Low-Voltage Power System Surge Overvoltage Protection: Dev Paul, Senior Member, IEEE
Low-Voltage Power System Surge Overvoltage Protection: Dev Paul, Senior Member, IEEE
Abstract—The unpredictable threat of transient overvoltages is switching frequencies and switched-mode power supplies, used
ever increasing in today’s low-voltage power supplies for every as- for their greater efficiencies contribute to noise. The ever in-
pect of industry. To calculate the magnitude, duration, and energy creasing application of silicon-controlled-rectifier (SCR)-based
of such transient overvoltages is not an easy task. Some loads are
becoming very sensitive to such overvoltages, thereby creating a power circuits and capacitors do contribute to the noise problem
challenge for the application engineer to design a reliable power for their own control systems.
supply system. To apply surge overvoltage mitigation devices re- Transient overvoltages are harmful to sensitive control
quires technical knowledge to understand their application limita- circuits and should be suppressed by application of transient
tions and configuration within a power system. Technical overview voltage surge suppressors (TVSSs). However, the problem is
of fundamentals of transients and associated noise is presented.
The importance of understanding applicable UL, IEEE, and IEC to quantify the magnitude, duration, and energy parameters of
Standards, and thorough review of manufacturers’ data on tran- the surge for proper evaluation to select TVSS devices. This
sient voltage surge suppressors (TVSSs) is included. TVSS testing paper provides a fundamental overview of transient surge and
requirements per the second edition of UL 1449 is presented. An associated noise in low-voltage power distribution systems.
overview of how to design a low-voltage power supply system to The TVSS application approach is included to help design
suppress transient overvoltages is included.
engineers in the selection of proper transient surge-suppression
Index Terms—Electromagnetic compatibility, electromagnetic devices.
interference, metal-oxide varistor, noise, spikes, surges, transient
voltage surge suppressor.
II. ELECTRICAL SURGES AND NOISE
I. INTRODUCTION Electrical noise generated within the facility by transient
surges corrupts low-voltage power supplies. In discussing the
V OLTAGE transients are brief and unpredictable. These
two characteristics make it difficult to detect and measure
them. Considerable work is in progress and much data is now
characteristics of transient surges and associated noise, it is
helpful to understand other related terms.
available from the power quality group to better understand
these transients [1]. Low-voltage power supply systems are A. Definitions—Noise and Noise-Related Terms
getting more disturbed in terms of power quality issues.
1) Noise can be defined as any form of electromagnetic en-
The switch-mode power supplies used for equipment such
ergy other than the desired signal and its harmonic com-
as fax machines, printers, variable-frequency drives (VFDs)
ponents.
for energy-efficient heating, ventilation, and air-conditioning
2) Transients are the momentary amplitude changes in
(HVAC) systems, elevators, escalators, electronic ballasts, etc.,
voltage or current or both;
and a great percentage of other loads are becoming nonlinear.
3) Surge is a term for either high-voltage noise or long-du-
Such loads generate current harmonics, leading to distorted
ration transients.
voltage. In addition to this distorted voltage, the switching and
4) Electromagnetic interference (EMI) is the impairment of
lightning surges propagating through the distribution system
a desired electromagnetic signal by an electromagnetic
lead to transient overvoltages.
disturbance such as noise. Since noise-related EMI often
Both analog and digital circuits use complex solid-state com-
occurs in the radio frequency range of 10 kHz to 30 MHZ,
ponents in today’s control systems and are inherently suscep-
the term radio frequency interference (RFI) is often used
tible to damage or malfunction from the electrical surges. The
instead of the general term EMI;
current trend toward more performance in smaller size has it-
5) Electromagnetic compatibility (EMC) is a device’s capa-
self contributed to the noise problem. Digital circuits with high
bility to perform its intended function within a given elec-
tromagnetic environment without adversely affecting or
Paper ICPSD 00–03, presented at the 2000 IEEE/IAS Industrial and being adversely affected by other devices sharing that en-
Commercial Power Systems Technical Conference, Clearwater Beach, FL, vironment;
May 7–11, and approved for publication in the IEEE TRANSACTIONS ON
INDUSTRY APPLICATIONS by the Power Systems Protection Committee of the 6) Electromagnetic environment is a set of conditions char-
IEEE Industry Applications Society. Manuscript submitted for review May 12, acterized by: 1) the presence of one or more kinds of dis-
2000 and released for publication July 26, 2000. turbance, energy, rise time, frequency, duration, and am-
The author is with EARTH TECH, Oakland, CA 94612-3060 USA (e-mail:
[email protected]). plitude of disturbance and 2) the effect that these distur-
Publisher Item Identifier S 0093-9994(01)00283-3. bances have on equipment within the environment.
