Copyright 2011 Surge Suppression Incorporated. Dr. D.H. Wilfong

Transcription

1 Dr. D.H. Wilfong

2 Seminar Overview The Transient Environment Product Specifications Criticality of Test Parameters TVSS Design Proper Application System Survey Technology Commitment IEEE Testing

3 Transient Environment

4 What Is A Transient? A Temporary excess of voltage and current on an electrical circuit that has been disturbed.

5 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

6 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 Internal- switching Major Causes External- lightning 20% 80% Source: General Electric, Current Scene, a Bulletin of Circuit Protection Technology

7 Transients Generated by Switching Results of switching off a 2-bulb four foot fluorescent fixture Source: General Electric Instrumentation and Computer Service Laboratory

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10 How Often Do Transients Occur? The range is 180,000 to 432,000 per hour in many active industrial environments Source: Specifying Engineer

11 Transient Disturbance

12 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

13 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 Source: Texas Instruments Laboratories

14 Failed (Burned) LED Driver

15 Close-up of Failed MOV in Driver

16 $141,000 of Warrantied LED Drivers

17 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

18 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

19 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

20 Product Specifications

21 Specification Data Maximum continuous operating voltage Input power frequency Peak surge current Noise attenuation Filter frequency range Energy dissipation (joule rating) Response Time

22 Specification Data Recovery time Altitude Protection mode Physical dimensions Weight Life expectancy Listings Measured Limiting (let-through) Voltage (surge remnant)

23 Standard Wave Forms- ANSI/IEEE C62

24 Standard Wave Forms- ANSI/IEEE C62

25 Standard Wave Forms- ANSI/IEEE C62

26 Criticality of Test Parameters

27 Laboratory Test Environment Dynamic or static test +/- polarity Phase angle Voltage Current Lead length

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30 Testing At Module

31 Test Module Result: 418 Volts

32 Test: Lugs

33 Test: Lugs Results: 556 Volts

34 Test: 6 in Lead Length

35 Test: 6 in Lead Length Result: 750 Volts

36 Testing At Module

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38 Test: 5 ft Lead Length Result: 1575 Volts

39 Test: 6 in Lead Length Result: 865 Volts

40 Improper Installation of TVSS Installed with 30 feet of lead length

41 Proper Installation of TVSS

42 Surge Voltage

43 Result: 70 volts

44 Result: 17 volts

45 Current

46 Test: 200 Amps Result: 70 Volts

47 Test: 500 Amps Result: 173 Volts

48 Test: 3000 Amps Result: 386 Volts

49 Phase Angle

50 Test: Phase Angle Result: 48 Volts

51 Test: 90 0 Phase Angle Result: 195 Volts

52 TVSS Design

53 SPD Components

54 Hybrid Network

55 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)

56 MOV Stress Test Data Source: Texas Instruments Laboratories

57 Proper Application

58 Transient Duration- TVSS Device

59 Transient Duration

60 Protection Types Fixed Clamping Performance Curve Frequency Responsive Performance Curve

61 2,000 Volt Ringing Transient from Electronic Motor Control With NO Surge Suppressor Present 2,000 Volts

62 2,000 Volt Ringing Transient from Electronic Motor Control WITH Standard Clamping Surge Suppressor Present 438 Volts

63 2,000 Volt Ringing Transient from Electronic Motor Control WITH Sine Wave Tracking Surge Suppressor Present 50 Volts

64 Spec Sheet for UL Recognized Component

65 SPD A1 Ring Wave Result: 865 volts

66 SSI A1 Ring Wave Result: 33 volts

67 UL Limited Current Overvoltage Test

68 SPD FAILED UL Limited Overvoltage Test & burned wood.

69 IEEE Standard (Emerald Book) Section 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.

70 10 Mode Protection Phase A Phase B A-N HVS A-G A-B A-C 60kA 60kA 60kA 60kA B-N B-G B-C Phase C C-N C-G Neutral N-G Ground True All Mode Protection distributes the surge over more paths and components Phase to Neutral Phase and Neutral to Ground Phase to Phase

71 Full System Coverage

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73 3 Levels of Protection SSI SSI SSI SSI SSI

74 Level 1

75 Level 1 21 kv SSI SSI SSI SSI SSI

76 Level 2

77 Level 2 21 kv SSI 1.1 kv SSI SSI SSI SSI

78 Level 3

79 Level 3 21 kv SSI 1.1 kv SSI 195 V SSI 195 V SSI SSI 195 V

80 Point of Use

81 Point of Use 21 kv SSI 1.1 kv SSI 195 V SSI O V 195 V SSI O V 195 V SSI O V

82 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.

83 The End Result 200,000 kv SSI 4700 kv SSI 800 V SSI O V 800 V SSI O V 800 V SSI O V

84 ROI

85 Proven Track Record

86 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.

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88 Problem: 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 $ to $7,500.00, not including the cost of labor or inconvenience of downtime to our customers Results after TVSS: We have been using SSI surge suppression products since 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.

89 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 Results after TVSS: Replacement Reductions % Savings Electric Motors 98% Lights 74% Computer and PC Boards 99.6% Equipment Downtime From 21.25% to 0.7%

90 Annual Maintenance Cost Name of Ride Year Prior to TVSS Year After TVSS Double O $15, $1, Santa M $67, $ Hurricane $13, $ Totals $96, $2, Investment for TVSS: $5,935 Source: Transient & Lightning Protection Cost and Effect by Alexander E. Othmer

91 Problem: A direct lightning strike destroyed two CPSB primary fuses and a power transformer. The strike also destroyed nine previously installed surge suppressors. The fabrication department went down. Results after TVSS: When power was restored, none of the 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

92 Problem: Electrical surges caused poor X-ray images when a new digital radiology computer was installed in a children s hospital Results after TVSS: Power is cleaner, images are clear, and a million dollar investment is now completely protected

93 Problem: They (St. Joseph s Hospital) were going through $9,000 in x-ray tubes every 6 months to 1 year Results after TVSS: They have had the same tube on now for over 4 years. It cut the service calls down by 80%

94 Problem: Fluorescent light replacement at many 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) 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

95 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

96 Department of the Air Force Problem: Results after TVSS: 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 Since the installation, they are saving so much money from no repairs and no downtime that they have been able to upgrade other facilities.

97 SCR Drive Generated Transient Activity Without TVSS With TVSS Source: GE Laboratory, Houston, TX

98 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.

99 NPBBU VFD Repair Activity

100 SSI

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103 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 TVSS Installed Cost: $2,679,350 Annual Post-Install Maintenance: $2,865,107 Yearly Maintenance Savings: $4,949,611 Payback Period in Years: 0.54 Total Estimated Payback: $141,047,596

104 View of McIntosh Power Plant from Larsen Power Plant

105 Event Costs For the period of June 26, 2000 through November 15, 2000 $786,000

106 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.

107 SSI Product

108 25-YEAR FULL REPLACEMENT WARRANTY Surge Suppression Incorporated warrants for a period of 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.

109 Surge Suppression Incorporated

110 Dedicated Load Circuit Protection Standard Clamping Sinewave Tracking Series connected dedicated load circuit protection Compact Size Terminal and Hardwire connections Simple installation

111 Data Line & Current Loop Models Multi-stage hybrid design Data rates to 100M/bps Low impedance/insertion loss Terminal, Coax and Hardwire connections Lowest let-through voltage levels

112 Telecom Line Models 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

113 Custom & Specialty Models

114 SPD for Airfield/Runway Lighting Applications

115 Hand-held Testing Unit for Airfield Lighting SPD

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