Professional Documents
Culture Documents
Norway
Sweden
Lithuania
Ireland Belarus
Netherlands Poland
United Kingdom
France
Belgium
Luxembourg
Blomberg, Germany
Czech Republic
Austria Slovakia
Russia
Ukraine Kazakhstan
Switzerland Hungary
Slovenia
infrastructure. USA
Portugal
Spain Italy
Croatia
Bosnia and
Herzegovina Kosovo
Montenegro
Romania
Serbia
Bulgaria Georgia
Azerbaijan China
South Korea
Japan
Macedonia Turkey
Greece
Tunisia Iraq
Lebanon
Morocco Cyprus Pakistan Taiwan
Mexico Israel Kuwait Bangladesh
Algeria India
Jordan Bahrain
Guatemala Egypt Qatar Sri Lanka
Honduras Saudi Arabia
Nicaragua Thailand Philippines
UAE
Costa Rica
Panama Venezuela Nigeria Oman Malaysia Vietnam
Ghana
Colombia Uganda Singapore
Kenya
Ecuador
Indonesia
Brazil
Peru Tanzania
Zambia
Bolivia Mozambique
Namibia Zimbabwe
Botswana
Paraguay
South Africa
Chile
Uruguay
Australia
Argentina
New Zealand
2 PHOENIX CONTACT
The basics of surge protection
We don't just want to support you with convincing solutions, but also
to be on hand with help and advice.This includes basic information
on the topics of technology and electronics that applies to all of
us. In this brochure, you will gain an insight into the field of surge
protection. Discover the most important facts in a nutshell. Discover
what solutions there are for the diverse challenges facing this sector.
Or deepen your knowledge of the context and background; something
only the specialists know.
We wish you – in the truest sense of the word – an exciting read!
PHOENIX CONTACT 3
Questions and answers
You probably have a great deal of questions – ranging from basic queries as
to how surge voltages even occur, to technical details about grid systems or
individual components of a surge protection concept, right through to the device
itself. Here you can refer to:
4 PHOENIX CONTACT
Contents
1. Surge voltages 6
1.1 The phenomenon of surge voltage 6
1.2 Causes 7
1.3 Coupling types 8
1.4 Direction of action 8
1.5 Effects 9
4. Quality features 22
4.1 CE declaration of conformity 22
4.2 Independent product certifications 23
4.3 Expertise in surge protection 24
6. Fields of application 28
6.1 Protection of AC systems 28
6.2 Protection of DC systems with linear voltage sources 40
6.3 Protection of photovoltaic systems 41
6.4 Protection of signal transmission circuits in MCR technology 46
6.5 Protection of signal transmission circuits in information technology 52
6.6 Protection of signal transmission circuits in telecommunications
technology 54
6.7 Protection of signal transmission circuits in transceiver systems 55
7. Glossary 56
8 References 59
PHOENIX CONTACT 5
The basics of surge protection | Surge voltages
1 Surge voltages
Various types of surge voltages occur in electrical plants and electronic systems. They are differentiated
mainly by their duration and power. Depending on the cause, a surge voltage can last a few hundred
microseconds, hours or even days. The amplitude can range from a few millivolts to some ten thousand
volts. The direct or indirect consequences of lightning strikes are one particular cause of surge voltages.
Here, during the surge voltage, high surge currents with amplitudes of up to some ten thousand amperes
can occur. In this case, the consequences are particularly serious. This is because the damaging effect first
of all depends on the power of the respective surge voltage pulse.
Every electrical device has a specific kilovolts, steep voltage increases and of time, can become a heavy financial
dielectric strength. If the level of a differences are often the consequence. burden – especially in comparison to the
surge voltage exceeds this strength, Surge protection is the only thing cost of a lightning and surge protection
malfunctions or damage can occur. Surge that helps. Indeed, the operator of an concept.
voltages in the high or kilovolt range electrical system generally replaces the
are generally transient overvoltages material damage to the system with
of comparatively short duration. They corresponding protection. However, the
generally last from a few hundred difference in time between failure of the
microseconds to a few milliseconds. system to maintenance represents a risk
As the maximum amplitude of such in itself. This failure is often not covered
transients can amount to several by insurance and, within a short period
6 PHOENIX CONTACT
The basics of surge protection | Surge voltages
1.2 Causes
Lightning strikes
It is above all lightning strikes (lightning
electromagnetic pulse, LEMP) that have
the greatest potential for damage among
all the causes of occurrence.They cause
transient overvoltages that can extend
across great distances and are often
associated with high-amplitude surge
currents. Even the indirect effects of
a lightning strike can lead to a surge
voltage of several kilovolts and result
in a surge current of tens of thousands Fig. 1: Lightning strikes have an extremely high potential for destruction
of amperes. In spite of the very brief
duration – a few hundred microseconds
to a few milliseconds – such an event circuits, very high currents can flow exchange leads to a brief surge voltage.
can lead to total failure or even the within a few milliseconds. These This presents a hazard, especially for
destruction of the affected installation. short- term current changes can lead to sensitive electronic components.
transient overvoltages.
