Application note Surge Protective Devices OVR Series - Enclosed SPD Mining and Aggregates ABB OVR Series Electrical surges can be a real downer. Sherwood Construction's stone quarry in Tulsa, Oklahoma, USA found this out the hard way. Upstream load switching by the utility was causing surges on the electrical network, having a direct impact on the power quality reaching the quarry. The surges were damaging the crusher, conveyor, motors and drives, causing downtime, loss of revenue and expense to replace the damaged equipment. The quarry manager estimates lost revenue and expenses in excess of $100 000. The quarry produces 1.2 million tons of construction aggregate per year, and uptime is the most critical element of the operation. Unplanned downtime creates operational and safety issues as customer trucks back up on site, haul trucks are required to load material from stockpiles and maintenance crews work to bring the operation back online. A solution was needed to ensure no further damage and downtime would result from electrical surges. Rep Tech Controls, Inc., the area independent ABB sales rep, and Advanced Industrial Devices, the local distributor, had a relationship with Sherwood Construction, providing the quarry with ABB products such as softstarters, contactors and overloads. They suggested ABB's new surge protective device, the OVR NE12 enclosed SPD. The OVR NE12 was developed to compliment ABB's existing DIN rail line of surge protective devices. It is designed for installation at the service entrance, protecting the entire facility or operation from external surges. The manager of the quarry is happy with the protection the OVR NE12 provides and recommends this type of device to others who require surge protection. "If this piece of equipment (OVR NE12 enclosed SPD) can keep us up and running, and help us produce more material in a given day, then it is successful and helps us reach our goals and be more productive". The model selected was the OVR NE 12 320 480 D X, to work with the 480 V Delta 3-phase network, provide 320 ka protection per phase, and come equipped with a surge counter/diagnostic screen. Since the installation of the OVR NE12 unit in mid 2010, the unit surge counter has recorded seven surge events and the quarry has experienced no surge related issues.
Product introduction OVR NE12 enclosed SPD The OVR NE12 enclosed surge protective device (SPD) is the latest addition to ABB's extensive range of surge protection products. It is designed to be installed at the service entrance, thereby protecting the entire facility from the harmful effects of transient surges. These surges are the result of: Direct and indirect lightning strikes Power company load switching Upstream load switching at other facilities. Extensive damage and expensive repairs can result from these types of disturbances if surge protection is not present. Features & benefits The OVR NE12 is a multistage protector with fast acting varistor (MOV) and EMI/RFI noise attenuation filter to limit overvoltage to values compatible with the sensitive equipment connected to the network. In addition to the OVR NE12, ABB recommends adding OVR DIN rail SPDs at branch panels and equipment, creating a multi-level approach to protection. General NEMA 12 enclosure All mode protection (L-L/L-N/L-G/N-G) Auxiliary contacts for remote monitoring Safety disconnect, fused LED power on/fault indicator Audible alarm. MOV technology 160 ka or 320 ka per phase Replaceable MOV blocks Visual and audible MOV replacement indication. Surge counter/diagnostic LCD display (optional) Count of surges 2 ka and higher with time and date Visual diagnostic information. Applications The OVR NE12 is suitable for protection for all manner of facilities and operations. It is designed with a NEMA Type 12 enclosure, and rated as a Type 2 SPD, requiring indoor installation on the load side of the main