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CONTENTS
PUBLISHER
Danny J. Salchert
OFFICE MANAGER
Anita Salchert
ASSOCIATE PUBLISHER
Rick Harless
rick@epsmag.net
CREATIVE DIRECTOR
6
Derek Gaylard
CONTRIBUTING WRITERS
Marc Luksch, John Olobri,
Gordon Smith, Glen Shomo
FEATURES
6
Cables for Modern Servo and Variable
Frequency Drives (VFD)
CIRCULATION DIRECTOR
Pam Fulmer
By Marc Luksch
18
Power Quality Analysis
By John Olobri
22
PRESIDENT
Hands-Off PQ Monitoring
Danny J. Salchert
By Glen Shomo
30
Power Quality Recording
By Gordon Smith
PROJECT PROFILE
26
22
Dena’ina Civic and Convention Center
Anchorage, Alaska
CASE STUDY
28
Megger Aids Columbia Gorge Community College
in Wind Energy Training
DEPARTMENTS
36 Product Focus
40 Ad Index
ON THE COVER
Cover photography provided by:
Alcan Cable
2
Electrical Products & Solutions • October 2009
Executive and Advertising Offices
3591 Cahaba Beach Road
Birmingham, AL 35242
toll free: 800.981.4541 phone: 205.981.4541
fax: 205.981.4544
www.epsmag.net • danny@epsmag.net
Electrical Products & Solutions™ is published
twelve times a year on a monthly basis by ABD
Communications, Inc., 3591 Cahaba Beach Road,
Birmingham, Alabama, 35242, USA. Electrical
Products & Solutions™ is distributed free to qualified
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per year for foreign subscribers (surface mail). U.S.
Postage paid at Birmingham, Alabama and additional mailing offices.
Electrical Products & Solutions™ is distributed to
qualified readers in the electrical contracting industry.
Publisher is not liable for all content (including editorial and illustrations provided by advertisers) of advertisements published and does not accept responsibility
for any claims made against the publisher. It is the advertiser’s or agency’s responsibility to obtain appropriate releases on any item or individuals pictured in an
advertisement. Reproduction of this magazine in
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POSTMASTER: Send address changes to
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PRINTED IN THE USA
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FEATURE • Helukabel
Cables
for Modern Servo and
Variable Frequency Drives (VFD)
By Marc Luksch
E
lectric drive systems with continuous torque and speed control
are widespread today. They allow
an optimal adjustment of the drive to the
respective application. Standard drive systems consist of three-phase alternatingcurrent asynchronous motors and related
controls via frequency converters.
A frequency converter consists of two
IGBT (= Insulate Gate Bipolar Transistor)-controlled units: 1) a rectifier that is
connected to a three-phase alternating current with a given frequency f1 (e.g. 50 or
60 Hz) and that generates a pulsating direct current; 2) an inverter that reconverts
the direct current in a new alternating voltage with variable level and frequency f2
(= 0 to 400 Hz). Via the motor supply cable the speed of the servo motor can be
controlled very precise by changing the
frequency f2.
through the motor power supply cable
• high overvoltage in the supply cable
• high leakage and interference currents
The strong electromagnetic interference
results from the extremely short turn-on
and turn-off-times of the IGB-transistors
(nanoseconds) and from the high pulse frequencies of the frequency converter (up to
20 kHz). This leads to a very high proportion of harmonic waves of the sinusoidal
output voltage of the converter. The strong
electromagnetic emissions, emanated especially from motor supply cables, result
in major interference with the distribution
Problems with electrical surge
network, the devices and data transfer.
As a consequence the European standard
Another problem is the stress through
EN 61 800-3 (July 2005) specifies the electrical surge. The voltage generated by
maximum interference level of drive sys- the frequency converter Continued on page 8
Non-beneficial effects
The great benefits of those frequency
converters – precise and continuously
variable torque and speed control – come
along with certain non-beneficial effects
that should be taken into consideration:
• strong electromagnetic interference
6
tems in order to ensure that signal transmissions are adequately protected against
interference. The regulation which differentiates between category C1 “residential
areas” and category C3 “industrial areas”
establishes the maximum permissible interference levels of the radio interference
voltage from 0.15 MHz up to 30 MHz and
of the radiated electromagnetic interference
from 30 MHz up to 1,000 MHz (1 GHz).
The described interference can be
avoided if well-shielded cables and, in
special cases, cables with additional line
filters are used.
Electrical Products & Solutions • October 2009
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FEATURE • Helukabel Continued from page 6
has a fundamental wave with an approximately sinusoidal course and an impressed
frequency between 0 and 400 Hz, depending on the set motor speed. That
process also creates harmonics in a high
frequency range of approximately 100
MHz. The fundamental wave and the harmonics are transmitted to the motor via
the motor supply cables.
When the characteristic impedance of
the motor supply cable is changed, impulse waves are generated at the beginning and end of the cable, which in turn
generate electrical surge through reflection of the harmonics (called reflected
wave phenomenon). This only occurs if
the length of the motor supply cable is
greater than the wavelength of the harmonic. With short cable lengths, i.e. if the
cable length is shorter than the wavelength, transient responses appear at the
frequency converter output. As a result
voltages are generated that are 2 to 3 times
greater than the motor voltage. Those
voltage peaks place a recurring load on
the insulation of the motor supply cable.
For this reason the insulation must be dimensioned in such a way that those voltage peaks do not have any harmful effects
(e.g. failure of cable due to arcing between conductors to shield).
