Dr. D.H. Wilfong
©Copyright 2011 Surge Suppression Incorporated®
Seminar Overview
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The Transient Environment
Product Specifications
Criticality of Test Parameters
TVSS Design
Proper Application
System Survey
Technology Commitment
IEEE Testing
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Transient Environment
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What Is A Transient?
A Temporary excess of
voltage and current on an
electrical circuit that has
been disturbed.
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What is the Magnitude of a Transient?
Institute of Electrical and
Electronics Engineers (IEEE)
studies show that transients
on a 120 volt power line can
reach as high as 5,600 volts
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High Voltage Surges On Building Wiring
External and internal influences can
cause voltage transient “surges” or
“spikes” as high as several thousand
volts on 120V circuits
Major Causes
Internal- switching
External- lightning
20%
80%
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Source: General Electric, “Current
Scene,” a Bulletin of Circuit Protection
Technology
Transients Generated by Switching
Results of switching off a 2-bulb four foot fluorescent fixture
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Source: General Electric
Instrumentation and Computer
Service Laboratory
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How Often Do Transients Occur?
The range is 180,000 to 432,000 per
hour in many active industrial
environments
Source:
Specifying Engineer
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Transient Disturbance
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Effects of Transients on Electronic Equipment
Case Study: U.S. Air Force
• Problem:
• Down Time,
Disruption of
Operation
• Loss of 5-6
Boards Per
Week
Source:
Texas Instruments Laboratories
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Effects of Transients on Electronic Equipment
Case Study: U.S. Air Force
 Damage to
computer chips
causes:
 Complete down
time
 Computer error
 Other problems
 UPS systems do
not address
transient problems
effectively
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Source: Texas Instruments Laboratories
Failed (Burned) LED Driver
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Close-up of Failed MOV in Driver
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$141,000 of Warrantied LED Drivers
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Effects of Transients on Electronic Equipment
Insulation is rated at
double the voltage plus
1000
Transient activity on a
120 volt line is in
excess of several
thousand volts
Conclusion:
Transients cause much
damage including the
constant breakdown of
insulation and can
cause failure
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Electrical Products Are Expected To Withstand:
Voltage X 2 + 1,000V
A study of clock motor performance
over several years showed that
electrical failures were practically
eliminated when the withstand
voltage level of the clock motor
insulation was increased from 2,000V
to 6,000V
Source: General Electric, “Current
Scene,” a Bulletin of Circuit
Protection Technology
©Copyright 2011 Surge Suppression Incorporated®
Why Surge Suppressors?
“Protection from transient voltage
surges will pay for itself in short
order in avoided equipment repair
costs alone…”
Source: General Electric, “Current
Scene,” a Bulletin of Circuit
Protection Technology
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Product Specifications
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Specification Data
 Maximum continuous operating
voltage
 Input power frequency
 Peak surge current
 Noise attenuation
 Filter frequency range
 Energy dissipation (joule rating)
 Response Time
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Specification Data
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Recovery time
Altitude
Protection mode
Physical dimensions
Weight
Life expectancy
Listings
Measured Limiting (let-through)
Voltage (surge remnant)
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Standard Wave FormsANSI/IEEE C62
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Standard Wave FormsANSI/IEEE C62
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Standard Wave FormsANSI/IEEE C62
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Criticality of Test Parameters
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Laboratory Test Environment
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Dynamic or static test
+/- polarity
Phase angle
Voltage
Current
Lead length
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Testing At Module
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Test Module
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Result: 418 Volts
Test: Lugs
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Test: Lugs
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Results: 556 Volts
Test: 6 in Lead Length
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Test: 6 in Lead Length
Result: 750 Volts
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Testing At Module
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Test: 5 ft Lead Length
Result: 1575 Volts
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Test: 6 in Lead Length
Result: 865 Volts
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Improper Installation of TVSS
Installed with 30 feet of lead length
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Proper Installation of TVSS
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Surge Voltage
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Result: 70 volts
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Result: 17 volts
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Current
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Test: 200 Amps
Result: 70 Volts
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Test: 500 Amps
Result: 173 Volts
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Test: 3000 Amps
Result: 386 Volts
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Phase Angle
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Test: 1800 Phase Angle
Result: 48 Volts
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Test: 900 Phase Angle
Result: 195 Volts
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TVSS Design
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SPD Components
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Hybrid Network
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Benefits of Electrochemical
Design
• Maintains consistent long-term
performance
• Unmatched performance
• Protection from extreme environmental
elements
• Protection against vibration and
movement
High tensile strength
• Environmentally friendly
HMIS value = 0 (non-toxic)
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MOV Stress Test Data
Source: Texas Instruments Laboratories
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Proper Application
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Transient Duration- TVSS Device
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Transient Duration
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Protection Types
Fixed Clamping Performance
Curve
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Frequency Responsive
Performance Curve
2,000 Volt Ringing Transient
from Electronic Motor Control
With NO Surge Suppressor Present
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2,000 Volts
2,000 Volt Ringing Transient from
Electronic Motor Control WITH
Standard Clamping Surge Suppressor Present
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438 Volts
2,000 Volt Ringing Transient from
Electronic Motor Control WITH
Sine Wave Tracking Surge Suppressor Present
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50 Volts
Spec Sheet for UL Recognized Component
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SPD A1 Ring Wave Result: 865 volts
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SSI A1 Ring Wave Result: 33 volts
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UL Limited Current Overvoltage Test
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SPD FAILED UL Limited Overvoltage Test & burned wood.