breaker or fuse. Here are some examples of operations that would benefit from an OVR NE12 enclosed SPD: Critical power (hospitals, data centers, etc) Renewable energy Water/wastewater Communications Manufacturing Commercial. Specifications Approvals: UL 1449-3rd Edition Listed, UL 1283, CSA 22.2 No. 8 Type 2 Surge Protective Device NEMA 12 enclosure Three service voltages (AC): 240/120 V Split phase, 480 V Delta and 480/277 V Wye 160 ka or 320 ka per phase protection Short circuit current rating (SCCR): 200 ka. ABB recommends the installation of the OVR NE12 enclosed SPD wherever uptime is a critical element of a facility or operation. 2 ABB Surge Protective Devices - OVR Series - Enclosed SPD
Product selection OVR NE12 enclosed SPD Choosing the correct model There are three steps to choosing the correct OVR NE12 model: Select service voltage Consult qualified personnel if the facility or operation service voltage is unknown. The OVR NE12 is available in three service voltages: --480 V Delta --480 Y/277 V --240/120 V Split phase Select the surge capacity (Imax) The surge capacity is the maximum discharge current (Imax) per phase. Each MOV is capable of withstanding multiple surges below the maximum surge level. Two protection levels are available: --160 ka per phase --320 ka per phase Choose a basic display or the surge counter/diagnostic LCD display --Basic display: LED lights and alarm --Surge counter/diagnostic LCD display: LED lights, alarm and LCD screen displaying percentage protection level, surge count and last surge date Once these three steps are complete, consult the tables below and on page 10 to select the unit. If technical assistance is required, please call ABB Technical Support at (888) 385-1221 option #4. State Indicator + Surge Counter/ LCD (optional) Replaceable MOV Blocks Safety Disconnect, Fused ABB Surge Protective Devices - OVR Series - Enclosed SPD 3
Product selection OVR NE12 enclosed SPD OVR NE12 enclosed SPD part number diagram Surge capacity 320 ka/phase or 160 ka/phase Service D = Delta Y = Wye SP = Split phase ABB SPD OVR NE12 320 277 Y X Enclosure rating NEMA 12 Service voltage 480 277 120 Option: X = Surge counter/ Diagnostic LCD display Blank = Basic display OVR NE 12 serie features Designation OVR NE 12 320 480 D X OVR NE 12 160 480 D X OVR NE 12 320 277 Y X OVR NE 12 160 277 Y X OVR NE 12 320 120 S P X OVR NE 12 160 120 S P X OVR NE 12 320 480 D OVR NE 12 160 480 D OVR NE 12 320 277 Y OVR NE 12 160 277 Y OVR NE 12 320 120 S P OVR NE 12 160 120 S P Service voltage Features Default visualization Green/red LED Audible alarm 480 V Delta Yes Yes Yes 480 Y / 277 V Yes Yes Yes 240/120 V Split phase Yes Yes Yes 480 V Delta Yes Yes No 480 Y / 277 V Yes Yes No 240/120 V Split phase Yes Yes No Surge counter OVR NE 12 serie service voltage and location Service entrance Main distribution panel Sub-distribution panel Network Service voltage Number of wires OVR NE12 enclosed SPD OVR DIN rail SPD OVR DIN rail SPD Delta Single phase Split phase Wye 240/120 V HLD 4W+G ---- OVR T23 N40 320 P TS U OVR T 23 N15 320 P U 240 V 3W+G ---- OVR T23 L40 320 P TS U OVR T 23 L15 320 P U 480 V 3W+G OVR NE 123 204 80 D (X) OVR NE 121 604 80 D (X) OVR T23 L40 550 P TS U OVR T23 L40 550 P TS U 600 V 3W+G ---- 3 x OVR 240 660 P TS U 3 x OVR T 240 660 P TS U 120 V 2W+G ---- OVR T21 N40 150 P TS U OVR T21 N15 150 P U 240 V 2W+G ---- OVR T21 N40 320 P TS U OVR T21 N15 320 P U 277 V 2W+G ---- OVR T21 N40 320 P TS U OVR T21 N15 320 P U 240/120 V 3W+G OVR NE 123 201 20 S P(X) OVR NE 121 601 20 S P(X) OVR T22 N40 150 P TS U OVR T22 N15 150 P U 480/240 V 3W+G ---- OVR T22 N40 320 P TS U OVR T22 N15 320 P U 208/120 V 4W+G ---- OVR T23 N40 150 P TS U OVR T23 N15 150 P U 480/277 V 4W+G OVR NE 123 202 77 Y (X) OVR NE 121 602 77 Y (X) OVR T23 N40 320 P TS U OVR T23 N15 320 P U 600/347 V 4W+G ---- OVR T23 N40 440 P TS U OVR T23 N40 440 P TS U 4 ABB Surge Protective Devices - OVR Series - Enclosed SPD