The high frequencies at the converter
output mean that high capacitance leakage currents are generated, which flow
over the shield and the motor housing to
the earth, and thus determine the crosssection of the braided shields and the
shield connections. The shield must be
designed in such a way that it is not excessively heated by the current flowing
through it. Especially with long cable
lengths, high earth capacitance can result
in reactive currents, which burden the frequency converter. Due to the inverter’s
over-current limit, it might no longer be
8
possible to transmit the necessary active
power to the motor. Care must also be
taken to properly ground these currents
and not change the voltage potential
which will affect the clock timing. Using
Electrical Products & Solutions • October 2009
a HELUTOP® EMC cable gland and attaching the cable ground wire to the panel
buss ground terminal are good practices
to help prevent this problem.
The reactive current does not contribute
to torque generation at the motor and
flows to earth as leakage current via the
shield and metallic motor parts. It can also
flow through the ball bearing of the motor
shaft, which can result in damage, such as
depressions in the ball bearing rings.
In order to compensate for the abovementioned effects of frequency converter
technology, HELUKABEL® offers motor
supply cables with optimised characteristics. Both the material used and the design are specially adapted for this
application.
Continued on page 12
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FEATURE • Helukabel Continued from page 8
The EMC (=Electromagnetic compatibility) requirements according to EN
61800-3 are fulfilled by a double shielding of special aluminium foil and an optimised braided shield of tinned copper
wire with a high degree of coverage (approx. 80%). The special suitability in the
frequency range from 30 to 1,000 MHz
HELUKABEL® TOPFLEX®-EMV UL/CSA
can be demonstrated easily using comparative measurements of the radiated
electromagnetic noise from unshielded
power supply cables and shielded EMC
power supply cables from HELUKABEL®. For the low frequency range of 1
MHz up to 30 MHz the high interference
protection is shown by the extremely
low coupling resistance of the shielded
cables.
EMC tests on motor
supply cables
The measurements were made in an
EMC laboratory.
The results of the interference level
measurements show clearly that the
HELUKABEL® motor supply cable with
an optimal shield did not exceed the
limit values for interference field
strength according to EN 61 800-3.
Moreover, the interference field
strengths of the unshielded cable are significantly above the limit values for industrial and residential areas, especially
at low frequencies.
Results of measurements of
the coupling resistance Rk
(Ohm/km)
TOPFLEX®-EMV
2YSLCY J 0.6/1kV
Manufacturer: HELUKABEL® GmbH
Cable type:
In the low frequency range between 1
MHz and 30 MHz a low coupling resistance
was measured, resulting in low interference
field strength in the surrounding area.
The
conductor
insulation
of
TOPFLEX®-EMV and TOPFLEX® MOTOR-EMV cables consists of electrically
high-quality materials based on polyethylene (PE). The special insulation is designed for the permanent voltage peaks of
the converter’s nominal voltage.
Nominal voltage:
Uo = 600 V
Max. permissible operating voltage:
Ub = 1200 V
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Electrical Products & Solutions • October 2009
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FEATURE • Helukabel Continued from page 12
TOPFLEX®-EMV and the TOPFLEX®
MOTOR-EMV have a lower operating
and shield capacitance than traditional
4 x 2.5 (AWG 14)
18
210
PVC-insulated motor supply cables. As a
result the capacitance disturbance currents
4 x 4 (AWG 12)
11
210
are considerably reduced, enabling low4 x 6 (AWG 10)
6
150
loss power transmission from the converter
4 x 10 (AWG 8)
7
180
to the motor. Moreover, the high quality
of the cable insulation provides a long ser4 x 16 (AWG 6)
9
190
vice life. These characteristics are further
4 x 25 (AWG 4)
4
95
improved by a symmetrical cable structure
4 x 35 (AWG 2)
3
85
with three balanced power conductors and
a ground conductor which is divided into
4 x 50 (AWG 1)
2
40
thirds (3 + 3 -conductor design) in the ca4 x 70 (AWG 2/0)
2
45
ble types TOPFLEX®-EMV 3 PLUS and
TOPFLEX® MOTOR-EMV 3/3 cables. Reeling after braiding at the HELUKABEL® factory
4 x 95 (AWG 3/0)
1
50
This results in an additional optimisation
The frequency converter output can also of the power transmission from the fre- NFPA 79 2007 and CSA FT4 for fixed or
be equipped with an electrical filter which quency converter to the motor.
continuous flex applications. The TRAYfilters out the high-frequency harmonics
CONTROL 600 and TOPSERV 600 VFD
TC-ER and continuous
and smoothes out the voltage peaks.
cable possess a superior oil performance
flex applications
of Oil Res I and II and are designed for
Impedance matched cables
Beside those high-end motor cables use in dry, high humidity and damp enviDue to the low dielectric constant of the HELUKABEL® offers a wide range of ronments and in the open unprotected inspecial conductor insulation the tray rated cables according to UL 1277, stallation in the cable tray or track. ❏
No. conductors x
cross-sec. (mm2)
1 MHz
Ohm/km
30 MHz
Ohm/km
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Electrical Products & Solutions • October 2009
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Page 16
PROJECT PROFILE • Alcan Cable
Dena’ina Civic and Convention Center
Anchorage, Alaska
W
hen the 200,000-square
foot Dena’ina Civic and Convention Center opened to occupants in the fall of 2008, it was
Anchorage, Alaska’s first Class A convention center, drawing clientele from
Western Canada and all over the United
States.
Located in downtown Anchorage, the
new facility has increased the city’s civic
and convention capacity by more than 300
percent. It boasts more than 37,000
square feet of meeting rooms, a 50,000square foot exhibit hall, and a total capacity for 408 event booths.
Ed Harris, project manager for electrical contractor Megawatt Electric LLC,
quickly realized that the choice of STABILOY® MC cable would save time and
money in the center’s electrical installation. “This project was on a very tight
schedule, and the cable saved us a lot of
time,” said Harris. “For example, in
Alaska the biggest push is to get temporary heat on. Using the Alcan STABILOY MC cable allowed us to quickly
get the electrical rooms heated up in order to get temporary power for the
heaters.”
