The Basics Of Surge Protection The Basics Of Surge . - Perle
The basics of surge protectionFrom the generation of surge voltagesright through to a comprehensive protection concept
In dialog with customersand partners worldwidePhoenix Contact is a global market leader in the field of electrical engineering,electronics, and automation. Founded in 1923, the family-owned company nowemploys around 14,000 people worldwide.A sales network with over 50 sales subsidiaries and 30 additional global salespartners guarantees customer proximity directly on site, anywhere in the world.Our range of services consists of products associated with a wide variety ofelectrotechnical applications. This includes numerous connection technologiesfor device manufacturers and machine building, components for modern controlcabinets, and tailor-made solutions for many applications and industries, suchas the automotive industry, wind energy, solar energy,the process industry or applications in the fieldof water supply, power transmission anddistribution, and the wedenDenmarkIrelandNetherlandsUnited rySloveniaRomaniaCroatiaSouth KoreaBosnia andSerbiaHerzegovina stanTaiwanBangladeshKuwaitIsraelIndiaJordan BahrainQatarSri LankaEgyptSaudi eriaGuatemalaHondurasNicaraguaCosta RicaPanama ndCzech RepublicLuxembourgFranceLithuaniaBlomberg, biaBoliviaBotswanaParaguayChileSouth AfricaUruguayArgentina2PHOENIX CONTACTAustraliaNew Zealand
The basics of surge protectionWe don't just want to support you with convincing solutions, but alsoto be on hand with help and advice.This includes basic informationon the topics of technology and electronics that applies to all ofus. In this brochure, you will gain an insight into the field of surgeprotection. Discover the most important facts in a nutshell. Discoverwhat solutions there are for the diverse challenges facing this sector.Or deepen your knowledge of the context and background; somethingonly the specialists know.We wish you – in the truest sense of the word – an exciting read!The very latest solutionsAt Phoenix Contact, particularemphasis is placed on developmentexpertise and a high degree ofmanufacturing capability. All keytechnologies, from full engineering, totool manufacturing, metal processing,and plastic production, right throughto electronics development andmanufacturing are all availablein-house. Since 1983, Phoenix Contacthas developed and manufactured surgeprotective devices and today is thetechnology leader in this area. Thecompany provides many innovativesolutions for every industry andapplication, among others, for Power supply Measurement and controltechnology Data technology and Transceiver systemsThe many years of experience inthis area means Phoenix Contactexcels, both in development andmanufacturing. The accreditedin-house lightning and high-currentlaboratory, the most sophisticated inthe world, is just part of this. It laysthe foundation for precise, constantlyadjusted test procedures and basicresearch tailored to the application –and can therefore be implemented forsolutions using current findings fromtheory and practice.Essentially, products with thehighest quality levels and cutting-edgetechnology.PHOENIX CONTACT3
Questions and answersYou probably have a great deal of questions – ranging from basic queries asto how surge voltages even occur, to technical details about grid systems orindividual components of a surge protection concept, right through to the deviceitself. Here you can refer to:What is a surge voltage?How does it occur?Section 1, Page 6What makes up a consistent surgeprotection concept?Section 2.3 et seqq., Page 13What damage can surge voltagescause?Section 1.5, Page 9How can the quality of surgeprotective devices be (officially)verified?Section 3.3, Page 18How does surge protection work?Section 4, Page 22Section 2.1, Page 10What legal or standard requirementsare there for surge protection?In which applications is surgeprotection particularly important?Section 6, Page 28Section 2.2, Page 11Explanation of terms4PHOENIX CONTACTSection 7, Page 56
Contents1. Surge voltages1.1 The phenomenon of surge voltage1.2 Causes1.3 Coupling types1.4 Direction of action1.5 Effects6678892. Surge protection: what should be noted?2.1 This is how surge protection works2.2 Lightning and surge protection standards2.3 Basic protective measures and equipment2.4 Lightning protection zones2.5 The protective circle principle1010111314153. Classification and testing ofsurge protective devices3.1 Requirements according to product standard IEC 616433.2 Key characteristics for surge protective devices3.3 Maintenance and testing according to IEC 623053.4 Pulse and high-current testing technology16161718204. Quality features4.1 CE declaration of conformity4.2 Independent product certifications4.3 Expertise in surge protection222223245. The lightning monitoring system5.1 Smart monitoring5.2 Lightning current detection2626276. Fields of application6.1 Protection of AC systems6.2 Protection of DC systems with linear voltage sources6.3 Protection of photovoltaic systems6.4 Protection of signal transmission circuits in MCR technology6.5 Protection of signal transmission circuits in information technology6.6 Protection of signal transmission circuits in telecommunicationstechnology6.7 Protection of signal transmission circuits in transceiver systems2828404146527. Glossary568 References59PHOENIX CONTACT54555