Switching operations
Switching operations (switching Electrostatic discharges
electromagnetic pulse, SEMP) can Electrostatic discharges (ESD) occur
generate induced surge voltages that if bodies with different electrostatic
spread to supply lines. In the case potential approach each other and result
of large switch-on currents or short in a charge exchange.A sudden charge
Fig. 2: Electric motors with high power induce surge voltages due to high switch-on currents Fig. 3: Electrostatic discharges present a danger,
particularly to sensitive electronics
PHOENIX CONTACT 7
The basics of surge protection | Surge voltages
Surge voltages can reach a circuit in is located in this magnetic field, then
various ways. In reality, it is usually a according to the induction principle, a
case of an overlap between individual voltage difference occurs here due to
coupling types. the change in the magnetic field strength.
L/+ L/+
UQ
N/- N/-
UL UL
PE PE
8 PHOENIX CONTACT
The basics of surge protection | Surge voltages
1.5 Effects
The German Insurance Association increase of approximately 20% become is not just a case of having effective
(GDV) regularly publishes statistics, apparent. Insurers consider one of the protection for fire and personnel, but
allowing conclusions to be drawn on causes to be that ever more sensitive also about excluding the possibility of
the total losses resulting from various electronic devices are finding their large financial risk.
causes. Following fires and storms, way into households. On average, an A further aspect that will underline
lightning strikes and surge voltages cause individual strike or damage from a surge the need for lightning and surge
the most damage. In 2012, their share of voltage amounted to €800 in 2013. This protection in the future is the increase
damage to all insured items totaled 18%. is the highest level since statistics began. of lightning strikes, as shown by
In other words, almost a fifth of insured For non-private systems, however, the statistics. Various studies have already
damage can be traced back to a surge consequences of a failure are generally shown that as part of global climate
voltage. much more serious, such as downtimes change, the frequency of storms is set
Device failure or defects caused by or data loss. The failure of a device or to increase. This development is thereby
surge voltages are more frequent than a machine that is used in a professional not only limited to regions which have
expected. According to statistics from environment often leads to costs that not displayed a high risk of strikes to
the GDV, surge voltages are in fact are many times higher than repairing the date, but extends to all regions on Earth.
the most frequent cause of damage. defective device.
These figures only apply to damage that For example, if a mobile
resulted in fire. communication mast fails, the cost for
Fig. 6 shows that the proportion of the operator can lie in the range of
damage caused by lightning and surge several euros per second. Calculated
voltages in 2013 has dropped by 20% over the course of a day, this
in comparison to the previous year. corresponds to damages of more than
The financial payments by insurance €100,000.
providers, however, fell by just 10%. If For this reason, a consistent surge
the values from the comparable year of protection concept is urgently required
2010 are taken as a basis, then a cost for industrial and business systems. It
400,000
300,000
200,000
100,000
0
2006 2006 2008 2009 2010 2011 2012 2013
Fig. 6: Number of damage cases caused by lightning strikes and surge voltages and level of insurance payments
PHOENIX CONTACT 9
2 Surge protection: what should be noted?
Effective surge protection is not just simply installed. It has to be individually coordinated –
to the system that is to be protected and the ambient conditions that are prevalent on site.
For this reason, the design and concept must be consistent. This means many details must
be taken into account, from considering the standards and stipulations right through to
classification according to lightning protection zone.
Surge protection should ensure that The way in which the surge protection
surge voltages cannot cause damage to works can be easily explained by means
installations, equipment or end devices. of the equipment's power supply diagram
As such, surge protective devices (Fig. 7).
(SPDs) chiefly fulfil two tasks: As described in Section 1.4, a surge
• Limit the surge voltage in terms voltage can arise either between
of amplitude so that the dielectric the active conductors as normal-
strength of the device is not mode voltage (Fig. 8) or between
exceeded. active conductors and the protective
• Discharge the surge currents conductor or ground potential as
associated with surge voltages. common mode voltage (Fig. 9).
PE PE PE
Fig. 7: Schematic power supply of a piece of Fig. 8: Effects of a surge voltage as normal-mode Fig. 9: Effects of a surge voltage as common
equipment voltage mode voltage
10 PHOENIX CONTACT
With this in mind, surge protective
devices are installed either in parallel L/+
to the equipment, between the active L/+
conductors themselves (Fig. 10) or N/-
SPD
SPD
between the active conductors and the N/-
protective conductor (Fig. 11).