Product introduction OVR DIN rail SPD Introduction Over 80 % of transient surges are caused by internal sources such as load switching and normal equipment operations. The installation of ABB OVR UL 1449 3rd Edition or IEC pluggable AC DIN rail SPDs will combat these surges and provide protection to valuable equipment and help keep an operation up and running. This new product range is approved as Type 4 recognized components and is usable in Type 2 applications. These products are of the same high quality as ABB UL 1449 2nd Edition devices, with improved safety as a result of additional testing required by the UL 1449 3rd Edition standard. Specifications UL 1449 3rd Edition - Type 4 Recognized Component Imax - 15 ka and 40 ka Maximum continuous operating voltage (Uc) - 175, 320, 440, 550 and 660 V AC Configuration - 1L, 2L, 3L, N, 1N, 2N, 3N IEC 61643-11 / EN 61643-11 ABB recommends a multi-level approach to surge protection. Combining OVR DIN rail SPDs with the OVR NE12 enclosed SPD will ensure the facility or operation is fully protected. Installation at branch panels, control panels and terminal equipment is recommended to provide the most complete protection. Features & benefits The OVR DIN rail SPDs utilize fast acting metal oxide varistor (MOV) technology to limit overvoltage to values compatible with the sensitive equipment connected to the network. End of life indicator This feature is standard on all ABB pluggable OVR DIN rail surge protectors. Each cartridge is equipped with a mechanical indicator which is green when the SPD is operational and protecting the system, and turns red when it has reached end of life. When this occurs, the cartridge must be replaced to guarantee protection. Pluggable The ability to efficiently maintain equipment is a key focus topic for industrial facilities. For this reason, ABB OVR DIN rail SPDs (excluding data line products) now utilize pluggable cartridges. Should one or more cartridges reach end of life, the electrical circuit does not have to be isolated, nor does the whole device have to be removed. Simply pull the dead cartridge from its housing and plug in a new one. IEC SPD range features UL SPD range features NOTE: A surge protector that has reached end of life does not interrupt service, it simply disconnects itself, and the system is no longer protected. NOTE: Pluggable surge protector cartridges are equipped with a "key" matched to each part number base, preventing incorrect replacements. H Remote indication (Optional - "TS" designation) This function, achieved by wiring an integrated 3-point 1 A volt-free contact, enables the operational state of the SPD to be monitored remotely. Technical features of the remote indicator 1 N.O. (Normally Open) contact and 1 N.C. (Normally Closed) contact Min. load: 12 V DC - 10 ma Max. load: 250 V AC - 1 A Connection cross section: 1.5 mm2 (16 AWG) Safety Reserve system Normal In Reserve End-of-life ABB Surge Protective Devices - OVR Series - Enclosed SPD 5
Product selection OVR DIN rail SPD 1 - Define the required standard to be compliant with UL 1449 3rd Edition or IEC 61643-11 2 - Determine the service voltage Consult qualified personnel if the facility or operation service voltage is unknown. 3 - Select the SPD maximum continuous operating voltage (MCOV, Uc) The MCOV should correspond to the service voltage. Example: If the service voltage is 480 V Delta, an SPD with 550 V or 660 V MCOV will be required. Surge protection devices must also provide a level of protection compatible with the withstand voltage of the equipment. This withstand voltage depends on the type of equipment and its sensitivity. The incoming surge protector may not provide adequate protection by itself, as certain electrical phenomena may greatly increase its residual voltage if cable lengths exceed 10 m. A second SPD may be necessary. See Coordination below. 