The basics of surge protection Surge voltages1Surge voltagesVarious types of surge voltages occur in electrical plants and electronic systems. They are differentiatedmainly by their duration and power. Depending on the cause, a surge voltage can last a few hundredmicroseconds, hours or even days. The amplitude can range from a few millivolts to some ten thousandvolts. The direct or indirect consequences of lightning strikes are one particular cause of surge voltages.Here, during the surge voltage, high surge currents with amplitudes of up to some ten thousand amperescan occur. In this case, the consequences are particularly serious. This is because the damaging effect firstof all depends on the power of the respective surge voltage pulse.1.1 The phenomenon of surge voltageEvery electrical device has a specificdielectric strength. If the level of asurge voltage exceeds this strength,malfunctions or damage can occur. Surgevoltages in the high or kilovolt rangeare generally transient overvoltagesof comparatively short duration. Theygenerally last from a few hundredmicroseconds to a few milliseconds.As the maximum amplitude of suchtransients can amount to several6PHOENIX CONTACTkilovolts, steep voltage increases anddifferences are often the consequence.Surge protection is the only thingthat helps. Indeed, the operator of anelectrical system generally replaces thematerial damage to the system withcorresponding protection. However, thedifference in time between failure of thesystem to maintenance represents a riskin itself. This failure is often not coveredby insurance and, within a short periodof time, can become a heavy financialburden – especially in comparison to thecost of a lightning and surge protectionconcept.
The basics of surge protection Surge voltages1.2 CausesThe typical duration and amplitude ofthe surge voltage varies depending onthe cause.Lightning strikesIt is above all lightning strikes (lightningelectromagnetic pulse, LEMP) that havethe greatest potential for damage amongall the causes of occurrence.They causetransient overvoltages that can extendacross great distances and are oftenassociated with high-amplitude surgecurrents. Even the indirect effects ofa lightning strike can lead to a surgevoltage of several kilovolts and resultin a surge current of tens of thousandsof amperes. In spite of the very briefduration – a few hundred microsecondsto a few milliseconds – such an eventcan lead to total failure or even thedestruction of the affected installation.Switching operationsSwitching operations (switchingelectromagnetic pulse, SEMP) cangenerate induced surge voltages thatspread to supply lines. In the caseof large switch-on currents or shortFig. 1: Lightning strikes have an extremely high potential for destructioncircuits, very high currents can flowwithin a few milliseconds. Theseshort- term current changes can lead totransient overvoltages.exchange leads to a brief surge voltage.This presents a hazard, especially forsensitive electronic components.Electrostatic dischargesElectrostatic discharges (ESD) occurif bodies with different electrostaticpotential approach each other and resultin a charge exchange.A sudden chargeFig. 2: Electric motors with high power induce surge voltages due to high switch-on currentsFig. 3: Electrostatic discharges present a danger,particularly to sensitive electronicsPHOENIX CONTACT7
The basics of surge protection Surge voltages1.3 Coupling typesSurge voltages can reach a circuit invarious ways. In reality, it is usually acase of an overlap between individualcoupling types.is located in this magnetic field, thenaccording to the induction principle, avoltage difference occurs here due tothe change in the magnetic field strength.Galvanic couplingCapacitive couplingTwo circuits that are connected to eachother in an electrically conductive waycan directly and mutually influence eachother. A change in the voltage or currentin a circuit generates a correspondingreaction in another circuit.An electrical field occurs between twopoints with different potentials.Thecharge carriers of objects within thisfield are aligned according to the fielddirection and strength, in line with thephysical principle of influence. As such,a potential difference also occurs withinthe object, in other words, a voltagedifference.Inductive couplingA rapidly rising flow of current througha conductor generates a magnetic field,with quickly changing strengths aroundthe conductor.If another conductor1.4 Direction of actionCommon mode voltage(asymmetrical voltage)Normal-mode voltage (symmetricalvoltage, differential mode)In the first instance, common mode surgevoltages present a hazard to objects thatare located between active potentials(phases and neutral conductors) and theground potential.In the first instance, the symmetricalsurge voltages present a hazard toobjects that are located between twoactive potentials.L/ L/ UQN/-N/ULULPEFig. 4: Common mode voltage8PHOENIX CONTACTPEFig. 5: Normal-mode voltage