A surge protective device functions in PE PE
the same way as a switch that turns
off the surge voltage for a brief time.
By doing so, a sort of short circuit
occurs; surge currents can flow to
ground or to the supply network. The Fig. 10: SPD between the active conductors Fig. 11: SPD between active conductors and the
voltage difference is thereby restricted protective conductor
(Fig. 12 and 13). This short circuit of
sorts only lasts for the duration of
the surge voltage event, typically a few
microseconds. The equipment to be L/+
protected is thereby safeguarded and
L/+
continues to work unaffected. N/-
SPD
N/- SPD
PE PE
Fig. 12: SPD between the active conductors in Fig. 13: SPD between active conductors and
the case of normal-mode voltage the protective conductor in the case of common
mode voltage
PHOENIX CONTACT 11
The basics of surge protection | Surge protection: what should be noted?
2.2.1 Lightning protection cost for a lightning protection system that can be conducted away safely
according to IEC 62305 compare to the costs of potential depending on the lightning protection
damage without a protection system? level. This is described by means of
Part 1: Characteristics of lightning The cost evaluation is based on the Lightning Protection Levels I to IV.
strikes
outgoings for the planning, assembly, and
In Part 1 of this standard [1], the maintenance of the lightning protection
characteristic properties of lightning system.
strikes, the likelihood of occurrence, and
the potential for hazard are taken into Parts 3 and 4: Planning aids and
account. specifications
If the risk assessment determines that
Part 2: Risk analysis lightning protection is required and cost-
The risk analysis according to Part 2 of effective, then the type and scope of the
this standard [2] describes a process specific measures for protection can be
with which, first of all, the need for planned based on Parts 3 [3] and 4 [4]
lightning protection for a physical of this standard. The lightning protection
system is analyzed. Various sources of level determined by risk management is
damage, e.g., a direct lightning strike in decisive for determining the type and
the building, come into focus, as do the scope of the measures.
types of damage resulting from this: For physical structures that require an
• Impact on health or loss of life extremely high level of safety, almost all
• Loss of technical services for the strikes must be captured and conducted
public away safely. For systems where a higher
• Loss of irreplaceable objects of residual risk is acceptable, strikes with
cultural significance lower amplitudes are not captured.
• Financial losses Fig. 14 shows the lowest peak value of
The financial benefits are determined strikes that can still be captured safely as
as follows: how does the annual total well as the highest peak value of strikes
I 3 – 200 kA 99%
of lightning
II 5 – 150 kA 97 %
III 10 – 100 kA 91 %
IV
16 – 100 kA 84 %
i/[kA]
10 50 100 150 200
12 PHOENIX CONTACT
The basics of surge protection | Surge protection: what should be noted?
2.2.2 Surge protection Likewise, structural systems with an • Industrial or business activities, e.g.,
according to explosion risk as well as structural hotels, banks, production systems,
IEC 60364-4-44 applications that could cause damage farms
to the environment (e.g., petrochemical In all other cases, a risk assessment
This standard [5] describes the systems or nuclear power plants) are must be carried out in line with the
conditions in which surge protective not included in the application of the international standard.
devices are to be used in low-voltage standard. For these processes, lightning
systems to protect the electrical strike standard IEC 62305 is to be used
installation against surge voltages. The exclusively.
area of application is thereby limited to Surge protective devices should be
surge voltages caused by atmospheric used if transient overvoltages could have
influences or as a consequence effects on the following:
of switching procedures that are • Human lives, e.g., safety systems,
transmitted by the power supply system. hospitals
Direct lightning strikes in a structural • Public and cultural institutions, e.g.,
system are not considered, only strikes loss of public services, IT centers,
in or in the vicinity of supply lines. museums
In order to consistently protect a Lightning Protection Level is the basis The location of the interception units
structural system from lightning strikes for this. This is derived from the risk on the building also has to be decided.
and surge voltages, various protective analysis. If there are no regulations or There are three methods of doing so:
measures or equipment that are tailored specifications for the external lightning • Rolling sphere method
to one another are required. A broad protection, a minimum of Lightning • Protective angle method
division can be made as follows: Protection Level III is recommended. • Mesh method
• External lightning protection
• Internal lightning protection
• Grounding and equipotential bonding
• Coordinated SPD system
PHOENIX CONTACT 13
The basics of surge protection | Surge protection: what should be noted?