0093–9994/01$10.00 © 2001 IEEE
224 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 37, NO. 1, JANUARY/FEBRUARY 2001
Fig. 7. Attenuation of common-mode noise through shielded transformer. *In some locations, sparkover of clearances may limit
the overvoltages.
of attenuation depends upon the relative magnitudes Fig. 8. Rate of surge occurrences versus voltage level at unprotected locations
for different exposures.
of transformer inter-winding capacitance and
winding-to— ground capacitance (see Fig. 6).
In the case of a shielded transformer, the introduction III. CAUSE OF SURGES AND NOISE
of a grounded shield between the windings results in
much better attenuation to common-mode transients. The various causes of surge overvoltage and associated noise
The electrostatic charge around the primary winding is are well documented.
conducted to ground by the shield before it can induce 1) Lightning: Lightning can produce various modes of noise
voltage into the secondary winding. The small amount and transient disturbances as follows:
of coupling of the electrostatic field around the shield • lightning and common-mode noise;
is generally called “effective capacitance” and is • lightning-induced electrostatic coupling;
much smaller than the inter-winding capacitance • lightning-induced magnetic coupling;
of an unshielded transformer (see Fig. 7). • lightning-induced conductive coupling;
11) One or more of the following parameters can charac- • lightning and normal-mode noise.
terize noise distortion: 2) Power-Factor-Correction Capacitors: Oscillation fre-
• single impulses or oscillatory signals; quencies are in the range of 1–20 kHz.
• rise and/or fall times; 3) Power System Switching: Included are fault-clearing de-
• duration; vices and load switching and electronic switching de-
• rate of repetition; vices.
• amplitude; 4) Lighting Exposure and Surge Intensity: The probability of
• frequency. surge voltage exceeding specific peak values is related to
The attenuation is generally described in decibel (dB) units. the levels of lightning exposure, as shown in Fig. 8 [12].
The logarithmic relationship of dB to attenuation in volts or am-
peres is shown by IV. WAVE SHAPE OF SURGES
Working groups of IEEE and IEC Standards have developed
dB or dB (1) different standard surge waves for testing TVSS devices meant
for outdoor and indoor application locations to the low-voltage
Thus, 60 dB could be stated as power distribution system [16].
1) Outdoor: Combo Wave—1.2/50 s voltage wave and
8/20 s current wave are predominant at the service
resulting in:
entrance outdoor location. However, lightning discharges
226 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 37, NO. 1, JANUARY/FEBRUARY 2001
TABLE I
LOCATION CATEGORIES
4) Sine-Wave Tracking: New technology tracks the ac sine tablish the roadmap for analysis and solution to the problem of
wave; this enables response to minor spikes and transients voltage transients and associated high-frequency noise.
that may pass through other categories of protection de-
1) Develop a complete one-line diagram of the low-voltage
vices.
power distribution system showing main transformer,
5) Others: These include data/signal/telephone TVSSs and
main switchboard, subpanels, feeders distribution trans-
noise-filtering devices [15].
formers, type of loads, and metering devices at each
panel. Show control, data communication, and other sen-
VII. SURGE SUPPRESSOR TEST REQUIREMENTS
sitive loads at appropriate locations throughout the fa-
The second edition of UL Std. 1449 [9] has important changes cility in one— line representation (see Fig. 11).