The basics of surge protection Surge voltages1.5 EffectsThe German Insurance Association(GDV) regularly publishes statistics,allowing conclusions to be drawn onthe total losses resulting from variouscauses. Following fires and storms,lightning strikes and surge voltages causethe most damage. In 2012, their share ofdamage to all insured items totaled 18%.In other words, almost a fifth of insureddamage can be traced back to a surgevoltage.Device failure or defects caused bysurge voltages are more frequent thanexpected. According to statistics fromthe GDV, surge voltages are in factthe most frequent cause of damage.These figures only apply to damage thatresulted in fire.Fig. 6 shows that the proportion ofdamage caused by lightning and surgevoltages in 2013 has dropped by 20%in comparison to the previous year.The financial payments by insuranceproviders, however, fell by just 10%. Ifthe values from the comparable year of2010 are taken as a basis, then a costincrease of approximately 20% becomeapparent. Insurers consider one of thecauses to be that ever more sensitiveelectronic devices are finding theirway into households. On average, anindividual strike or damage from a surgevoltage amounted to 800 in 2013. Thisis the highest level since statistics began.For non-private systems, however, theconsequences of a failure are generallymuch more serious, such as downtimesor data loss. The failure of a device ora machine that is used in a professionalenvironment often leads to costs thatare many times higher than repairing thedefective device.For example, if a mobilecommunication mast fails, the cost forthe operator can lie in the range ofseveral euros per second. Calculatedover the course of a day, thiscorresponds to damages of more than 100,000.For this reason, a consistent surgeprotection concept is urgently requiredfor industrial and business systems. It340 millionis not just a case of having effectiveprotection for fire and personnel, butalso about excluding the possibility oflarge financial risk.A further aspect that will underlinethe need for lightning and surgeprotection in the future is the increaseof lightning strikes, as shown bystatistics. Various studies have alreadyshown that as part of global climatechange, the frequency of storms is setto increase. This development is therebynot only limited to regions which havenot displayed a high risk of strikes todate, but extends to all regions on Earth.Insurance payments in euros280 millionNumber of damage 00820092010201120122013Fig. 6: Number of damage cases caused by lightning strikes and surge voltages and level of insurance paymentsPHOENIX CONTACT9
2Surge protection: what should be noted?Effective surge protection is not just simply installed. It has to be individually coordinated –to the system that is to be protected and the ambient conditions that are prevalent on site.For this reason, the design and concept must be consistent. This means many details mustbe taken into account, from considering the standards and stipulations right through toclassification according to lightning protection zone.2.1 This is how surge protection worksSurge protection should ensure thatsurge voltages cannot cause damage toinstallations, equipment or end devices.As such, surge protective devices(SPDs) chiefly fulfil two tasks: Limit the surge voltage in termsof amplitude so that the dielectricstrength of the device is notexceeded. Discharge the surge currentsassociated with surge voltages.L/ L/ L/ N/-N/-N/-PEPEPEFig. 7: Schematic power supply of a piece ofequipment10The way in which the surge protectionworks can be easily explained by meansof the equipment's power supply diagram(Fig. 7).As described in Section 1.4, a surgevoltage can arise either betweenthe active conductors as normalmode voltage (Fig. 8) or betweenactive conductors and the protectiveconductor or ground potential ascommon mode voltage (Fig. 9).PHOENIX CONTACTFig. 8: Effects of a surge voltage as normal-modevoltageFig. 9: Effects of a surge voltage as commonmode voltage
With this in mind, surge protectivedevices are installed either in parallelto the equipment, between the activeconductors themselves (Fig. 10) orbetween the active conductors and theprotective conductor (Fig. 11).A surge protective device functions inthe same way as a switch that turnsoff the surge voltage for a brief time.By doing so, a sort of short circuitoccurs; surge currents can flow toground or to the supply network. Thevoltage difference is thereby restricted(Fig. 12 and 13). This short circuit ofsorts only lasts for the duration ofthe surge voltage event, typically a fewmicroseconds. The equipment to beprotected is thereby safeguarded andcontinues to work unaffected.L/ L/ SPDN/SPDN/PEPEFig. 10: SPD between the active conductorsFig. 11: SPD between active conductors and theprotective conductorL/ L/ SPDN/SPDN/PEFig. 12: SPD between the active conductors inthe case of normal-mode voltagePEFig. 