve distance. The protective distance is only a few meters.
XAlways mount surge arresters as close as possible to the apparatus to be protected 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“.

8 | Operating instructions | EN | 1HC0075079 AB
5.4 Mounting
CAUTION!
Incorrect system voltage.
Damage to the switching gear and the surge arrester.
XDo 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.
The base 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:
bolts
foundation bolts
nuts
bolt locks
any required balancing washers
5.4.1 Minimum distances between surge arresters and earth
XObserve national regulations and the rules of the system owner regarding minimum permissible
distances between the surge arresters and the earth.
5.4.2 Connections
The POLIM®4.5 ID surge arrester is to be mounted earthed.
XMount the metallic side bars of the surge arresters directly to the earthed frame.
XConnect both side bars of the surge arrester with earth.
XConnect the high voltage connection with the head terminal U of the surge ar-rester. Use stranded
cable.
XObserve recommended torques (Clause 3.3.3)
XCarefully clean contact surfaces before mounting and lubricate with acid-free contact grease.
XEnsure selection of suitable material pairs.

1HC0075079 AB | EN | Operating instructions | 9
5.4.3 Earthing
XObserve national regulations and the requirements of the system owner.
XConnect surge arresters to the system ground via the shortest path.
XObserve recommended minimum diameters:
copper Ø 40 mm2
aluminum Ø 80 mm2

10 | Operating instructions | EN | 1HC0075079 AB
6 Maintenance, upkeep
6.1 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:
àDisconnect the system from the power supply.
àSecure the system against being switched on again.
àEnsure that the system is de-energised.
àEarth the system and short-circuit it.
àCover or cordon off neighbouring energised parts.
The surge arresters do not contain wearing parts and are therefore maintenance-free. Replacement
parts are not needed.
6.2 Replacement after overloading
Overloading during operation can lead to damaging (e.g. traces of fire, fractures, thrown out pieces)
of the surge arrester from arcs.
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 damaged surge arresters.
XKeep a small percentage of installed surge arresters in reserve.

1HC0075079 AB | EN | Operating instructions | 11
7 Disposal
POLIM®4.5 ID surge arresters are environmentally-friendly products which must be disposed of
based on the respective applicable regional regulations in an environmentally-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 aluminum
metal-oxide varistors
fibreglass-reinforced plastic straps
steel mounting hardware
Silicone rubber (not halogenated)
The silicone rubber can break down into SiO2 and CO2, thus uncovering the encased metal-oxide
varistors.
Metal-oxide varistors
The metal-oxide varistors are sintered ceramics consisting of about 90 % of ZnO. The following addi-
tions are also contained within:
percent by weight between 1 % and 4 %: Bi2O3 and Sb2O3, which are considered to be dangerous
substances according to EU ordinances.
percent by weight between 0.1 and 1 %: NiO and Cr2O3, which are considered poisonous and dan-
gerous 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 of the metal-oxide varistor).
The substances are ligated as a mixed 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 disposed of as industrial waste without infringing on EEC
guidelines.
No danger to personal health or the environment is present during normal operation.

For more information please contact:
ABB Switzerland Ltd.
High Voltage Products
Surge Arresters
Jurastrasse 45
CH-5430 Wettingen
Phone: [phone]
Telefax: [phone]
E-Mail: [e-mail]
www.abb.com/arrestersonline
Notice:
We reserve the right to make
technical changes or modify the
contents of this document without
prior notice. With regard to purchase
orders, the agreed particulars
shall prevail. ABB does not accept
any responsibility whatsoever for
potential errors or possible lack of
information in this document.
We reserve all rights in this document
and in the subject matter and
illustrations contained therein. Any
reproduction, disclosure to third
parties or utilization of its contents
– in whole or in parts – is forbidden
without prior written consent of ABB.
Copyright© 2012 ABB
All rights reserved
Document-ID: 1HC0075079 AB | EN