Technical Paper

Demystifying surge protection standards AS1768:2007 vs.

IEC61643-11:2011

For immediate release

Although the benefits of surge protection are well documented, and are
especially prevalent now that Australian businesses and homes are inundated
with electronic products, confusion still exists regarding the differences
between the European and Australian standards that govern the use of surge
protection devices.

An effective surge protection system will increase safety and productivity from
fully functioning equipment, while helping to minimise loss of equipment in the
event of a surge.

As a manufacturer and distributor of European electrical and electronic

devices, including surge protection devices in Australia for over 40 years,
Weidmuller has worked with Australian Standards for all products to ensure
these are met. Two lots of paperwork are complied with, the European CE
and C-Tick (RCM) as well as ATEX and IECEX. As a manufacturer of surge
protection, we work with the current ASNZS1768 standards. In the future,
AS1768 may follow AS/NZS5033 for photovoltaic systems and adopt
IEC standards.

The AS1768:2007 and IEC61643-11:2011 standards covering point of entry

to a building is where these two standards primarily differ. Under Australian
standards, Category C protection requires an Imax value (1 shot peak
current) of between 40-100kA depending on the classification C1-C3. IEC
Class 1 devices all define Iimp values that are considerably lower. So what
is the difference?

Installation standards Table 1

Test impulse standards Table 2

Continues
The difference is the waveform used for testing. Under the rigorous IEC
scheme, all testing must be performed by a certified test laboratory. The
IEC 61643-11 uses a test waveform of 10/350µs for building entry protection
specified for Class 1 products. Both the Iimp and Imax are tested. The test
states that the Iimp value (impulse discharge current) is lower than the Imax
due to the waveform size and duration time, which exceeds the 8/20µs
waveform. This can be seen in Figure 1.

The Iimp value and Imax value rating are normally documented on datasheets
and product face as shown in Figure 2. The Iimp will nominally state a 25 to
35kA rating, which equates to an Imax of 100kA in our tests, with Iimp of
12.5kA equating to Imax of 50kA. So when using IEC tested Class 1 products,
the use of the Imax rating enables easy identification in line with AS1768 as
shown in Table 3.

Table 3

Figure 1

Figure 2

Two other important tests that Class 1 surge protection devices are required
to meet under IEC standards are the Temporary Over Voltage (TOV) and safe
failure mode for end of life. These tests help reduce fires and damage caused
from surge protection devices overheating.

Continues
Temporary Over Voltage is a major issue for surge protection devices and
can be catastrophic. Class 1 devices under IEC61643-11 must pass a TOV
test of 335V for 5 seconds, and 435V for 120 minutes based on a neutral
breakage. Passing these tests ensures there is no physical damage to the
housing, no electrical hazards created, the unit is still IP20 finger safe, can
disconnect safely if failed, and that it displays a visual indication.

In the case of safe disconnection, the Australian surge protection standards

require protective fusing of the device to ensure safe disconnection at end of
life, when the device could provide a short circuit to neutral/earth. This also
provides safe replacement or disconnection if the device is not pluggable and
requires wiring changes. This is no different for a Class 1 device under IEC
rules, with the added assurance the device will also safely disconnect in a
manner that ensures the surge protection device cannot cause a fire, or
damage the housing exposing electrical components, while providing
indication of failure.

With regards to fusing, an update to the Australian standards nominated

fusing to be specified by the manufacturer. However, IEC standards actually
require surge protection devices to be tested for the correct fuse rating.

During testing, the graph of fuse ratings listed in Figure 3 was developed to
determine the correct fuse rating for the device. Tests with NH type fuses and
8/20µs waveform indicated a 125A fuse was required to pass a 40kA surge.
Likewise for a 70kA impulse, a 200A fuse was required. Yet most 40kA surge
diverters are installed with 125A or smaller main fuses so this is not possible,
but the graph does enable the customer or designer to use a suitable fuse
rating for the protection required in the geographical area to be installed. A
surge protection device fuse cannot be larger than the main fuse and should
be a factor of 1:1.6 or approximately two sizes smaller. Too small a fuse will
be damaged or melted by a high surge current and disconnect the surge
protection. Too big a fuse may cause the main building fuse to fail instead of
the surge protection device at the end of its life.

Figure 3 Lighting current strength of NH fuses for surge currents 8/20µs.

It should also be noted that surge protection devices can operate effectively
for many years but will one day fail. A contact output on surge protection
devices will help alert users to the fact that the device needs replacing. A
buzzer or flashing light can be used to attract attention and have the device
replaced as soon as possible.

Continues
Category B/Class II and Category A/Class III models are also rigorously tested
under IEC requirements. Category B/Class II are tested to the 8/20µs test
pulse and rated in Imax value. Class II models still provide features of safe
disconnect with indication, over temperature, and TOV. Category A/Class III
models are tested by 8/20µs pulse and the Class D 1, 2/50µs.

Rest assured that the Imax can be used to determine the required value and
whether an IEC class I, II or III device can be used safely under Australian
standards. Ideally, a Class I device is suitable for use in a Category C
application for the best protection of point of entry, a Class II device for a
Category B application, and a Class III for Category A.

Standards play an important role to ensure safety in design and installation

of products, so installation of surge protection should always be in
accordance with AS/NZS 3000:2007 wiring rules and AS/NZS 1768:2007
surge protection standard.

About Weidmuller
Weidmuller is the world-leading provider of intelligent solutions for electrical
connectivity, transmission, conditioning and processing of power, signal and data
in industrial environments.

Dynamic and pioneering, Weidmuller has a long history in developing innovative

products in electrical connectivity and electronics that exceed market
expectations.

The Australian operation is a centre of excellence for the design and

manufacturing of the Group's electronics products, which deliver undisputed
quality and reliability.

Weidmuller Pty Ltd

43 Huntingwood Drive
Huntingwood NSW 2148
T +61 (0)2 9671 9999
F +61 (0)2 9671 9900
E info@weidmuller.com.au
W www.weidmuller.com.au