In addition, because of the design of
the ceilings, the typical feeder run would
include bends of more than 360°. Since
STABILOY MC Cable isn’t limited to
the 360° bend rule, the cable allowed the
contractors to eliminate many j-boxes,
splices and access points that would have
been necessary with conventional pipe
and wire.
Time and cost weren’t the ony savings
the cable allowed. Mike Plaster, electrical
superintendent for Megawatt Electric, said
that because the construction was on a single square block, the storage space for materials was limited. But, said Plaster,
STABILOY
MC Cable
16
Electrical Products & Solutions • October 2009
“since the cable was all together with the
wire in it, we didn’t have to haul and store
a bunch of pipe and boxes and fittings-I
could just run the cable and connect at
both ends.”
Harris has used Alcan Cable’s building
wire products for previous installations,
and one of the reasons he keeps coming
back is their excellent customer support.
When he has to introduce engineers to the
cable and to show them its strengths and
benefits, he sometimes encounters resistance, but his local Alcan Engineer, Alex
Mak, is always ready with product literature and statistics to address all of the engineers’ concerns.
“One main reason we’ve been going
with Alcan is the amount of effort they’ve
put in and everything they’ve done to
make things work for us,” said Harris.
“They’ve stood behind everything they
ever said they were going to do.” ❏
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FEATURE • AEMC
Power Quality Analysis
By John Olobri, Director of Sales and Marketing, AEMC® Instruments
W
hen it comes to power quality analysis there is a
wide variety of instrument choices. The application at
hand, of course, will dictate the most appropriate instrumentation to employ. Intermittent problems call for data logging types of power analyzers. Continuous monitoring and
reporting is the job of the permanently installed analyzer. On-site
analysis also referred to as “punctual testing”, requires a device
that is both a data logger as well as a direct reading (scope meter)
power analyzer. For the balance of this article we will direct our attention to some of the features and functions found in these newer
handheld scope meter/power analyzers.
There are many instances where it is advantageous to determine problems and provide solutions on-site minimizing downtime and cost. To do this, the technician must have the ability to
know what is going on electrically and to record it.
Some of the fundamental features and functions important in a
18
Electrical Products & Solutions • October 2009
field troubleshooting power problems are:
• Ease of hookup — there are a variety of electrical networks
that must be identified and connected to in order to obtain information. One advantage of scope meter analyzers is the ability to
offer graphical hookup diagrams for the technician, saving a considerable amount of time and preventing errors in the hookup. Another useful tool available with these types of analyzers is the
ability to display the relationship of voltage and current inputs
vectorially, commonly referred to as a “phasor”diagram. This diagram assists technicians in quickly determining that he or she
has properly hooked up the instrument to the network being tested.
• Waveform analysis — a key element in troubleshooting is the
ability to look at and analyze individual waveforms. To do this effectively on a three phase system, a color display is a must. The
use of different colors makes it easy to distinguish both voltage and
current waveforms for each phase. The ability Continued on page 20
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FEATURE • AEMC Continued from page 18
to review individual phase waveforms is also a valuable feature
available in many handheld power quality analyzers. Real-time
display of data is also quite helpful.
• Transient capture — many times the culprit is a surge or sag
which can be difficult to see on moving waveforms on the display. The ability to trigger off a surge or sag showing the previous
waveform, as well as the offending and following waveforms,
solves this problem. This is a feature that is a must to evaluate
these problems effectively.
• Event capture – often it is valuable to set alarm levels to
determine the number of times a voltage or current has exceeded
or dropped below this alarm level and what the duration was. A
good quality handheld power analyzer can store and display several thousand of these events.
• Energy analysis — the ability to show total power, reactive
power and watt hours can be a valuable troubleshooting and system characterization tool. A good quality power analyzer will
provide data both digitally and graphically.
• Recording — to assist the user in further analysis back in the
office or lab after a troubleshooting session, recording capability
is extremely important. Good quality analyzers of the scope meter variety also provide the ability to set both sample rate and
recording time length. This captures most waveform and trend
data while optimizing the ability for off-site analysis and frees
up the technician to perform other tasks on site.
To further assist the field engineer or technician in their troubleshooting efforts, it is important to be able to perform these
tests simultaneously and record them. This also provides significant analysis capability after-the-fact. One can compare waveform transient captured energy and events to effectively
troubleshoot all quality issues.
• Report generation — Data analysis software is crucial for
this review process, by using the software the technician has the
ability to not only reproduce waveforms and trend plots but also
allows them to zoom in to see small sections of data. The software
will also annotate the data and print reports along with the technician’s comments.
There are many more features that could be discussed here.
The important features to consider when selecting a handheld
power quality analyzer are: the ability to display and record the
key variables associated with power and the ease of interface in
connecting the instrument to the system to collect the data. A
large easy-to-read color graphic display with user prompts is fundamental. Large data storage capability (in the gigabyte range)
and the ability to simultaneously record waveform transient events
and energy make the technician’s troubleshooting abilities powerful and effective.
As with any situation, the right tool for the right job is a wise
choice. A handheld recording scope meter power analyzer is the
right choice for on-site power quality troubleshooting. ❏
John Olobri holds degrees in both Electrical and Industrial Engineering and
has worked in the design and marketing of instrumentation for over 35 years.
He began his career designing Oscillographic chart recorders in the mid
1970s. Since then he has held positions of Service Manager, Product
Marketing Manager and Sales Manager for several instrument
manufacturers. For the past thirteen years, John has been the Director of
Sales and Marketing for AEMC® Instruments where he has been actively
involved in the areas of Insulation Resistance, Ground Resistance, Power
Quality Testing and Data Logging.
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Page 22
FEATURE • Power Monitors, Inc.