2.3.2 Internal lightning 2.3.3 Grounding and • Incorporate all lines that cross
protection equipotential bonding between different zones into the local
equipotential bonding using suitable
The internal lightning protection The grounding system aims to distribute SPDs
system should prevent dangerous spark and discharge the captured lightning • Coordinate different types of
formation inside the system. Sparks can current to ground. Here, the type of SPDs: the devices must address
be caused by lightning current in the grounding system is more important each other selectively in order to
external lightning protection system than the grounding resistance. The prevent individual components from
or in other conductive parts of the lightning current is a very short pulse overloading
structural system. that behaves like a high-frequency • Use short supply lines for the parallel
The internal lightning protection current. Effective equipotential bonding connection of SPDs between active
system consists of equipotential bonding is also important. Equipotential bonding conductors and the equipotential
and the electrical insulation of external connects all electrically conductive parts bonding
lightning protection systems. with each other via conductors – • Lay protected and unprotected lines
Lightning protection equipotential active conductors are protected by separately
bonding is a combination of measures surge protective devices. By doing so, • Only ground equipment via the
that prevent potential differences. They it protects against all types of couplings. respective SPD (recommended)
mainly connect the lightning protection
system to metal installations, internal 2.3.4 Coordinated SPD system
systems, as well as electrical and
electronic systems within the system. A coordinated SPD system is
This occurs by means of equipotential understood to be a multi-level system
bonding lines, surge protective devices of surge protective devices that are
or isolating spark gaps. coordinated with each other.
To insulate the external lightning The following steps are recommended
protection system, a minimum distance in order to achieve a high-performance
between electrical lines and metal SPD system.
installations must be kept, referred to • Divide the structural system into
as the separation distance. lightning protection zones
14 PHOENIX CONTACT
The basics of surge protection | Surge protection: what should be noted?
LPZ 3
Area inside the building which may
only be subjected to extremely low
or hardly any surge voltages or surge
currents and very weak or non-existent
electromagnetic fields.
PHOENIX CONTACT 15
The basics of surge protection | Classification and testing of surge protective devices
16 PHOENIX CONTACT
The basics of surge protection | Classification and testing of surge protective devices
PHOENIX CONTACT 17
The basics of surge protection | Classification and testing of surge protective devices
Normative surge current pulses steep. Consequently, the voltage-limiting manufacturer. This pulse shape contains
The voltage-limiting function of the SPDs function of the SPD must be applied at several times the electrical load in
is tested using surge currents with a very short notice. comparison to the (8/20 μs) pulse shape,
pulse shape of (8/20 μs) (Fig. 19), i.e., SPDs that are designed to protect at the same amplitude. It therefore
with a rise time of 8 μs and a decay time against direct lightning currents are places a considerably higher load on the
to half value of 20 μs. This particularly additionally loaded with surge currents SPD in terms of energy.
dynamic pulse shape also provides with a pulse shape of (10/350 μs)
information regarding the response (Fig. 20).
behavior of the SPD. The voltage rise The maximum amplitude is based on the
associated with this surge current is very pulse discharge current specified by the
100 100
I 90 I
(%) (%)
60
50
30
10 10
0 0
8 10 350
20 t (µs) t (µs)
To achieve high system availability, systems – internal and external a lightning protection expert. Inspecting
system operators must regularly lightning protection – is required as the SPDs is also part of this. The
inspect and maintain their electrical part of lightning protection standard standard also demands that maintenance
systems (Table 1). This is stipulated by IEC 62305- 3 [3], also in Appendix E.7. is properly documented. The three
legislators, supervisory authorities or Specialist knowledge is required in following points are particularly
professional associations based on the order to carry out professional testing important to note:
respective system type. Regular testing of lightning protection systems. For this
and maintenance of lightning protection reason, this test must be carried out by
I and II 1 2 1
III and IV 2 4 1
18 PHOENIX CONTACT
The basics of surge protection | Classification and testing of surge protective devices
3.3.2 CHECKMASTER 2
test device
PHOENIX CONTACT 19
The basics of surge protection | Classification and testing of surge protective devices
SPD
current
conditions, as well as the surge voltage generator
Power supply system
events.
Fig. 22: Resistance and inductance on the high- and low-voltage side of the Fig. 24: Testing stations of the high-current testing system
testing transformer
20 PHOENIX CONTACT
The basics of surge protection | Classification and testing of surge protective devices
Fig. 25: Fully automated testing system for determining the overload and Fig. 26: Lightning surge current generator
failure behavior of surge protective devices according to IEC 61643-11 [6]
PHOENIX CONTACT 21
The basics of surge protection | Quality features
4 Quality features
The quality and performance of surge protective devices are hard for a customer to
assess. Correct functioning can only be tested in suitable laboratories. Besides the
external appearance and haptics, only the technical data provided by the manufacturer
can provide any guidance. Even more important is a reliable statement from the
manufacturer regarding the performance of the SPD and the execution of the tests
specified in the respective product standard from series IEC 61643.