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IEEE Standard 1100-1999
(Emerald Book)
Section 8.6.1
“Surge protective devices used for three phase, four wire
circuits are generally recommended to be connected in all
combinations of line to line, line to neutral, line to ground
and neutral to ground.”
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10 Mode Protection
Phase A
A-N
60kA
Phase B
Phase C
Neutral
HVS
B-N
A-G
A-B
A-C
60kA
60kA
60kA
B-G
C-N
B-C
C-G
N-G
Ground
True All Mode Protection distributes the surge over more paths and
components
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Phase to Neutral
Phase and Neutral to Ground
Phase to Phase
Full System Coverage
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3 Levels of Protection
SSI
SSI
SSI
SSI
SSI
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Level 1
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Level 1
21 kV
SSI
SSI
SSI
SSI
SSI
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Level 2
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Level 2
21 kV
SSI
1.1 kV
SSI
SSI
SSI
SSI
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Level 3
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Level 3
21 kV
SSI
1.1 kV
SSI
195 V
SSI
195 V
SSI
195 V
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SSI
Point of Use
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Point of Use
21 kV
SSI
1.1 kV
SSI
195 V
SSI
195 V
SSI
SSI
195 V
©Copyright 2011 Surge Suppression Incorporated®
OV
OV
OV
Sask Power Testing
Purpose
“To compare electrical characteristics of various low voltage
surge arrestors under lightning impulse voltages up to 200 kV.
Previous tests have shown that lightning hits on the primary of
the oil field transformers can create spikes of about 20 kV on
the secondary when the primary has arrestor protection. When
no primary arrestor protection is provided, far higher voltages
are possible.”
Test Set-Up
“All units were impulsed with a 1.2x50
joules waveform at voltage levels of 50,
100, and 200 kV.”
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The End Result
200,000 kV
SSI
4700 kV
SSI
800 V
SSI
800 V
SSI
SSI
800 V
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OV
OV
OV
ROI
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Proven Track Record
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Surge Protection in Airport
Facilities
 Airports throughout the U.S.A. and Abroad
are Being Equipped with Surge Protection.
Sarasota – Orlando – Huntsville – Memphis
 The Sarasota Bradenton Int’l Airport is
taking a coordinated Suppression approach
in the Infrastructure Upgrade of the
Terminal & Facilities.
©Copyright 2011 Surge Suppression Incorporated®
Problem:
Results
after TVSS:
“My desire in writing this letter is to express the
success we have had with the surge protection you
helped us install on our Hobart 400HZ Ground Power
Units. We were seeing lightning damage to our units
on the average of one every six weeks. This damage
would result in a cost of $3000.00 to $7,500.00, not
including the cost of labor or inconvenience of
downtime to our customers”
“We have been using SSI surge suppression products
since 1993. Electrical switchboards, electrical panels,
PLC’s security system electronics, video cameras,
security gates, parking lot ticket spitters, data lines,
and telephone lines is our history of installation. In
every case, our “surge and spike” problems have
ceased. We are currently constructing a multi-deck
parking facility and SSI is our first and last priority.”
©Copyright 2011 Surge Suppression Incorporated®
Problem:
“The effects of electrical surges caused by
frequent lightning strikes had to be
minimized on 34 people movers that
transported 10,000 people hourly. All
devices had electrical/electronic devices
critical to safe operation and 25% of the
equipment was computer controlled”
“Replacement Reductions
Results
after TVSS:
Electric Motors
% Savings
98%
Lights
74%
Computer and PC Boards
99.6%
Equipment Downtime From 21.25% to 0.7%”
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Annual Maintenance Cost
Name of Ride
Year Prior to TVSS
Year After TVSS
Double O
$15,910.17
$1,242.70
Santa M
$67,767.20
$
97.78
Hurricane
$13,022.66
$
926.97
Totals
$96,700.03
$2,267.65
Investment for TVSS: $5,935
Source: Transient & Lightning Protection Cost and Effect by
Alexander E. Othmer
©Copyright 2011 Surge Suppression Incorporated®
Problem:
“A direct lightning strike destroyed two
Results
after TVSS:
“When power was restored, none of the
CPSB primary fuses and a power
transformer. The strike also destroyed nine
previously installed surge suppressors. The
fabrication department went down.”