Hands-Off
PQ Monitoring
By Glen Shomo
I
ncreasing access to notebook computers, PDA’s, and other portable computing devices for electric utility and
industrial maintenance personnel has
changed the way power quality instrumentation is used on a daily basis. Rapid on-site
setup and initialization, downloading of
recorded data, and redeployment of
recorders is now commonplace. This expanded flexibility has also promoted an increase in hands-on, on-site monitoring of
real time waveforms, requiring safety policies and arc flash prevention procedures to
be readdressed as users are more frequently
exposed to hazardous voltages. Recent advancements in power quality recording instruments address these issues by providing
a wireless connection to handheld display
and data storage devices, allowing safe
power quality monitoring and control without the need for bulky personal protective
equipment.
Early PQ monitoring
The introduction of portable, lower cost
power quality monitoring equipment over
twenty years ago represented a revolutionary replacement of paper strip chart
recorders typically used to document long
term voltage variations. Paper records were
replaced with solid state storage of measured voltages and currents, allowing the
detection and analysis of short duration
power line events such as instantaneous
sags and swells. While some small, lower to
mid-range instruments provided a front
panel display of measured values, on-site
information was typically limited to periodic averages of rms voltage and current.
Recorders were placed at locations of suspected power quality problems, left to accumulate data for some period of time, and
then retrieved for data downloading and
analysis using a desktop office computer.
In more recent years on-site retrieval of
recorded PQ data has become more prevalent as laptops, PDA’s, and other portable
PC devices became more affordable. Equipping electric utility and other field maintenance crews with portable data collection
devices has eliminated the need to return to
a central location for PQ recorder downloading and initialization prior to installing
the equipment at a new location.
Live Monitoring Risks
The use of laptops, PDA’s, and ruggedized field PC’s for on-site instrumentation
setup, initialization, and data retrieval has
produced a more efficient use and deployment of power quality recorders. The ability
to quickly select appropriate recorder settings from stored profiles, and view
recorded data on-site has promoted shorter
recording sessions at multiple locations
within identified problem areas as a practical and useful approach to locating the
source of electric utility disturbances and
voltage distortions.
This expansion in power quality moni22
Electrical Products & Solutions • October 2009
toring features and flexibility has produced
a corresponding increase in on-site monitoring of real time information. The ability
to view a variety of real time displays including voltage and current waveforms,
power, individual harmonics, and THD has
promoted a more flexible and efficient base
for on-site problem analysis and decision
making. This expansion in real time information available to the user, however, has
produced a corresponding increase in the
risks to the safety of the user. Real time
viewing of alpha-numeric or graphic displays located on the monitoring instrument
typically requires the user to make direct
contact with handheld or portable equipment. When monitoring hazardous voltages
this requires the use of cumbersome personal protective equipment (PPE) such as
insulated gloves and covers, eye protection,
OSHA approved clothing, and possibly an
arc flash suit to protect the user from the
risk of electric shock and possible arc flash
events. Using laptops or other portable
computers as the real time display device
can partially separate the user from hazardous voltages, but the direct connection
of an RS232 or USB cable to the monitoring equipment still presents a degree of risk
to the user. Voltage leads and communications cables used with hazardous voltage
monitoring equipment must be regularly inspected for damage to the insulation that
can result from the harsh and abusive environment associated with outdoor use. Normal wear and tear can produce damage to
Continued on page 24
the outer insulating
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FEATURE • Power Monitors, Inc. Continued from page 22
jacket of voltage leads and serial cables.
Even tougher insulating materials such as
those made from rubber compounds and
polyurethane can eventually be cut, pinched
in vehicle doors, or punctured when crushed
between a hard-soled work boot and roadside gravel. Openings in the insulation from sharp cuts, for
example, can spread when flexed
during installation. Exposed
wires on voltage measurement
leads or communications cables
can contact hazardous voltages
on adjacent conductors creating
faults and resulting arc flash events,
or energize equipment being held by
the operator to dangerous potentials.
Wireless Solutions
One particular advancement in power
quality monitoring that has raised the level
of safety to users during on-site monitoring
and data collection is the integration of various wireless technologies in the instruments. Wireless connections between the
monitoring equipment and a laptop or handheld display device eliminates the need for
user contact with the instrument and hardwired serial communications cables. Once
the monitoring instrument is installed the
wireless connection provides a safe conduit
for viewing power quality information at a distance outside arc flash
protection boundaries without the
need for bulky personal protective
equipment (PPE).
Bluetooth® wireless technology, available for the past several
years in some power quality instruments, provides a small, low
power consumption solution for
compact, lightweight instruments. The
first to be introduced were Version 1.1 compliant, Class 2 devices, with a data transfer
rate of 720kbps and an output power level
of 2.5mW (+4dBm). While Class 2 devices
are rated for practical line-of-sight operating
ranges of only 30-50 ft., in practice the output power is sufficient to achieve successful
wireless connections at walk-up distances
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Electrical Products & Solutions • October 2009
with a power quality recorder installed inside most metallic enclosures such as meter
bases, switchgear, and breaker panels. This
is primarily due to the small quarter-wavelength (about 1.2 in) of the 2.4GHz Bluetooth wireless operating frequency,
allowing the signal to radiate from unshielded conductors,
Continued on page 26
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FEATURE • Power Monitors, Inc. Continued from page 24
small openings, and the imperfect interface
between the enclosure and a lid, panel, or
door.
Wireless connections to power quality
recorders have been further enhanced by
the more recent introduction of higher
power Class 1 Bluetooth wireless modules,
with an output power of 100mW (+20dBm)
and operating ranges up to 300ft. These
modules incorporate the Enhanced Data
Rate (EDR) of Bluetooth Version 2.0 which
provides a data transfer rate of 2.1Mbps,
three times faster than the Class 1 modules.