4 - Select the SPD surge capacity (Imax) Surge capacity is the amount of energy the SPD can withstand from a single surge event. The higher the surge capacity, the longer the device will protect the system. A second surge protector may be required if the surge capacity of the first is not capable of diverting all surge current to ground. See Coordination below. 5 - Remote monitoring (Optional) Integrated auxiliary contact for remote monitoring available on models with "TS" designation. Consult the Service Voltage and Location table on page 16 for help in the selection of SPDs. UL OVR Din Rail SPD - Part number diagram Phases 1P = No notation 2P = 2L 3P = 3L 1P+N = 1N 2P+N = 2N Surge capacity (Imax) 15 ka 40 ka Pluggable OVR NE12 3N 40 320 P TS U ABB SPD Designation Type 2 Apps Max voltage (Uc) 150 (175 V) Auxiliary contact (Optional) UL 1449 3rd Edition 320 V 440 V 550 V 660 V 6 ABB Surge Protective Devices - OVR Series - Enclosed SPD
Complete facility protection Installing surge protection at the main distribution panel is only the beginning of protecting the entire operation. As most transient surges are created internally, it is necessary to install surge protection at sub-distribution panels (equipment protection) to be fully protected. Stepping down the Imax level from the service entrance panel toward equipment to be protected is recommended. For example, if a 40 ka Imax SPD is installed in the main distribution panel, then 15 ka Imax SPDs should be installed in sub-distribution panels for equipment protection. Wiring rules The impedance of the cables increases the voltage across the connected equipment. Therefore, the length of the cable between the surge protector and the equipment should be minimized. The surge protective device should be installed as close to the equipment to be protected as possible. If this is not possible (the equipment is over 30 m from the panel), then a second surge protector must be installed. Coordination It may be necessary to add a second surge protector, wired to the incoming unit, to achieve the required voltage protection and/or surge capacity. For Type 2 or 4 SPDs, installing this second unit a minimum of 1 m from the first unit will allow the two to work together, achieving the required protection. IEC OVR Din Rail SPD Part number diagram Max. discharge current Imax 8/20 15 ka 40 ka 70 ka 120 ka Impulse current Iimp 10/350 15 ka 25 ka s: with safety reserve P: pluggable device OVR T2 N1 40 275 s P TS Designation: T1: Type 1 SPD T1+2: Type 1+2 SPD HL: Type 1+2 SPD with MOVs T2: Type 2 SPD PLUS: Autoprotected SPD PV: Photovoltaic SPD TC: Dataline SPD WT: Wind turbine SPD Phases: 1N: 1 phase (left) - neutral (right) 3N: 3 phases (left) - neutral (right) N1: neutral (left) - 1 phase (right) N3: neutral (left - 3 phases (right) 3L: 3 poles 4L: 4 poles without: 1 pole Max. operating voltage Uc 440 V 320 V 275 V 150 V 75 V Auxiliary contact ABB Surge Protective Devices - OVR Series - Enclosed SPD 7
h 1 h 2 OPR Early streamer emission air terminal The OPR efficiency (ΔT) Lightning is one of the most spectacular meteorological phenomena. Generated by the interaction of clouds elements (water and ice), it can kill, injure and damage. The unique efficiency of the OPR Early streamer emission is based on the difference (ΔT), measured in a laboratory, in between the emission time of the OPR and the one from a simple rod. The OPR ESE air terminal is composed of a striking point connected to a down conductor to conduct the lightning to the ground. Upward leaders Without OPR Upward leaders Meeting point Meeting point Return arc Complete autonomy During a storm the ambient electric field may rise from 600 V to 10-20 kv/m. When the electric field reach this level representing a minimum risk for a lightning, the OPR begins to get activated and generates high voltage pulses, helping to create and propagating