22 PHOENIX CONTACT
The basics of surge protection | Quality features
A true mark of quality is a product and therefore also the confirmation of for the European Economic Area. It
certification from an independent performance specifications is becoming is the same as the CE declaration of
testing institute. These can also confirm increasingly important. conformity and can also be extended on
fulfillment of the respective product this basis.
standard. Furthermore, they can also KEMA, VDE, ÖVE, and more
document additional characteristics This seal, issued by independent testing GL, ATEX, IECEX, and more
of the products, such as resistance to institutes, confirms that the current These approvals verify the behavior
the effects of shocks and vibrations or version of the respective product of the products in specific ambient
safety requirements of specific domestic standard from the IEC 61643 series is conditions.
markets. fulfilled. GL certifies the products' resistance
The regulatory requirements to external influences in the maritime
placed on SPDs sometimes require UL, CSA, EAC, and more environment as well as at sea, e.g.,
highly complex tests that only a few These approvals are examples of the shocks, vibrations, humidity or salt
testing laboratories in the world are requirements of specific domestic concentration levels.
fully capable of carrying out. For ever markets. ATEX and IECEx in turn confirm the
more manufacturers and providers of What's more, in their own standards, products' suitability for use in potentially
SPDs, specifically in the lower pricing UL and CSA place safety requirements explosive areas, such as those that
segment, the specifications regarding on the products for the North American frequently arise in the process industry.
the performance of the devices are markets or areas influenced by American
also to be taken into account. As such, markets. In contrast, EAC is rather an
the independent certification of SPDs administrative approval of the products
PHOENIX CONTACT 23
The basics of surge protection | Quality features
Application know-how • Develop and master innovative basic Measures to ensure quality are critical
The further development of electrical technologies and should be carried out in series
systems and system technology always • Structure development processes manufacturing as part of routine
leads to new technologies, and as a • Develop new protection concepts testing. For surge protective devices,
consequence of this, to completely as well as devices with tailor-made destructive testing that records the
innovative technical solutions that place properties product characteristics right to the
very specific requirements on surge performance limit and beyond can
protection. One example is the system Testing and certification be useful. In this way, any possible
technology that is used for renewable Testing systems that simulate real deviations in manufacturing processes
energies (photovoltaics and wind conditions are essential in order to and consequently in product quality can
power). For this reason it is important develop surge protection concepts and be detected at an early stage.
to really understand the system to be devices. This also applies to technical
protected and its environment, in order laboratory trials.
to develop tailor-made surge protective
devices. Manufacturing and quality
assurance
Research and development Manufacturing surge protective devices
The basis for ongoing development is suitable for the market with the highest
intensive commitment to fundamental quality levels demands that many aspects
research and technological development. relating to processes and procedures
The following tasks are part of this: are taken into account during the
• Determine the precise requirements development phase of these products.
placed on surge protective devices This requires early interlinking of
(protection objectives) product development activities with
• Make new, appropriate materials process and procedure development.
available for applications
24 PHOENIX CONTACT
The basics of surge protection | Quality features
Fig. 30: Quality assurance in the production process Fig. 31: Realistic testing conditions
PHOENIX CONTACT 25
The basics of surge protection | The lightning monitoring system
The LM-S lightning monitoring system can detect and analyze lightning strikes in real
time. It provides information online about the intensity of the strike based on the
typical lightning parameters. By consolidating the system operating parameters and
the measuring data, the system provides a better basis for making decisions regarding
control and maintenance.
Lightning strikes can cause devastating destruction to the system is often only
damage to buildings and systems. They monitored once consequential damage
can result in extensive destruction that has occurred.
can also have consequential damage. As a result, smart monitoring
The damage is dependent on the systems are used more and more.
power and location of the strike. But They constantly monitor the different
the design of the lightning and surge functions in a system. They immediately
protection concept has a bearing on the report results to a central control
extent of the damage. unit. This helps the system to react
Systems that are particularly at risk immediately to errors and thereby to
of lightning strikes are those in exposed prevent consequential damage as well as
locations or with a large surface area, long downtimes.
e.g., wind turbine generators, power
plants, industrial operations covering
a large area, and rail systems. In such
systems, complete lightning protection
is generally very difficult, or even
impossible, to implement. Damage or
26 PHOENIX CONTACT
The basics of surge protection | The lightning monitoring system
The LM-S lightning monitoring system If lightning strikes are measured in wind
(Fig. 32) has the option of lightning turbines or buildings, conclusions can
current detection: if a strike hits the be drawn at any time from the relation
lightning interception rod, a magnetic between the lightning parameters and
field is created around the protective the destruction associated with this.
device that carries the lightning current. Furthermore, the evaluation enables
The LM-S uses the Faraday effect to conclusions to be drawn about the
measure this current. As such, the light efficiency of the lightning protection
is polarized in the measuring path of system.
the sensor. The magnetic field resulting Lightning information systems are
from the lightning strike makes the also used to collect information on
previously polarized light measurable lightning strikes for claims settlement.