A WiFi configured power quality instrument adds an additional dimension to
remote monitoring and data retrieval via a
local network or over the internet. PQ engineers can remotely view real time voltage and current waveforms, check power
factor and THD trends, and schedule system status queries. More efficient monitoring and centralized information
retrieval can be implemented to continuously assess system performance, allow
easier location of outages, and provide
faster response to system problems.
The introduction of a 153kbps CDMA
cellular modem option provides an additional means of remote access to power
quality recorders. While early modems provided slow 1200 baud connections through
a generally unreliable analog cell network,
the significantly higher reliability and wide
availability of current digital cell networks
provide a practical solution for wireless
connection to remotely located monitoring
points. Recorders equipped with a digital
cell modem can be configured for unique
monitoring operations such as sending
email alerts of various disturbance events
or over/under voltage conditions that have
exceeded user settable thresholds.
These advancements in wireless connectivity in power quality monitoring equipment provide a safe interface for instrument
setup, control, and evaluation of recorded
data, eliminating the risks associated with
wired connections and the need for confining personal protective equipment. Wireless access enhances the efficiency,
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Electrical Products & Solutions • October 2009
application, and remote management of
power quality information.
For more information about these advanced wireless power quality recorders,
contact Power Monitors Inc., 800-2964120. PMI also provides 24/7/365 technical
support. ❏
As Senior Design Engineer for PMI,
Glen Shomo develops electronic power
quality analysis equipment. With over
35 years experience from design to
manufacturing, he leads electricalmechanical product evaluation and
integration, and engineering support to
production. Shomo, a Professional
Engineer, ensures PMI’s product
compliance to UL/IEC safety standards,
and is listed on several U.S. patents
including digital communication over
power lines, and several current PMI
products. Additionally, Shomo hosts
the educational podcast series,
Everything Power Quality, available
at www.everythingpowerquality.org.
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CASE STUDY • Megger
Megger
Helps Students with their Tests!
tudents at Columbia Gorge
Community College in The
Dalles, Oregon, will now be able to
gain hands-on experience of testing wind
turbine systems, thanks to test equipment
supplied to the college by Megger.
In line with Megger’s strong commitment to promoting the education of engineers and to advancing the adoption of
renewable energy sources, the company
has provided the college with DCM340
clampmeters for measuring currents in cables without disconnecting them, MIT400
Series insulation resistance and continuity testers, a DLRO10HD Dual power 10
A low resistance ohmmeter, a wind turbine lightningprotection test lead set, a
DET4TCR2 four-terminal earth/ground
S
28
resistance tester and soil resistivity tester
with an accessory kit.
Megger has also supplied a quantity of
“Stitch In Time” manual, a complete
guide to electrical insulation testing, “Getting Down To Earth” booklet, a practical
guide to earth resistance testing and “ A
Guide to Diagnostic Testing Above 1
kV,” a handbook containing guidelines for
insulation testing greater than 1 kV. The
donations are made in partnership with
Transcat (Wind Energy Division), one of
Megger’s largest distributors located in
Rochester, New York.
The instruments will be presented at the
ribbon cutting of the new renewable energy lab on the Columbia Gorge campus.
They will be used to train students enrolled
Electrical Products & Solutions • October 2009
in a new Renewable Energy Training
(RET) program at the school.
“The test equipment from Megger is a
really valuable resource for us,” said Dr.
Susan J. Wolff, Chief Academic Officer
for Columbia Gorge. “With it, our students
will be able to gain valuable testing experience that will be extremely useful to them
in their employment after they have graduated. We are very grateful to Megger for
its support, which is helping us to give our
students the best possible training.”
“Training for the upcoming generation
of engineers is very important to us,” said
Megger’s David Danner, “and, in particular, we like to ensure that students gain
practical hands-on experience of testing.
We believe that the best way to do this is
to arrange for them to train using the same
instruments that they will be using after
they graduate. We are, therefore, delighted
to be able to provide Columbia Gorge
Community College with this selection of
Megger test equipment.”
Megger’s support for Columbia Gorge
Community College is just one aspect of
the company’s ongoing commitment to
education. Megger is working with many
other community colleges throughout the
USA, and even has its own training subsidiary – The AVO Institute – where it
helps to provide professionals within the
electrical industry with skills that cover
every facet of electrical testing. ❏
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FEATURE • ACR Systems Inc.
Power Quality Recording
By Gordon Smith, AScT, Product Manager, ACR Systems Inc.
T
he term Power Quality has a different meaning depending on the audience. Electricians are faced with
chasing down problem situations which are
not the necessarily the direct fault of the
electrical system. Convincing clients of the
true cause without proof is time consuming. Today, with the advent of energy saving electronics, loads such as lighting,
controls and computers are all susceptible to
power line disturbances.
The challenge is convincing the end user
that dirty power is the cause of a failure
mode without expending much effort. Having this information also helps the contractor avoid the pit fall of providing the wrong
solution. A device that simply tells clients
whether they have good or bad power is
what is needed.
APPLICATIONS
Looking at the measurement products in
the market place, they can be associated
with different load types.
Plug Loads
First look at every day Plug Loads. These
consist of many different varieties and can
be broken down depending on whether residential, commercial or industrial. In homes
30
you will find compact florescent lighting,
consumer electronics and appliances (including furnace controls). The latter equipment is often the most overlooked when it
comes to power line disturbances. In rural
locations, how often have reports come in
that stoves, fridges and dishwashers have
suddenly gone on the fritz? This is good for
the local retailers but what about the home
owner who has no explanation. The utility
could be blamed, but there is no proof.
Case in point: we take for granted that
the line frequency is consistent – we are
hooked to the power grid that hardy fluctuates. What happens if the grid goes offline and the power plant has to wind up?