an upward leader. After a strike on the OPR, the lightning current is driven to ground by the down conductor to the earth termination system. With OPR R p1 R p2 R p3 Radius of protection The radius of protection (Rp) of the OPR is calculated according to the NF C 17 102 (edition 2011). It depends on the OPR efficiency (ΔT) expressed in micro-seconds. The maximum value for ΔT is 60 µs. h 3 The risk assessment shall be calculated according to the NF C 17 102 Annex A / IEC 62305-2 and will define the protection level (LPL I, II, III or IV) which will be used in the determination of the OPR radius of protection. LPL I LPL II LPL III LPL IV Rolling sphere radius r(m) 20 30 45 60 Rp(h) : Protection radius at a given height (h) Rp(h) = 2rh - h 2 + Δ(2r + Δ) (for h 5 m) For h < 5 m, refer to the table below h : Height of the OPR tip above the surface(s) to be protected r(m) : Standardized striking distance (m) = 10 6.ΔT (OPR efficiency) OPR radius of protection Protection level I (r = 20 m) II (r = 30 m) III (r = 45 m) IV (r = 60 m) OPR OPR 30 OPR 45 OPR 60 OPR 30 OPR 45 OPR 60 OPR 30 OPR 45 OPR 60 OPR 30 OPR 45 OPR 60 h (m) Radius of protection Rp (m) 2 19 25 31 22 28 35 25 32 39 28 36 43 3 29 38 47 33 42 52 38 48 58 43 57 64 4 38 51 63 44 57 69 51 65 78 57 72 85 5 48 63 79 55 71 86 63 81 97 71 89 107 6 48 63 79 55 71 87 64 81 97 72 90 107 8 49 64 79 56 72 87 65 82 98 73 91 108 10 49 64 79 57 72 88 66 83 99 75 92 109 15 50 65 80 58 73 89 69 85 101 78 95 111 20 50 65 80 59 74 89 71 86 102 81 97 113 45 43 65 76 58 75 89 75 90 105 89 104 119 50 40 65 74 57 75 88 75 90 105 89 104 120 55 36 65 72 55 75 86 74 90 105 90 105 120 60 30 65 69 52 75 85 73 90 104 90 105 120 8 ABB Surge Protective Devices - OVR Series - Enclosed SPD
A complete expertise OPR ordering details T Description Type Order code Weight µs kg 30 OPR 30 IMH3000 2CTB899800R7000 2.400 45 OPR 45 IMH4500 2CTB899800R7500 2.400 60 OPR 60 IMH6000 2CTB899800R7100 2.400 Mast to be ordered separately. Maximum operating temperature: 120 C. Masts Height Description Type Order code Weight (1 pce) m kg 2.3 Stainless steel ESEAT mast Ø 30 MAT3002 2CTH070002R0000 3.000 3.0 Stainless steel ESEAT mast Ø 35 MAT3503 2CTH070011R0000 5.200 To be noted that the MAT3503 needs to be ordered with it screw and fixing kit KFP0035 made of a connecting clamp especially designed for Ø 35 mm mast. 2300 169 46 OPR Lightning rod head Kit for MAT3503 Description Type Order code Weight (1 pce) kg Screw and fixing KFP0035 2CTH050027R0000 - OPR with a stainless steel mast Ø 30 - L = 2.3 m Installing / testing The installation and verification of lightning protection systems using one or more OPR units must be performed in accordance with the manufacturer's recommendations and to the NF C 17 102 standard. Or SDB SDB - Sub Distribution Board ABB Type 2 Auto protected surge protective device OVR Plus N1 40 or OVR Plus N3 40 OPR ESE air terminal OPR ABB Type 1 Surge protective device OVR T1 3N 25 255 TS Or Or MDB Telecom Board Electronic Lightning strike counter With data recording Mechanical Lightning strike counter Main power input MDB - Main Distribution Board Telephone input ABB pluggable telephone and data line surge protective device OVR TC 200V P ABB Surge Protective Devices - OVR Series - Enclosed SPD 9
Contact us ABB France Low Voltage Products Division Pôle Foudre Soulé & Hélita 1, avenue des Victimes du 11 juin 1944 BP 303 F-65203 Bagnères-de-Bigorre / France Tel. : +33 (0)5 62 91 45 60 Fax : +33 (0)5 62 91 45 62 You can find the address of your local sales organisation on the ABB home page http://www.abb.com/contacts -> Low Voltage products Note We reserve the right to make technical changes or modify the contents of this document without prior notice. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB. Copyright 2014 ABB - All rights reserved 1TXH000327B0201 - Printed in France (09.2014 PDF) www.abb.com/lowvoltage