affecting the test requirements for safety and performance of 2) Review the utility company incoming primary power
permanently connected TVSS products. This edition includes source grounding method and configuration in order to
the "end of life" mode testing, which could result in damage to select proper primary surge arrester to be located at the
products from a large surge event, a sustained overvoltage such primary side of the main power transformer.
as a loss of neutral, or installation error such as improper bonding 3) Establish an equipment layout sketch indicating
or misoperation. MOV element of TVSS can cause a short circuit raceway and wiring types, configuration, and approxi-
condition when its goes into a thermal runaway condition. If not mate lengths.
properly contained, equipment damage may result. 4) Review grounding, bonding, and shielding provisions of
The TVSS must pass the following tests without the evidence the distribution system as needed for equipment protec-
of risk of fire or electric shock [9]. tion, personnel safety, and high-frequency shielding of
1) Overvoltage: The TVSS must withstand 110% of rated data and control systems [6], [7].
voltage for seven hours. 5) Establish maximum continuous operating voltage at
2) Abnormal Overvoltage, Full Phase Voltage—High Cur- each main power distribution panel based upon the
rent: The TVSS must withstand 25 kA at full phase utility voltage regulation and the effect of the trans-
voltage of 208 V for 120 V and 480 V for 277 V. The former taps, if any.
overvoltage is applied for seven hours. 6) Perform three-phase and single-phase short-circuit anal-
3) Abnormal Overvoltage, Full Phase Voltage—Limited Cur- ysis to establish maximum expected short-circuit cur-
rent: The TVSS must withstand5 A (also 2.5, 0.5, and0.125 rent at all critical locations within the power distribution
A) at full phase voltage of208 V for 120 V and 480 Vfor277 system where TVSSs are to be applied.
V. The overvoltage is applied for seven hours. 7) Review facility site in association with configuration of
4) Voltage-Limiting Test and Duty Cycle (Pulse Life) Test: power distribution system and loads to determine the de-
The test is performed for L-L, L-N, L-G, and N-G con- gree of outside transient surge exposure as well as the
nections of TVSS subjecting an impulse surge of 6 kV internal switching surge propagation [3], [12].
and 0.5 kA, limiting voltage is measured and recorded. 8) Analyze power distribution system design for possible
The device is then subjected to ten consecutive 6-kV and ferroresonance condition which could lead to failure of
3-kA positive impulses at 60-s intervals, and ten consec- surge arresters [13].
utive 6-kV and 3-kA negative impulses at 60-s intervals. 9) For each location, establish the TVSS category type, pro-
Following the duty cycle test, the TVSS is subjected to an- tection modes, high-frequency noise-filtering require-
other 6 kV and 0.5-kA impulse and the limiting voltage ments, and the means of connection to the equipment
is measured and recorded. The average of the limiting that needs surge protection.
voltage test is to fall within the minimum suppressed 10) Establish TVSS local or remote monitoring require-
voltage ratings and is not to exceed the suppressed voltage ments.
rating by greater than 10%. 11) At Category A locations, make analysis of the choice
5) Surge Current Test: This test is designed to qualify each between the series-connected or the parallel-con-
device to withstand a standard Category C3 transient. The nected TVSS devices. This may require reviewing the
device must withstand two consecutive (one positive and problem with the equipment vendor to assure proper
one negative) 6-kV and 10-kA surge impulses (C3). After application.
testing, the device must stay connected to the service at 12) Review design of grounding, bonding, and shielding, a
rated voltage for seven hours or until thermal equilibrium. key element to the success of TVSS application [1].