If the switch over takes place prematurely,
the line frequency starts low and the current into the loads is extraordinary. The
end results are items switched on at the
time burn up.
Similar circumstances can happen in
the city. If high voltage lines touch low
voltage caused by an accident, suddenly
there is a voltage surge beyond belief.
Again all loads are susceptible yet the
story is less likely to be told as homes and
businesses have more sources for replacement products and repair services.
In commercial establishments, business
Load Type
Measurement Tool
Plug
Voltage Disturbance Recorder
Lighting
AC Current Data Logger
Motors
3-Phase Power Analyzer
Electrical Products & Solutions • October 2009
machines are the most vulnerable to dirty
power. Crashed computers have the biggest
impact on business. Not only can the hardware be damaged and legacy systems hard
to replace but the data held within is considered a critical asset. The cost of recovery is immeasurable.
Businesses have a false sense of security
relying on Surge Protection and Uninterruptable Power Supplies. The little known
fact is these are prone to failure just as all
other equipment is. So how can you tell?
Checking before and after the protection
gear is a sure sign of whether it is functioning properly or is adequate for the job.
Since power line disturbances are random, a
long term analysis is what is required.
The test instruments that can detect
these anomalies range widely in sophistication and price. Voltage Disturbance
Recorders (VDR) are the lowest cost
around $750 and provide easily interpreted
information. The most comprehensive
Power Quality Analyzers (PQA) used by
electric utilities are upwards of $30,000
and can only be deployed on a short term
basis for troubleshooting as a result nevermind the expertise to operate them. In
the middle are $2500 to $10,000 Graphical
PQ Analyzers that have to be tied into panels. The VDR on the other hand plugs directly into a convenience outlet.
Industrial plants also suffer from power
related problems. The difference here is
the source of the events can be caused on
site. Automation is often added to existing
circuits that have motors attached. Voltage spikes caused by these inductive loads
can get thru to the controls degrading their
components and eventually leading to failure and downtime. Solid state relays SSR, Variable frequency drives - VFD and
Switch mode power supplies - SMPS are
all at risk.
The VFD requires a 3-Phase Analyzer
to get any usable data at the appropriate
terminals. However more prevalent in light
industry are single phase Variable speed
drives – VSD whose circuit can be monitored with a VDR. In heavy industry, often
there is a convenience outlet placed inside
the controls cabinet for plugging in a laptop. This is an ideal place to record as the
DCS, PLC, or RTU is supplied by the
same power.
Lighting Loads
For lighting circuits the biggest issue is
brown-outs. This is a
Continued on page 32
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FEATURE • ACR Systems Inc. Continued from page 30
Events
Impulse
Surges/Sags
Outages
Frequency
Causes
Inductive Loads
Lightning
Accidents
Transmission Line
Overloading
Load Switching
Power Transmission
UPS Switch Over
Accidents
Generator Startup
Power Plant
period of time when the voltage sags below
normal causing the lights to false start. This
is uncomfortable to the occupants not to
mention the decreased longevity of ballasts.
Brown-outs can be caused by pour wiring
or events outside the premises. As circuits
evolve, they are added to and the lighting
panel becomes overburdened especially as
single phase plug loads are added.
There are two approaches to monitoring,
one is to make sure the 3-phase circuit remains in balance and the other is to detect
voltage drops. Using a Data Logger read-
Solutions
Snubber Circuits
Transient Voltage Surge Protection
Restitution
Constant Voltage Transformer
Rewiring
Over Voltage Protection
Uninterruptable Power Supply (UPS)
Always On UPS
Backup Generator
Frequency Monitor
Accountibility
Motor Loads
ings are recorded at a preset time interval –
usually set to 1 or 2 minutes to pick up brief
high load combinations. The easiest way
to make sure there is a balanced load is to
unobtrusively clamp around the current carrying conductors with split-core Current
transformers - CT. This also avoids having to wire into High Voltages for temporary deployment.
The alternative is using a VDR which
records events on the low voltage plug side.
Its thresholds can be set according to voltage tolerances. For example, set to ±10%
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32
of nominal which is 105V and 129V for the
117VAC line voltage. The result is the
recorder will report the magnitude and duration of sags. Over a given period of time,
the severity can be determined by the sure
number of events. In the same way, the
other disturbances such as impulses and frequency variation can be interpreted having
detrimental impact if there are a lot.
Electrical Products & Solutions • October 2009
Motors require more complex information to determine their behavior and accordingly poly-phase analysis tools are the
best choice. They are more likely to be affected by and cause severe harmonic distortion in both voltage and current. High
loads and VFD switching characteristics
cause the waveforms to become incompatible with other loads and can ultimately
affect the incoming power source. The
power utility is responsible to ensure
neighbors do not fell these effects. Power
analyzers are best deployed in this case.
When walking into a complaint about intermittent power distur- Continued on page 34
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FEATURE • ACR Systems Inc. Continued from page 32
bances, the first step is to determine the
most likely cause. The VDR is an economical way of setting the course to finding a
solution without expending a lot of effort.
Long term deployment is the key to protecting assets. Data logging has the best
chance of catching events without being
there at the time. PQ devices reveal information that otherwise cannot be seen.
SOLUTIONS
The solutions to Power Quality Problems are straight forward when the cause
is known.
Impulse Events
An example of impulses that can wreak
havoc is inductive kickback caused by
machinery switching off. This is usually
motors but can be any wound coil such as
a transformer. Electronic controls if not
design correctly, not only degraded but
can be triggered on. Solid state relays –
SSR subjected to high voltage short duration impulses (high dV/dt) can turn on
randomly. The problem is often misinter-
if the impulse events are getting thru the
protection gear. Placing a VDR on the output of a power bar or UPS that has surge
suppression and seeing impulse events is
telltale. Replacement of the faulty devices is
necessary to protect critical assets – recommendation to better ratings is prudent.
