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Erection, maintenance and disposalInverted installation

Zinc oxide silicone-housed surge arresters PEXLIM R-X, Q-X and P-X

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The following instruction is valid for PEXLIM R-X, PEXLIM Q-X and PEXLIM P-X surge arresters for inverted mounting. For other installations, e.g. vertical upright mounted arresters, other instructions are valid.

Serious material damage, severe personal injury and/or death can be the result of not following this instruction. Therefore, the personnel responsible for the installation of the equipment shall read and follow the instruction carefully.

Handling and maintenance of all the surge arresters described in this instruction must be done by personnel trained for this type of work.

WARNING!All work related to the surge arresters shall be made with disconnected and earthed conductors. Follow all regulations and rules stated by international and national safety regulations.

Normally, surge arresters operate at a high voltage. Therefore, they must be installed in such a way that only qualified personnel has access to it.

Important information

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Table of contents

Important information

General

Unpacking and checking on arrival

Lifting the surge arrester

Line terminal

Grading ring

Insulating base, earth terminal and surge counter Mounting of arrester units

Installation on structure

Connection of conductors

Maintenance and checking

Disposal

1.

2.

3.

4.

5

6.

7.

8.

9.

10.

11.

Chapter Page

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4

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5

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A packing list is attached to each package. When unpacking, the contents of the cases shall be checked against respective packing list. If there is any shortage or parts damaged during transport, the ABB representative should be informed immediately.

Surge arresters are dimensioned for a Maximum Permissible Service Loading of 2500 Nm (PEXLIM P-X and PEXLIM Q-X) and 1500 Nm (PEXLIM R-X) defined as:

The bending moment (in Nm) acting at the base of a surge arrester resulting from the vector sum of all possible loads (eg. the line conductor load, the wind load, the arrester weight and earthquake) in the direction perpendicular to the arrester axis.

Its design admits a visible deflection at normal load. It is recommended to connect the line conductor vertically to lower the mechanical stresses.

Surge arresters are dimensioned for an operating voltage that is equal to or lower than the continuous operating voltage Uc (as per IEC) or MCOV (as per ANSI). The Uc- or MCOV-value is shown on the rating plate. To obtain the best protection performance, the surge arrester must be connected with as short leads as possible. However, the mechanical aspects must be taken into consideration!

Special instruments or tools are not required for assembly and erection of the surge arrester. It is recommended to assemble all details of a complete arrester before mounting it on the structure.

2. Unpacking and checking on arrival

1. General

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Fig 3.1

Lift the surge arrester by the line terminal or the flange. Use of shackles or lifting eye bolts are recommended. See fig. 3.1.

Range of weights of the surge arresters is 14-147 kg.

3. Lifting the surge arrester

Do not lift the surge arrester by its insulator!

4. Line terminal

Adjust the line terminal to desired position. Recommended tightening torque is 100 Nm. (M20). See fig. 4.2.

Line terminal with clamp: when the line conductor is to be connected, assemble the clamp according to the assembly instruction delivered with it.

Fig 4.1 Fig 4.2

100 NmM20

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5. Grading ring

When a grading ring is supplied, it must be fitted to the arrester, otherwise the correct performance is not guaranteed. If the surge arrester has a grading ring, assemble the stays with the ring/rings according to table 5.1.The recommended tightening torque for M10 bolts are 49 Nm. M6 screws are tightened with a screw driver.