13) Carefully review the TVSS vendor literature for each
VIII. TVSS APPLICATION APPROACH category for specific requirements and safety test re-
quirements [9]. If possible, contact the vendor to address
It is important that the application engineer has the basic un-
questions and concerns to obtain clarification of TVSS
derstanding of the published literature on transient surge over-
characteristics and performance specifications. TVSS
voltage environment and the surge wave shapes used in testing
performance criteria and specifications shall include at
the TVSS [17], [18].
least the following:
To avoid guesswork and misapplication of the TVSS, the ap-
plication engineer, perhaps, should develop his/her own list of a) surge current capability: performance, safety;
evaluation factors. These evaluation factors, in general, will es- b) fail-safe design;
228 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 37, NO. 1, JANUARY/FEBRUARY 2001
Fig. 11. Category classification defined by IEEE Std. C62.41 and IEC Std 664 for TVSS application.
c) UL listing, testing, and suppression voltage; merely by their surge-chopping and energy-absorption capa-
d) modes of protection; bility without proper application guidance and criteria. A new
e) EMI/RFI filtering capability; UL standard [9] requires their test withstand capability and
f) life-cycle testing; not all TVSSs could meet such requirements. With a thorough
g) monitoring features; understanding of the applicable standards, and knowledge of
h) short-circuit withstand capability and fusing surge propagation through the power distribution system, the
rating; design engineer should be able to make a proper selection of
i) response time. TVSS for the application.
Proper application of TVSS devices in a low-voltage power
distribution system may require all or a combination of the fol-
IX. CONCLUSION lowing.
To avoid guesswork and misapplication of TVSSs, an 1) Apply both primary and secondary surge-suppressor de-
engineering analysis of transient surge overvoltages and vices at the main transformer [13].
high-frequency noise is required. Application engineers must 2) Implement integrated surge-suppressor device at the
learn to evaluate the transient environment and should have main panel [11].
technical knowledge to fully understand the limitations of 3) Apply “cascaded network” approach [1], [13].
commercially available TVSSs for each specific location in 4) Apply power quality pyramid for design of distribution
the power system. Some manufacturers promote their TVSSs system [11].
PAUL: LOW-VOLTAGE POWER SYSTEM SURGE OVERVOLTAGE PROTECTION 229
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the facility.
Dev Paul (M’73–SM’90) received the B.Sc. degree
REFERENCES with honors in mathematics and the B.E. (Honors)
and M.S.E.E. degrees in electrical engineering from
[1] Recommended Practice for Powering and Grounding Sensitive Elec- Punjab University, Chandigarh, India, in 1965, 1969,
tronic Equipment, (Emerald Book), 1992. and 1971, respectively. He completed further studies
[2] The New IEEE Standard Dictionary of Electrical and Electronics Terms, in power systems at the University of Santa Clara,
5th ed., IEEE Std. 100, 1992. Santa Clara, CA, in 1975.
[3] F. D. Martzloff, “Matching surge protective devices to their environ- In 1972, he joined EARTH TECH (formerly
ment,” IEEE Trans. Ind. Applicat., vol. 21, pp. 99–106, Jan./Feb. 1985. Kaiser Engineers), Oakland, CA, as a Design
[4] , “Transient control levels, a proposal for insulation coordination in Engineer and has worked on a variety of heavy
low-voltage systems,” IEEE Trans. Power App. Syst., vol. PAS-95, pp. industrial, cogeneration, commercial, DOD and
120–129, Jan./Feb. 1976. DOE facilities, and rapid transit rail projects. In his present position as a
[5] , “Coordination of surge protectors in low-voltage ac power Principal Electrical Engineer, he is responsible for the overall design, analysis,
circuits,” IEEE Trans. Power App. Syst., vol. PAS-99, pp. 129–133, studies, specification, installation, project engineering, startup work, and
Jan./Feb. 1980. system integration. He has authored papers published in IEEE Industry
[6] , “The propagation and attenuation of surge voltages and surge cur- Applications Society (IAS) and APTA conference proceedings. His main fields
rents in low voltage ac circuits,” IEEE Trans. Power App. Syst., vol. of interests are power system analysis, protection, grounding, and harmonics.
PAS-102, pp. 1163–1170, May/June. 1983. Mr. Paul is an active member of several IAS Committees. He received the
[7] W. H. Lewis, “Recommended power and signal grounding for control Award of Distinction for his M.S.E.E. thesis work on power system stability.
and computer rooms,” IEEE Trans. Ind. Applicat., vol. IA-21, pp. He is a Registered Professional Engineer in the States of California, Nevada,
1503–1516, Nov./Dec. 1985. and Oregon.