equipment had been damaged because of
the protection of the installed surge
suppressors. The entire shop resumed work
within 30 minutes of power restoration. The
surge suppressors had performed well,
saving both time and money”
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Problem:
Results
after TVSS:
“Electrical surges caused poor X-ray
images when a new digital radiology
computer was installed in a children’s
hospital”
“Power is cleaner, images are clear,
and a million dollar investment is now
completely protected”
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Problem:
Results
after TVSS:
“…They (St. Joseph’s Hospital) were
going through $9,000 in x-ray tubes
every 6 months to 1 year”
“… They have had the same tube on
now for over 4 years. It cut the
service calls down by 80%”
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Problem:
”Fluorescent light replacement at many
Results
after TVSS:
“Light replacement in the area were
reduced by over 50%. At one site, monthly
light replacement costs were reduced by
75%. As a result, Phillips’ management
established the use of surge suppressors
as the standard”
corporate Phillips service stations were
excessive. A standard service station has
over 600 linear feet of fluorescent lights.
(Cost per station per month over $300 for
fluorescent tubes and ballasts)”
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Los Alamos National Laboratory
“…The frequent failures of the 3 ton air
conditioners and fluorescent lights, which are
not fed from the motor-generator, stopped
after the installation of the surge protectors.
I have concluded that the combination of
high quality motor-generator sets with high
quality surge protectors can reduce
electronics failures to near zero over a period
of many years, even in the most difficult field
conditions”
©Copyright 2011 Surge Suppression Incorporated®
Department of the Air Force
Problem:
“Since 1974, an Air Force base has
suffered repeated storm induced
radar failures. During one particular
storm, one lightning strike caused an
estimated $100,000 in parts loss”
Results
after TVSS:
“Since the installation, they are saving
so much money from no repairs and
no downtime that they have been
able to upgrade other facilities.”
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SCR Drive Generated Transient
Activity
Without TVSS
With TVSS
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Source: GE Laboratory, Houston, TX
Problem: “Average monthly service cost of five
variable frequency drive units was
$700”.”
Results
after TVSS:
“Installation of TVSS resulted in an
80% decrease in monthly cost of
repairs.”
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NPBBU VFD Repair Activity
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SSI
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FLOATING AIRPORTS
RESULTS FROM U.S. NAVY’S $2.8 MILLION INVESTMENT IN
SURGE SUPPRESSION FOR 30 SHIPS OF THE FLEET
Annual Pre-Install Maintenance: $7,814,718
Yearly Maintenance Savings:
TVSS Installed Cost:
$2,679,350
Payback Period in Years:
0.54
Annual Post-Install Maintenance: $2,865,107
Total Estimated Payback:
$141,047,596
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$4,949,611
View of McIntosh Power Plant from Larsen Power Plant
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Event Costs
For the period of
June 26, 2000
through
November 15, 2000
$786,000
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Results from TVSS
Since installation of Surge Protection
Equipment, even with documented
lightning surges on the main feeders
for the pumps .
NO MORE MOTOR FAILURES!
Periodic testing of motor insulation
resistance continues.
Results for the latest tests are the same
as the results from when the motor was
returned after being rewound.
The 12 month normal rewind cycle has
now become 24 to 36 months.
©Copyright 2011 Surge Suppression Incorporated®
SSI Product
©Copyright 2011 Surge Suppression Incorporated®
25-YEAR
“FULL REPLACEMENT WARRANTY”
Surge Suppression Incorporated warrants
for a period of twenty
twenty-five (25) years from
date of retail purchase that if its product
ceases to properly function as a direct result
of any electrical anomaly, including
lightning, Surge Suppression Incorporated
will repair or replace the product without
charge, subject to the terms and conditions
set forth herein.
©Copyright 2011 Surge Suppression Incorporated®
Surge Suppression Incorporated
©Copyright 2011 Surge Suppression Incorporated®
Dedicated Load Circuit Protection
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Standard Clamping
Sinewave Tracking
Series connected dedicated load circuit protection
Compact Size
Terminal and Hardwire connections
Simple installation
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Data Line & Current Loop Models
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Multi-stage hybrid design
Data rates to 100M/bps
Low impedance/insertion loss
Terminal, Coax and Hardwire connections
Lowest let-through voltage levels
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Telecom Line Models
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POTS (Voice Grade), ISDN, DSL, T1, fax and modem lines
Terminal strip, modular jack and punch-down block
Single to multi-line configurations
Lowest let-through voltage levels
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Custom & Specialty Models
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SPD for Airfield/Runway Lighting Applications
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Hand-held Testing Unit for Airfield Lighting SPD
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