(Fig. 33). The system transmits the These systems can locate a lightning
light signal from the sensor via fiber strike with a precision of up to 200 m.
optics to the evaluation unit. The Whether and at what point the lightning
characteristics of the lightning events – strikes a building or system can only be
maximum amplitude, lightning current determined with a lightning monitoring
slope, specific energy, and charge – are system – such as the LM-S.
detected and stored along with the date Fig. 33: Operating principle, Faraday effect
and time of the lightning strike.
PHOENIX CONTACT 27
The basics of surge protection | Areas of application
6 Fields of application
The IEC 61643 product standard divides applications where surge protective devices
are used into low-voltage systems, telecommunications and signal processing networks,
as well as photovoltaic installations. In general, all areas have very different individual
system prerequisites. Correspondingly, all the solutions or steps involved can vary
greatly. It is worth examining these applications in closer detail.
SPD
SPD
28 PHOENIX CONTACT
The basics of surge protection | Areas of application
The multi-level functionality limits the Nominal voltage of the Conductor-neutral Rated
lightning protection level from zone power supply system conductor voltage surge voltage
to zone. The amplitudes and specific (mains) according to derived from the total
energies of the surge voltages or surge IEC 60038 nominal AC voltage Overvoltage category
currents to be expected gradually or nominal DC
Three- Single- voltage
decrease. The voltage value to which I II III IV
phase phase
the individual SPDs must limit the
V V V V V V V
surge voltages also decreases. This is
achieved by correspondingly low voltage 50 330 500 800 1500
protection levels: their upper limits 100 500 800 1500 2500
are based on the dielectric strength 120 – 240 150 800 1500 2500 4000
of the equipment to be protected in
230/400
the immediate vicinity. The dielectric 300 1500 2500 4000 6000
277/480
strength is specified according to
400/690 600 2500 4000 6000 8000
IEC 60664-1 [9] in the overvoltage
categories I to IV (Table 3). 1000 1000 4000 6000 8000 12,000
Table 3: Overvoltage categories based on the nominal voltage
6.1.2 Type 1: lightning current
arrester
lower the energy input to be managed.
Type 1 surge protective devices must With regard to the abrupt change of
fulfil the highest requirements in terms impedance, and therefore also the
of amplitude and specific energy from voltage difference across the spark gap,
surge voltages or surge currents, as they the non-linear characteristic is referred
are supposed to protect from direct to as voltage-switching. A significant
lightning strikes. In the typical installation advantage that arises from the low
environment of the main distribution, residual voltage is the low load on the Fig. 36: Equivalent circuit of an enclosed spark
the demand placed on the short-circuit equipment to be protected as a result gap
withstand capability is often very high. of voltages above the specified nominal
In order to be able to meet these voltage or maximum continuous voltage.
requirements, powerful technology is For the comparatively long duration of the dielectric strength of the air alone.
required, e.g., spark gap technology. lightning currents, the residual voltage Even if the installation environment
of a spark gap is very low, in the range of type 1 SPDs does not generally
Spark gap technology of the maximum continuous voltage require it, the voltage protection level
The operating principle of a spark gap of the device to be protected. Type 1 of modern, triggered spark gaps is often
is initially very simple: two electrodes SPDs with voltage-limiting components at the level of the lowest overvoltage
are placed at a specific distance from are often several hundred volts over category I (based on the nominal voltage
each other and create an insulating state this – a significantly greater load for the of the system).
(Fig. 36). If there is a voltage present protected equipment.
between the two electrodes that causes Modern spark gaps are generally
the dielectric strength of the air (approx. encapsulated in robust, enclosed steel
3 kV/mm) in this space to exceed the housings, so that during the discharge
surge voltage, then an electric arc is process, no ionized gases generated
formed. In comparison to the insulating by the electric arc can escape into the
state with an impedance in the giga-ohm environment. Furthermore, spark gaps
range, the impedance of the electric arc are often triggered:
is extremely low and so, therefore, is the They have additional wiring to support
voltage drop across the spark gap. the through-ignition of the spark gap.