Accidents such as vehicles hitting
power poles is an event that can cause catastrophic failures which there is normally
no recourse except when the victim has
proof that the damage likely occurred at
the same time. A high voltage detected by
the VDR with a time and date stamp is all
Figure 1 – TRIAC Control Circuit w/Snubber
that is needed to file a claim against the
preted as a faulty device and new ones are driver’s insurance policy.
sourced from a different manufacturer.
The more economical solution is to add a Surges
snubber circuit consisting of a resistor and
Over voltage - OV is likely caused by
capacitor across the control switch – see transmission problems and can either burn
Figure 1.
out equipment or cause UPS protection to
High voltage impulses caused by light- stay engaged deep cycling batteries. Did
ning strikes can pass thru protection gear if you know that low cost UPS power supit has degraded over time – transient pro- plies will deep discharge the battery detection devices protect by absorbing energy, stroying its ability to hold a charge if left
they will eventually fail. How you can tell is on too long? Suppliers do not divulge this
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Electrical Products & Solutions • October 2009
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crucial piece of information as it would
detract from sales. Again the VDR tells
how frequently this type event occurs and
the length of time. The electric utility
needs to be advised and a remedy found –
often transformers are oversized especially in new developments.
Sags
Brown-out conditions can happen more
often than noticed by human observation.
Checking every cycle can reveal short duration repeatable events. This is caused by
a myriad of irregularities such as simultaneous random loads coming on line, to
pour wiring such as overheated splices.
High load currents at the crest of the AC
sinusoid caused by SMPS are becoming
more predominant, it is important to attend to rewiring as overheated circuits can
result in fires.
The VDR left in place over the long
term has the best chance of exposing these
conditions especially as they creep in if
they aren’t already prevalent. At the end
of a transmission lines, remote sites can
10/12/09
8:35 AM
Page 35
suffer from prolonged sags – this can be connect crucial equipment but it is not
fixed by installing a Constant voltage practical to deploy everywhere. It is imtransformer - CVT.
portant that speed switches are operational
on backup generators. The only other reOutages
course is to hold the power station acPower failures are the most noticeable countable with proof of damage that can
event and seem to be easily prevented be correlated with their records.
however their frequency and duration
need to be considered when sizing backup CONCLUSION
power. Another consideration is time it
Contractors have a role to play in edutakes to switch power sources – critical cating clients about power line disturbances,
data can be lost if systems don’t perform explaining their causes and providing soluadequately. Placing a VDR on the output tions. This starts with approaching them
of a UPS can reveal the amount of time with a device that can reveal a true picture
power is completely lost.
of what is really happening. With first hand
Solutions include investing in high-end experience, it is easy to convince clients that
backup power sources such as Always on installing a Power Quality monitoring deUPS or longer duration power generators. vice on a permanent basis is their first line
of defense in protecting business assets
Frequency
against dirty electricity.
As mentioned, frequency deviations
The PowerWatch VDR is the most conoutside the 60Hz norm can damage all de- venient method of capturing voltage disturvices powered on at the time. Computers, bances. Consider selling a device that can
lights and motors alike are susceptible as be left on site – when its indicator light
current raises and over heats components. blinks, the customer calls to find out why,
Frequency monitors are available to dis- giving contractors a new revenue stream. ❏
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October 2009 • epsmag.net
35
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PRODUCT FOCUS
<<<< Cooper Lighting Introduces the Sure-Lites
Concealed Emergency Light
Architecturally pleasing emergency lighting is visible
only when you need it
Cooper Lighting, a division of Cooper Industries, Ltd. (NYSE: CBE), has
introduced the Sure-Lites Concealed Emergency Light Series (CEL Series), a new aesthetically pleasing emergency light that is recessed in
the ceiling or wall and only visible when in use. Designed for applications
where the finest architectural appearance is required, the CEL Series offers maximum protection with high quality MR16 lamps to light a path of
egress during an emergency, but minimal intrusion within the environmental setting when not in use.
The CEL emergency light is fully recessed in the wall or ceiling and when power is lost, the doors open automatically, lighting
a path of egress up to 150 feet from two powerful MR16 halogen lamps (up to 75W each). Standard run time is 90 minutes, but
the CEL Series is available with an extended run time of 120 minutes. The fixture automatically returns to the closed position when
power is restored. The series has four available locking lamp positions for each lamp, ensuring optimal light distribution. A continuous cam, precision motor drive offers dependable operation of the opening and closing of the doors.
Standard features include Self Diagnostics and Self Testing to ensure code compliance and product performance. The selfdiagnostic unit will automatically perform the tests required by the NFPA 101 Life Safety Code every 30 days. The system
indicates the status of the unit at all times using an LED indicator that is located near the test switch.
The fixture comes with a specification grade durable off-white textured powder coat finish that can be field painted or
covered with wallpaper to match any color or surface.
For more information, visit
www.cooperlighting.com
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Electrical Products & Solutions • October 2009
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Affordable New FLIR i7 Infrared Camera Offers 120x120 Resolution >>>>
New thermal imager offers pro-grade resolution for $2,995
FLIR Systems (NASDAQ: FLIR), the global leader in infrared, unveiled the all-new FLIR i7 thermal imaging infrared camera today, the first-ever professional-grade thermal imaging camera under $3,000. The new FLIR i7 couples RESNET-compliant 120x120 (14,400) pixel infrared resolution with
2% accuracy and 0.1ºC thermal sensitivity—a robust combination of capabilities to quickly detect electrical, HVAC, mechanical, and energy-audit-related problems.