Table 5.1. Grading ring arrangement

PEXLIM P132-XH170 — P150-XH170 APEXLIM P132-XV170 — P192-XV170 APEXLIM P192-XM245 A

PEXLIM P180-XH245 — P228-XH245 APEXLIM P210-XV245 — P228-XV245 APEXLIM P180-XV245 — P198-XV245 B

PEXLIM P216-XH300 — P276-XH300 BPEXLIM P216-XV300 — P276-XV300 BPEXLIM P258-XH362 — P288-XH362 C

PEXLIM P258-XV362 — P288-XV362 CPEXLIM P330-XH420 — P360-XH420 C

PEXLIM Q090-XV123 — Q096-XV123 APEXLIM Q108-XH145 — Q120-XH145 APEXLIM Q108-XV145 — Q120-XV145 A

BPEXLIM Q132-XH170 — Q150-XH170 APEXLIM Q132-XV170 — Q192-XV170 APEXLIM Q192-XM245 B

PEXLIM Q180-XH245 — Q210-XH245 BPEXLIM Q216-XH245 — Q228-XH245 APEXLIM Q180-XV245 — Q228-XV245 C

PEXLIM Q216-XH300 — Q276-XH300 CPEXLIM Q216-XV300 — Q276-XV300 CPEXLIM Q258-XH362 — Q288-XH362 C

PEXLIM Q258-XV362 — Q288-XV362 CPEXLIM Q330-XH420 — Q360-XH420 C

PEXLIM R090-XV123 — R102-XV123 APEXLIM R108-XH145 — R120-XH145 APEXLIM R108-XV145 — R120-XV145 A

PEXLIM R132-XH170 — R150-XH170 APEXLIM R162-XV170 — R192-XV170 A

Type designation Type designation

Mou

nted

on

the

top

flang

e of

the

top

unit

Mou

nted

on

the

top

flang

e of

the

top

unit

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49 NmM10

Grading ring according to table 5.1.(The numbered circles refer to the mounting alter-natives in the right column)

A

B

C

1

2

3

4

Mounting

49 NmM10

M10x25Washer

M6x25

M10x40Washer

M6x12

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6. Insulating base, earth terminal and surge counter

This instruction covers insulating bases 1HSA430 000-A and -B. 1HSA430 000-B is identical to -A except that the bolts used are of UNC-type. If you have purchased -B, please use the bolts sizes indicated in brackets.In case where another insulating base is to be fitted, the installation instructions included with the delivery shall be followed.

The bolt M12x45 (1/2” x 45) is only used to fix the earth terminal.If diagnostic indicator EXCOUNT-II is to be mounted, the longer bolt M12x50 (1/2” x 51) shall be used instead. In this case the M12x45 (1/2” x 45) bolts is not required and can be discarded.Recommended tightening torque is 84 Nm.

Fig 6.1

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For installation of diagnostic monitor EXCOUNT II, see assembly instruction included with it.

For installation of a surge counter (EXCOUNT A) ensure that:The arrester is insulated from the structure by an insulating base.The length of the conductor between the arrester and the surge counter shall not be less than 0.5 m and shall as a recommendation, not exceed 5 m, see figure 6.2. Longer lengths up to 10 m could be used, but please note that longer connection leads means a disadvantage from protection point of view since its inductance is added in series with that of the arrester. The conductor shall be insulated for 5xL kV (LIWL), where L is the conductor length in meter as shown in figure 6.2. (This could be achieved by using a bare conductor on insulators or a cable).The surge counter is installed according to the supplied assembly instruction.

Fig. 6.2 With earth terminal and/or surge counter EXCOUNT-A

Fig. 6.3 With diagnostic indicator EXCOUNT -II

1) Requirements on M12 (1/2”) bolts for anchoring to the structure: These bolts are not supplied with the arrester. Recommended tightening torque: According to strength class, however, max. 120 Nm. Strength class: 8.8 or higher. Material: Hot dip galvanized steel or waxed stainless steel. Required threaded grip length: 15 to 20 mm. A washer shall be placed under the bolts head.

1)1)

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7. Mounting of arrester units

Multi-unit arresters must be erected with their units in the correct order as shown in fig. 7.1. All units in an arrester have the same serial number with a consecutive suffix number to identify their position, i.e. top-unit = N..../1, next unit = N..../2, marked on the flanges. The position is always with respect to the high voltage connection i.e. high voltage connection is made to the top unit.Please note that arresters intended for inverted installation has an “H” at the end of the type designation.

Fig 7.1

84 NmM12

84 NmM12

4 x M12x204 x washer

3 x M12x403 x M12 Nut6 x Washer

Engraved text onthe flanges:

TOP UNIT Surge ArresterPEXLIM (type designation)N. XXXXXXXX/1

Surge ArresterPEXLIM (type designation)N. XXXXXXXX/2

Main rating plate:

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8. Installation on structure

Note the lifting instructions in paragraph 3. Fit the arrester to the structure according to fig. 8.1 if insulating base is not used. Otherwise se paragraph 6. Drilling plan is shown in fig. 8.2. Anchoring bolts and nuts are not provided with the arrester.Ensure that the chosen bolts have sufficient mechanical strength, in order to handle the loads described in paragraph 1.

