ABB POLIM-R User manual

ABB
Operating instructions Surge arrester
Type POLIM®-R
Publication No. 1HC0075743 AA
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©R surge arrester ABB
2 EN Doc. 1HC0075743 AA
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. Installation position 11
5.4.2. Minimum distances between surge arresters and earth 11
5.4.3. Connections 12
5.5. Earthing 12
6. MAINTENANCE, UPKEEP 13
6.1. Replacement after overloading 13
6.2. Cleaning in case of heavy pollution 14
7. DISPOSAL 15

ABB Operating instructions for POLIM©R surge arrester
Doc. 1HC0075743 AA EN 3
1. ABOUT THIS DOCUMENT
These operating instructions are part of the POLIM®-R 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®-R surge arrester.
1.2. Target group
The target group of these operating instructions is professionals in the field of high-
voltage technology.
The POLIM®-R 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©R surge arrester ABB
4 EN Doc. 1HC0075743 AA
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
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.
This 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.
Measures for avoiding the danger appear here.

ABB Operating instructions for POLIM©R surge arrester
Doc. 1HC0075743 AA EN 5
2.2. Basic safety precautions
2.2.1. Product safety
The POLIM®-R has been constructed using state-of-the-art technology and official-
ly recognised safety-related rules. Danger to life and health of the user or third par-
ties could arise or damage of the POLIM®-R and other property could occur while
the POLIM®-R is in use, however.
The POLIM®-R 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.
Keep the operating instructions intact and fully readable, and store them in
such a way that they are accessible to operating personnel at all times.
Decommission and replace overloaded or damaged POLIM®-R units.
2.2.2. Personnel-related measures
Train personnel in professional and safe working with high-voltage technology.
Train and instruct personnel in working on the POLIM®-R using the operating
instructions.
Personnel being trained, instructed or provided with general education may
only work with the POLIM®-R under constant supervision by an experienced
high-voltage technology professional.
2.2.3. Organisational measures
Observe all safety- and danger-related information regarding the POLIM®-R.
The 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.
Only trained and instructed professionals may be authorised.
Clearly assign areas of responsibility for working with the POLIM®-R. Make
them known and adhere to them.
Only 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®-R.
Check 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©R surge arrester ABB
6 EN Doc. 1HC0075743 AA
3. DESCRIPTION
3.1. Intended use
The POLIM®-R is a surge arrester intended for use in low- and medium-voltage
applications. Surge arresters protect the insulation of devices against unaccept-
able 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®-R outside of its in-
tended application range as specified in this document.
3.2. Structure and function
The POLIM®-R.. -1 surge arrester is constructed from one or more in series con-
nected non-linear metal-oxide (MO) resistors. The POLIM®-R.. -2 surge arrester is
constructed from parallel 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 prac-
tically without delay. Thus any further increase in voltage is limited to the specified
residual voltage values. After the decline of the overvoltage the arrester immedi-
ately 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 MO resistors or stacks of them are connected with the ground plate and top
termination. 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.
Thanks to its high and very high energy absorbing capability the POLIM®-R is es-
pecially suited for overvoltage protection of:
transformers, cables, capacitors
generators
machines
locomotives and other apparatuses in railway applications
other low- and medium-voltage apparatuses and systems
Variants of the surge arrester POLIM®-R suitable for the use in d.c. systems are
also available. They differ from POLIM®-R surge arresters for a.c. systems by the
appendix Das second letter in the complete term of classification
(e.g. POLIM®-R 0.44-1 ND).

ABB Operating instructions for POLIM©R surge arrester
Doc. 1HC0075743 AA EN 7
3.3. Technical data
The technical data, dimensions, weights and installation distances are specified in
the following documents:
surge arrester POLIM®-R .. N for applications in a.c. systems in the pamphlet
1HC0075866.
surge arrester POLIM®-R .. ND for applications in d.c. systems in the pamphlet
1HC0075867.
dimensional drawings of POLIM®-R
3.3.1. Technical data on the surge arrester
The rating plate, molded in silicone, on labels or engraved, contains the following
data:
Data Meaning
POLIM®-R Type designation
In .. kA Nominal discharge current In
POLIM®-R .. -1 N
POLIM®-R .. -2 N
Version for a.c. applications
Complete type designation with specification of the
maximum permissible continuous operating voltage Uc
POLIM®-R .. -1 ND
POLIM®-R .. -2 ND
Version for d.c. applications
Complete type designation with specification of the
maximum permissible continuous operating voltage Uc
Uc = .. kV Maximum permissible continuous operating voltage Uc
xx-20xx Date of manufacture: month - year
HA … Serial number

Operating instructions for POLIM©R surge arrester ABB
8 EN Doc. 1HC0075743 AA
3.3.2. Application guidelines
The following guidelines apply for the use of POLIM®-R surge arresters:
"Application guidelines - Overvoltage potection"
Dimensioning, testing and application of metal-oxide surge arrresters in
medium voltage systems, pamphlet 1HC0075561
"Application guidelines - Overvoltage potection"
Dimensioning, testing and application of metal-oxide surge arrresters in
railway facilities, 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 Torque
[Nm] Minimum screw-in depth
[mm]
Maximum
screw-in depth
[mm]
M10 Head end
terminal 30 12 16
3.3.4. Behaviour in fire
The silicone housing of the surge arrester is self-extinguishing.