13: SPD between active conductors andthe protective conductor in the case of commonmode voltage2.2 Lightning and surge protection standardsNational and international standardsprovide a guide to establishing a lightningand surge protection concept as well asthe design of the individual protectivedevices. A distinction is made betweenthe following protective measures: Protective measures against lightningstrike events: lightning protectionstandard IEC 62305 [1] [2] [3] [4]deals with this. A key component ofthis is an extensive risk assessmentregarding the requirement, scope,and cost-effectiveness of a protectionconcept. Protective measures againstatmospheric influences or switchingoperations: IEC 60364-4-44 [5]deals with this. In comparison withIEC 62305, it is based on a shortenedrisk analysis and uses this as the basisfor deriving corresponding measures.In addition to the standards mentioned,if applicable, other legal andcountry- specific stipulations are also tobe considered.PHOENIX CONTACT11
The basics of surge protection Surge protection: what should be noted?2.2.1 Lightning protectionaccording to IEC 62305Part 1: Characteristics of lightningstrikesIn Part 1 of this standard [1], thecharacteristic properties of lightningstrikes, the likelihood of occurrence, andthe potential for hazard are taken intoaccount.Part 2: Risk analysisThe risk analysis according to Part 2 ofthis standard [2] describes a processwith which, first of all, the need forlightning protection for a physicalsystem is analyzed. Various sources ofdamage, e.g., a direct lightning strike inthe building, come into focus, as do thetypes of damage resulting from this: Impact on health or loss of life Loss of technical services for thepublic Loss of irreplaceable objects ofcultural significance Financial lossesThe financial benefits are determinedas follows: how does the annual totalcost for a lightning protection systemcompare to the costs of potentialdamage without a protection system?The cost evaluation is based on theoutgoings for the planning, assembly, andmaintenance of the lightning protectionsystem.that can be conducted away safelydepending on the lightning protectionlevel. This is described by means ofLightning Protection Levels I to IV.Parts 3 and 4: Planning aids andspecificationsIf the risk assessment determines thatlightning protection is required and costeffective, then the type and scope of thespecific measures for protection can beplanned based on Parts 3 [3] and 4 [4]of this standard. The lightning protectionlevel determined by risk management isdecisive for determining the type andscope of the measures.For physical structures that require anextremely high level of safety, almost allstrikes must be captured and conductedaway safely. For systems where a higherresidual risk is acceptable, strikes withlower amplitudes are not captured.Fig. 14 shows the lowest peak value ofstrikes that can still be captured safely aswell as the highest peak value of strikesI99%3 – 200 kAof lightningIIIIIIV10Fig. 14: Lightning Protection Levels12PHOENIX CONTACT97 %5 – 150 kA10 – 100 kA91 %16 – 100 kA84 %50100150200i/[kA]
The basics of surge protection Surge protection: what should be noted?2.2.2 Surge protectionaccording toIEC 60364-4-44This standard [5] describes theconditions in which surge protectivedevices are to be used in low-voltagesystems to protect the electricalinstallation against surge voltages. Thearea of application is thereby limited tosurge voltages caused by atmosphericinfluences or as a consequenceof switching procedures that aretransmitted by the power supply system.Direct lightning strikes in a structuralsystem are not considered, only strikesin or in the vicinity of supply lines.Likewise, structural systems with anexplosion risk as well as structuralapplications that could cause damageto the environment (e.g., petrochemicalsystems or nuclear power plants) arenot included in the application of thestandard. For these processes, lightningstrike standard IEC 62305 is to be usedexclusively.Surge protective devices should beused if transient overvoltages could hav
Discover the most important facts in a nutshell. Discover . Questions and answers You probably have a great deal of questions – ranging from basic queries as to how surge voltages even occur, to technical details about grid systems or individual components of a surge protection concept, right through to
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steady fl ow from the header tank through the surge pipe. This fl ow creates a measurable head loss (due to friction) along the surge pipe from the header tank to the surge tower. To create the surge, students quickly shut the surge valve downstream of the surge pipe. VDAS displays and records the pressure surge in the surge tower. Students
surge protection units provide premier surge protection for AC power at the service entrance. These products provide protection for residential electrical equipment by reducing power surges to an acceptable level for surge strips to handle at the point of use. UL 1449 3rd Edition Type 1 and Type 2 Surge Protection Type 1 Surge Protective
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