This characteristic is ideal for This limits the voltage protection level
discharging lightning currents: the lower to a very low level – significantly lower
the residual voltage of the spark gap, the than the voltage that results based on
PHOENIX CONTACT 29
The basics of surge protection | Areas of application
Enclosed Electric-arc-cooling
steel housing insulating parts
30 PHOENIX CONTACT
The basics of surge protection | Areas of application
Varistor technology
Varistors (variable resistor or
V 2000
metal oxide varistor, MOV) (Fig. 39) are
semiconductor components made from 1000
metal oxide ceramics. They exhibit a
non-linear current-voltage characteristic 800
PHOENIX CONTACT 31
The basics of surge protection | Areas of application
6.1.4 Type 3: device protection 6.1.5 Coordinating In the direction of the external
different SPD types protection zones, the coordination
Type 3 surge protective devices are between type 2 SPDs and upstream type
generally installed right in front of the The lightning protection zone concept 1 SPDs must once again be ensured.
terminal device to be protected. Due to provides coordinated surge protective As the possibility of direct lightning
differing installation environments, type devices for all lines that cross between strikes or partial lightning strikes must
3 SPDs are available in a very wide range zones. Their power values are based on be considered here, which can only
of designs. For example: in addition to the protection class to be achieved. be borne by type 1 SPDs, selective
standard DIN rail mounting, there are Depending on the zone transition, addressing of the SPDs is particularly
devices for installation in sockets or for different types are therefore required important otherwise the type 2 SPDs
direct mounting on a PCB of the end (refer to Table 2). The requirements for could be overloaded.
device. individual SPD types are defined in the As the technologies used for type 1
Technologically speaking, type 3 SPDs product standard for surge protective SPDs are very different, there are no
are most similar to type 2, which are devices, IEC 61643-11 [6]. general conditions for coordination.
based on varistors, but the requirements A multi-level protection concept can Type 1 SPDs based on spark gaps
in terms of nominal discharge capacity in be derived from this (Fig. 42). provide a clear advantage in this area.
comparison to type 2 are even lower. Starting from the internal protection Their comparatively low residual voltage
Often it is sensible to link the zones, a type 3 SPD and an upstream of just a few hundred volts throughout
protection of the power supply to type 2 SPD are to be coordinated. It most of the duration of the lightning
the protection of other interfaces must be ensured that type 3 SPDs are current ensures the current flow is
in the terminal device, such as data not overloaded in terms of energy. Since almost completely transitioned.
communication lines. There are surge voltages of a lower amplitude are
combined devices for this purpose. They expected in this area of the protection
take on the surge protection for all zone concept, selective addressing is
corresponding (supply) lines. already guaranteed by a Uc of the type 3
SPD, which is greater than or equivalent
to the type 2 SPD.
HV
SPD
SPD
SPD
Type 2
SPD
SPD
SPD
Type 2/3
32 PHOENIX CONTACT
The basics of surge protection | Areas of application
PHOENIX CONTACT 33
The basics of surge protection | Areas of application
SPD
SPD
SPD
SPD
in the Northern and Central American N, and GND (Fig. 48).
regions. The most important are:
• Wye system Split-phase system
• Delta system This widely used two-phase system
• Split-phase system is grounded by means of a center tap
between the two phases and a neutral
Wye system conductor is routed from there. A PE
These systems correspond to the two- phase power supply consists of
TN systems; the neutral point of four conductors: L1, L2, N, and GND Fig. 50: CT1 connection scheme or 4+0 circuit
the supplying transformer is directly (Fig. 49).
grounded and from there, the protective
conductor (grounding conductor, GND) 6.1.8 Connection scheme
is routed to the consumer system. L1 L2 L3 N
Insulated wye systems do also exist, but Surge protective devices are part of the
there are comparably few. A possible equipotential bonding of a structural
SPD
SPD
SPD
neutral conductor is generally first of system. In the event of a surge voltage,
all tapped within the consumer system. they connect the active conductor
This then corresponds to a TN-C-S in electrical installations with the
system. A three-phase power supply grounding.
SPD
consists of four or five conductors: Depending on the grid system of the
L1, L2, L3, if appropriate, N, and GND consumer system, different SPDs can
(Fig. 47). be used. They are combined in various PE
connection schemes (CT), to establish
Delta system this connection. In the installation Fig. 51: CT2 connection scheme or 3+1 circuit
These systems have no direct equivalent directive for surge protection,
according to IEC. Grounding either takes IEC 60364-5-53 [11], the following types
place via one of the phases (corner- are specified:
grounded) or via a center tap between • CT1 connection scheme: a number of active conductors (Fig. 50).
