Erection, maintenance and disposal Inverted installation Zinc oxide silicone-housed surge arresters PEXLIM R-X, Q-X and P-X 1
Important information 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. WRNING! ll 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. 2
Table of contents hapter Page 1. 2. 3. 4. 5 6. 7. 8. 9. 10. 11. 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 onnection of conductors Maintenance and checking Disposal 2 4 4 5 5 6 8 10 11 11 14 15 3
1. General 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 IE) or MOV (as per NSI). The Uc- or MOV-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 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 BB representative should be informed immediately. 4
3. Lifting the surge arrester 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. Do not lift the surge arrester by its insulator! Fig 3.1 4. Line terminal djust 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. 100 Nm M20 Fig 4.1 Fig 4.2 5
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 Type designation Mounted on the top flange of the top unit Type designation Mounted on the top flange of the top unit PEXLIM P132-XH170 P150-XH170 PEXLIM P132-XV170 P192-XV170 PEXLIM P192-XM245 PEXLIM Q180-XH245 Q210-XH245 PEXLIM Q216-XH245 Q228-XH245 PEXLIM Q180-XV245 Q228-XV245 B PEXLIM P180-XH245 P228-XH245 PEXLIM P210-XV245 P228-XV245 PEXLIM P180-XV245 P198-XV245 B PEXLIM Q216-XH300 Q276-XH300 PEXLIM Q216-XV300 Q276-XV300 PEXLIM Q258-XH362 Q288-XH362 PEXLIM P216-XH300 P276-XH300 PEXLIM P216-XV300 P276-XV300 PEXLIM P258-XH362 P288-XH362 B B PEXLIM Q258-XV362 Q288-XV362 PEXLIM Q330-XH420 Q360-XH420 PEXLIM P258-XV362 P288-XV362 PEXLIM P330-XH420 P360-XH420 PEXLIM R090-XV123 R102-XV123 PEXLIM R108-XH145 R120-XH145 PEXLIM R108-XV145 R120-XV145 PEXLIM Q090-XV123 Q096-XV123 PEXLIM Q108-XH145 Q120-XH145 PEXLIM Q108-XV145 Q120-XV145 PEXLIM R132-XH170 R150-XH170 PEXLIM R162-XV170 R192-XV170 BPEXLIM Q132-XH170 Q150-XH170 PEXLIM Q132-XV170 Q192-XV170 PEXLIM Q192-XM245 B 6
Grading ring according to table 5.1. (The numbered circles refer to the mounting alternatives in the right column) 1 M6x12 Mounting 2 B 49 Nm M10 M10x25 Washer 3 M6x25 4 49 Nm M10 M10x40 Washer 7
6. Insulating base, earth terminal and surge counter This instruction covers insulating bases 1HS430 000- and -B. 1HS430 000-B is identical to - except that the bolts used are of UN-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 EXOUNT-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 8
1) 1) 1) Requirements on M12 (1/2 ) bolts for anchoring to the structure: These bolts are not supplied with the arrester. Recommended tightening torque: ccording 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. washer shall be placed under the bolts head. Fig. 6.2 With earth terminal and/or surge counter EXOUNT- Fig. 6.3 With diagnostic indicator EXOUNT -II For installation of diagnostic monitor EXOUNT II, see assembly instruction included with it. For installation of a surge counter (EXOUNT ) 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. 9
7. Mounting of arrester units Multi-unit arresters must be erected with their units in the correct order as shown in fig. 7.1. ll 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. Main rating plate: 84 Nm M12 3 x M12x40 3 x M12 Nut 6 x Washer Engraved text on the flanges: Surge rrester PEXLIM (type designation) N. XXXXXXXX/2 TOP UNIT Surge rrester PEXLIM (type designation) N. XXXXXXXX/1 84 Nm M12 4 x M12x20 4 x washer Fig 7.1 10
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. nchoring 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. Fig 8.1 Without insulating base Fig 8.2 Drilling plan 9. onnection of conductors ll earth terminals are compatible with both copper and aluminium conductors, as well as all line terminals except 1HS410 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. 11
9.1. onnection of line conductor The line conductor should be as short as possible. onnect the line conductor 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. Warning! Faulty connection onnection of the conductor must be done correctly. For vertical mounting the conductor must be fixed edge to edge with the clamp Fig. 9.1 onnection of single line conductor can be done from top or side. Fig. 9.2 onnection of double line conductor can be done from top or side. Service loading Maximum Permissible Service Loading (MPSL) Definitions as per amendment (no 2) to IE 60099-4 Dynamic bending moment Table 9.1 PEXLIM R-X 1500 Nm 2500 Nm PEXLIM Q-X PEXLIM P-X 2500 Nm 4000 Nm 12
9.2. onnection of earth conductor onnect 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 13
10. Maintenance and checking properly chosen and installed PEXLIM surge arrester is maintenance-free, when operating under normal operating conditions, during its lifetime. However, the tightening torques on terminals shall be checked and if necessary adjusted to the right value at inspections of the plant. leaning PEXLIM 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: rrester 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. rresters must be spray-washed evenly in order to avoid overheating. Do not use high pressure on the water. For extreme environments (e.g. high acidity, cement) please contact BB. General Should 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 BB Leakage urrent Monitor, LM, together with BBs clip-on current meter or BB diagnostic indicator EXOUNT-II is recommended. For description of the LM/EXOUNT-II and measurement procedures, please refer to relevant catalogues. 14
11. Disposal Surge arresters, type PEXLIM, consists of an outer insulator made of nonhalogenated 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): Bi 2 O 3 Sb 2 O 3 Hazardous substances (according to the ouncil Directive 91/689/EE on hazardous waste), existing in more than 0,1 % weight but less than 1 % are NiO r 2 O 3 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 decompose into SiO 2 and O 2 and may in the long run expose the metal oxide part. s the substances of the sintered metal oxide varistors exists in an oxidized state, a leaching test according to EP-test (Federal Register /vol. 45, No 98 / Rules and Regulation), has shown that the sintered bodies may be disposed of without violating the EE Directive. 15
Producer: SWG/F MF NOTE! BB Power Technology Products B is working with continous improvements, therefore we reserve the right to change design and specifications without notice. BB Power Technology Products B High Voltage Products Surge rresters ssembly instruction: 2528en Edition 3, 2002-04 SE-771 80 LUDVIK, SWEDEN Tel: +46 (0)240 78 20 00 Telefax: +46 (0)240 179 83 E-mail: arresters.div@se.abb.com Internet: http://www.abb.com/arrestersonline