9. Connection of conductors

Fig 8.1 Without insulating base Fig 8.2 Drilling plan

All earth terminals are compatible with both copper and aluminium conduc-tors, as well as all line terminals except 1HSA410 000-L and -N which cannot be combined with copper conductors. In these cases use stainless steel washers between the aluminium terminal and the copper conductor.

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Warning! Faulty connection

9.1. Connection of line conductor

The line conductor should be as short as possible. Connect the line conduc-tor to the line terminal in such a way that the possible bending moment under any circumstances does not exceed the maximum value! (See table 9.1) Maximum diameter of the conductor is 34 mm (for line terminal with clamp). The surge arrester design admits a visible deflection, which e.g. can appear due to the mechanical loading of the line conductor. This will not damage the arrester as long as the bending moment does not exceed the maximum usable load shown below in table 9.1.

Fig. 9.1 Connection of single line conductor can be done from top or side.

Fig. 9.2 Connection of double line conductor can be done from top or side.

Connection of the conductor must be done correctly. For vertical moun-ting the con-ductor must be fixed edge to edge with the clamp

Service loading

Maximum Permissible Service Loading (MPSL)Definitions as per amendment (no 2) to IEC 60099-4

Dynamic bending moment

PEXLIM R-X

1500 Nm

2500 Nm

PEXLIM Q-XPEXLIM P-X

2500 Nm

4000 Nm

Table 9.1

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9.2. Connection of earth conductor

Connect the earth terminal to the common earth system with as short conductor as possible. The earth conductor cross-section shall be chosen in accordance with local regulations and earth fault current requirements. The earth terminal (with clamp) accommodates conductor sizes from 8 mm to 34 mm diameter.For assembly of clamp see figure 9.3.

Fig. 9.3

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10. Maintenance and checking

A properly chosen and installed PEXLIM surge arrester is maintenance-free, when operating under normal operating conditions, during its lifetime. How-ever, the tightening torques on terminals shall be checked and if necessary adjusted to the right value at inspections of the plant.

Arrester insulators usually have shorter flash-over distances than other insulators for the same system voltage, which means a higher risk for external flash-over during washing.

Arresters must be spray-washed evenly in order to avoid overheating.Do not use high pressure on the water.

GeneralShould a routine check be desired, the only reliable method is to measure the resistive component of the leakage current periodically. For this purpose, use of ABB Leakage Current Monitor, LCM, together with ABBs clip-on current meter or ABB diagnostic indicator EXCOUNT-II is recommended. For description of the LCM/EXCOUNT-II and measurement procedures, please refer to relevant catalogues.

CleaningPEXLIM arresters do not require any cleaning of the external surfaces for their lifetime. The surface may appear to be dirty, but this is of no significance.

Should however for any reason the arresters be subjected to live washing observe the following in addition to normal precautions for live washing:

For extreme environments (e.g. high acidity, cement) please contact ABB.

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11. Disposal

Surge arresters, type PEXLIM, consists of an outer insulator made of non-halogenated silicon rubber with end fittings and terminals made of stainless steel alternatively aluminium or copper. The inside of the arrester consists of metal oxide varistors, steel spacers, aluminium components, glass fibre loops and aramide fibres.

The metal-oxide varistors are sintered bodies composed mainly of ZnO (90 %), with the following other substances in more than 1 % weight (in accordance with the common market rules for hazardous components):

Bi2O3

Sb2O3

Hazardous substances (according to the Council Directive 91/689/EEC on hazardous waste), existing in more than 0,1 % weight but less than 1 % are

NiOCr2O3

In addition the metal-oxide varistors are coated with a thin glass layer (<0,1 % weight) containing PbO.

When the arrester is disposed of the silicone parts will eventually decom-pose into SiO2 and CO2 and may in the long run expose the metal oxide part. As the substances of the sintered metal oxide varistors exists in an oxidized state, a leaching test according to EPA-test (Federal Register /vol. 45, No 98 / Rules and Regulation), has shown that the sintered bodies may be disposed of without violating the EEC Directive.

ABB Power Technology Products ABHigh Voltage ProductsSurge Arresters

SE-771 80 LUDVIKA, SWEDENTel: +46 (0)240 78 20 00Telefax: +46 (0)240 179 83E-mail: arresters.div@se.abb.comInternet: http://www.abb.com/arrestersonline

Assembly instruction: 2528enEdition 3, 2002-04

NOTE! ABB Power Technology Products AB is working with continous improvements, therefore we reserve the right to change design and specifications without notice.

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