ABB Operating instructions for POLIM©R surge arrester
Doc. 1HC0075743 AA EN 9
4. TRANSPORTATION, UNPACKING AND STORAGE
Transportation
CAUTION
Surge arresters not secured during transportation
Damage to surge arresters that have fallen during transport.
Secure surge arresters against sliding or falling before transportation.
Observe safety precautions printed on the packaging for proper handling
during transportation and storage.
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 pack-
aging material.
After 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.
Examine shipment immediately to check for damage.
Notify 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.
Store surge arresters in a well-ventilated, clean room.
Remove plastic film to prevent the formation of condensation water.

Operating instructions for POLIM©R surge arrester ABB
10 EN Doc. 1HC0075743 AA
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.
Allow only authorised professionals to perform work on the surge arrester.
Observe 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 arres-
ter
Ignition of flammable materials by an arc and flying burning parts.
Do not store flammable materials near the surge arrester.
When working near the surge arrester, do not wear easily flammable clothing.

ABB Operating instructions for POLIM©R surge arrester
Doc. 1HC0075743 AA EN 11
Surge arresters only protect medium-voltage and low-voltage apparatuses when
they are located within the protective distance The protective distance is only a few
meters.
Always 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.
In cases of doubt, calculate the protective distance according to the formulas
in the "Application guidelines – Overvoltage protection".
5.4. Mounting
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.
Do not use surge arresters intended for d.c. systems in a.c. systems.
Observe the "Application guidelines - Overvoltage protection" from ABB
Switzerland Ltd
Before mounting, ensure that the characteristic data on the rating plate of the
surge arrester matches the requirements of the power system.
Ensure that system voltage applied at the terminals of the arrester does not
exceed the maximum permissible continuous operating voltage of the surge
arrester.
5.4.1. Installation position
The POLIM®-R surge arresters can be mounted in all positions.
5.4.2. Minimum distances between surge arresters and earth
Observe national regulations and the rules of the system owner regarding min-
imum permissible distances between the surge arresters and the earth.

Operating instructions for POLIM©R surge arrester ABB
12 EN Doc. 1HC0075743 AA
5.4.3. Connections
The base or the wall 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
nuts
bolt locks
Mount the ground plate of the surge arresters directly to the frame. Connect
ground plate of the surge arrester with earth.
Connect the high voltage connection with the head end terminal of the surge
arrester. Use a stranded cable.
Observe recommended torques (Clause 3.3.3).
When tightening the bolt, the torque shall be countered by a spanner at the
top end terminal.
Carefully clean contact surfaces before mounting and lubricate with acid-free
contact grease.
Ensure selection of suitable material pairs.
5.5. Earthing
Observe national regulations and the requirements of the system owner.
Connect surge arresters to the system ground via the shortest path.
Observe recommended minimum diameters:
Copper dia. 20 mm2
Aluminum dia. 40 mm2

ABB Operating instructions for POLIM©R surge arrester
Doc. 1HC0075743 AA EN 13
6. MAINTENANCE, UPKEEP
DANGER
System uses high voltage
Death, serious bodily harm and damage to the switching gear may result from an
electric shock.
Allow only authorised professionals to perform work on the surge arrester.
Observe 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. Replacement after overloading
Overloading during operation can lead to damaging (e.g. traces of fire, fractures) of
the surge arrester from arcs.
Minimal animal bites of the silicone housing (e.g. by birds, martens, mice etc.) do
not hinder the functioning of the surge arrester. Heavy bites do reduce the insula-
tion capacity of the silicone housing, however.
CAUTION
Damage to the surge arrester
Damaged surge arresters no longer protect the switchgear.
Check the surge arresters visually on a regular basis to ensure that they are
in sound condition.
Replace damaged surge arresters.
Keep a small percentage of installed surge arresters in reserve.

Operating instructions for POLIM©R surge arrester ABB
14 EN Doc. 1HC0075743 AA
6.2. 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.
Clean 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

ABB Operating instructions for POLIM©R surge arrester
Doc. 1HC0075743 AA EN 15
7. DISPOSAL
POLIM®-R 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 straps
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.