The compact FLIR i7 reveals abnormal temperature readings with crisp images displayed on a large 2.8”
(71mm) high-resolution color LCD. The FLIR i7’s fully-automatic design, intuitive menu navigation, and focus-free lens make it easy to use even for newcomers to thermal imaging. Three measurement modes are
available for extensive analysis of job sites: spot (center), area (minimum/maximum), and isotherm
(above/below). Image controls include three palette options: iron, rainbow, and black & white.
Tom Scanlon, vice president, Americas Thermography at FLIR Systems, commented, “The FLIR i7 represents FLIR’s solid commitment to introducing powerful thermal imaging capabilities at affordable prices. Only
FLIR can offer 120x120 resolution matched with high thermal sensitivity for under $3,000. Across industries
and professions, budget is no longer an excuse to go without thermal imaging’s time-saving and efficient diagnostic capabilities. Every company should have at least one.”
Up to 5,000 images can be captured and stored on the FLIR i7’s MicroSD card (included). Browsing images
on the large LCD is easy using FLIR’s onboard thumbnail gallery feature. Image transfer to a PC is easy via the
MicroSD card or USB connection. Unlike proprietary image formats, FLIR’s patented radiometric JPEG format
permits you to analyze temperature data directly from a common image format using FLIR’s QuickReport™
software (included).
For more information, visit
www.goinfrared.com
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October 2009 • epsmag.net
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PRODUCT FOCUS
New Master Proheat® LCD Heat Gun >>>>
offers Digital Display with Locking,
Adjustable Temperature & Air Flow
Controls
Master Appliance Corp., North America’s leading designer
and manufacturer of professional quality heat tools for industry, is proud
to introduce its new UL Certified Model PH-1400 Proheat LCD Dial-In Heat Gun, featuring separate, easy-to-use, controls for digitally displayed temperatures in 10° increments, from 130°F to 1000°F (50°C-540°C), in your choice of degrees Fahrenheit or Celsius
and adjustable air flow control from 4 to 16 CFM. Its electronic circuitry, with closed loop
temperature feedback system, maintains constant temperature at all airflow settings and
while using any of the many attachment options.
The Proheat LCD Dial-In Heat Gun is compact, light weight, and ergonomically designed for
superb balance and grip with convenient, top mounted, dial-in controls for easy temperature
and air flow adjustment. The Temperature and Air Flow Lock-In feature provides added management control – perfect for production applications requiring consistent application of heat.
For added safety, the Power-interrupt Reset prevents damage caused by returning electricity if the heat gun
is left in the “Hot” position during a power failure.
The Proheat LCD Dial-In Heat Gun’s full-featured design makes it ideal for demanding applications in the aerospace, automotive, electronic, laboratory and general industrial workplace, including heating temperature sensitive materials, bending and forming plastics, applying/removing decals, curing resins, drying filler, soldering and
desoldering, shrinking tubing and others where heat and air flow control is needed.
For more information, visit
www.masterappliance.com
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Electrical Products & Solutions • October 2009
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Top-Tier Cable Tie Installation Tool >>>>
Ready For Action
Hayata, LTD. introduces its new cable tie installation tool, the BT12000 QuikTie™.
Designed with a lithium-ion battery, the rugged BT12000 delivers longer-lasting power in
a lighter, more compact tool. Featuring a 4:1 productivity advantage over standard tools,
the BT12000 was built with speed and productivity in mind. Variable torque adjustment
provides the BT12000 the necessary tension needed for uniform cable tie installation without the risk of damaging cable jackets. Teaming the BT12000 with Hayata’s roller ball and ladder style cable ties
creates a powerfully secure cable restraining and bundling system.
Designed to work seamlessly with Hayata ties of all widths, the
BT12000 also features a built-in work light and a 30-minute battery
recharge time.
Established in 1999, Hayata is a worldwide supplier of stainless steel
cable ties, banding, and installation tools. Hayata offers a full line of UL
listed, Lloyds, and ABS approved cable ties; including roller ball, ladder,
and releasable styles, in both coated and uncoated finishes. Also available is an array of installation tools, both manual and battery-powered,
to assist in the application of all ties and banding.
For more information, visit
www.hayata.com
October 2009 • epsmag.net
39
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Advertiser INDEX
This advertisers index is compiled as a courtesy to our readers. While every effort is made to provide a complete and accurate listing of companies, page numbers and
reader service numbers, the publisher is not responsible for errors.
Company
PG#
RS#
Company
ACOM TOOLS, LLC
ACR SYSTEMS
AEE SOLAR
AEMC INSTRUMENTS
AG BODY
ALBER CORPORATION
ALCAN CABLE
BYTE BROTHERS
CONEST
COPPER DEVELOPMENT ASSOCIATION
DENT INSTRUMENTS
ELECTRI-FLEX COMPANY
ERICSON MFG.
EVERGREEN SOLAR
EXTECH INSTRUMENTS
E-Z METER
GENERATOR INTERLOCK TECHNOLOGIES
HELUKABEL USA, INC.
14
32, 34
15
IBC
34
IFC
31
12
33
29
36
35
19
27
5, 7
24
10
9
31
38, 40
13
2
39
1
21
30
22
20
42
41
15
19
7, 8
34
10
9
HIOKI USA
HOTBEND
ICC
KRENZ & COMPANY
MEGGER
PG LIFELINK
PHASE-A-MATIC
POWER MONITORS, INC.
SEATEK
SINGLETOUCH
SOLARWORLD CALIFORNIA
SOUTHWIRE
SPERRY INSTRUMENTS
STEELMAN INDUSTRIES
STRIP-TEC
SUMMIT TECHNOLOGY
UNDERGROUND DEVICES
UTILITY METALS
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Electrical Products & Solutions • October 2009
PG#
RS#
13
38
17
24
1, 3
11
38
25
37
32
BC
21
23
14
26
4
20
40
12
44
14
35
4, 5
11
45
18
43
37
3
16
17
32
36
6
33
46
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