two phases (high-leg). The GND is combination of SPDs that have a • CT2 connection scheme: a
routed from the respective grounding mode of protection between each combination of SPDs that have
point to the consumer system. Insulated active conductor (outer conductor a mode of protection between
delta systems do also exist, but there and neutral conductor, if present) each outer conductor and neutral
are comparably few. and PE conductor. This connection conductor and a mode of protection
The neutral conductor is, if required, scheme is often designated as a x+0 between the neutral conductor and
also usually tapped within the consumer circuit, whereby x represents the the PE conductor. This connection
L1
L1
L1
N
L2 N
L2 L3 L2
L3 N
GND GND GND
Fig. 47: Wye system Fig. 48: High-leg and corner-grounded delta Fig. 49: Split-phase system
system
34 PHOENIX CONTACT
The basics of surge protection | Areas of application
scheme is often designated as a x+1 6.1.9 Connection and In the case of branch wiring, the SPD
circuit, whereby x represents the overcurrent protection can or must be protected depending on
number of outer conductors (Fig. 51). of SPDs the nominal value of the F1 upstream
The possible uses of this connection overcurrent protective device, with a
scheme in the individual grid systems are If transient overvoltages occur, an second additional overcurrent protective
listed in Table 4. inductive voltage drop can result on the device, F2, with a lower nominal value.
electrical conductors. This additional This wiring enables use in systems
voltage drop in the connecting cables with nominal currents of any strength,
can weaken the protective effect, provided the prospective short-circuit
particularly when connecting surge current on the SPD installation location
protection in parallel to the equipment does not exceed its short-circuit
to be protected. With this in mind, the withstand capability.
SPD connecting cables are always laid The V-wiring, however, can only
as short as possible with the largest be used up to a nominal value of the
possible bending radii. upstream overcurrent protective device
CT2 connection scheme SPDs can essentially be connected in
Phoenix Contact mainly provides two different ways:
SPDs with the CT2 connection • Branch wiring (stub wiring), refer to
scheme for TN and TT systems. Fig. 52
The advantages of this connection • V-wiring (V-shaped wiring), refer to a
type are: Fig. 53
• Can be used universally in all In both cases, the total of the cable
countries worldwide lengths a, b, and c, must not exceed
b
• Lower voltage protection level 0.5 m. In the case of the V-wiring, this is
between outer and neutral particularly easy to ensure, as here only
SPD
conductor length c is of relevance. As such, even
• No leakage current to the the overall protection level (consisting of c
protective conductor due to the voltage protection level of the SPDs
the use of spark gaps between and voltage drop over the connecting
the neutral and protective cables) can be minimized as much as
conductor possible.
Connection scheme
Grid system at
the SPD installation location
CT1 CT2
TN system
Only downstream of a
SPD
PHOENIX CONTACT 35
The basics of surge protection | Areas of application
F1 or a nominal current of the system protective conductor for type 1 upstream overcurrent protective
that does not exceed the continuous SPDs: min. 16 mm2 devices.
current capacity of the connecting cables – Connection cross section of the • The final overcurrent protective
and the connection terminal blocks of main grounding busbar or the device before the SPD must not
the SPD. protective conductor for type 2 exceed the maximum nominal
As part of the electrical installation, SPDs: min. 6 mm2 value of the upstream overcurrent
corresponding legal or regulatory • Over a specific nominal value of the protective device as specified by the
requirements are to be fulfilled for the upstream overcurrent protection, the SPD manufacturer.
connection and overcurrent protection minimum cross section is determined • The upstream overcurrent protective
of surge protective devices that by the connecting cables' need for device should, as far as possible, be
principally aim to ensure the operational short-circuit withstand capability able to bear the required amplitudes
reliability of the system. Furthermore, • If the SPD connecting cables of lightning and surge currents,
for correct functioning of the surge carry operating current, then the depending on the Lightning Protection
protection, specific conditions are to continuous current load can be used Level. In particular with regard
be taken into account with regard to to determine the minimum cross to high-energy lightning currents,
connection and fuse protection. section as of a certain current value under- dimensioned fuses can pose
The requirements are based on a risk, as they can be destroyed in a
various parts of IEC 60364 for creating Overcurrent protection very short time due to high-energy
low-voltage systems: on the one When designing the overcurrent inputs.
hand, Part 5, Section 53, Main Section protection of SPDs, the various elements Adhering to the selectivity is therefore
534 [11], regarding the selection and must first be prioritized: the top priority. In the simple case
setup of surge protective devices, and • Priority of the system supply: that the two overcurrent protective
on the other, Part 4, Section 43 [12], Branch wiring with separate F2 devices to be taken into account are gG
regarding protective measures against overcurrent protective device in the fuses, then a nominal value of 1250 A
overcurrent, as well as the product branch applies, which must be F2 × 1.6 ≤ F1.
standard for surge protective devices, • Priority of the system surge If one or both of the overcurrent
IEC 61643-11 [6]. protection: V-wiring or branch wiring protective devices is a circuit breaker,
without separate F2 overcurrent then their tripping characteristics must
Connection cross sections protective device be compared with each other or with
If these requirements are combined, this In the first case, the separate F2 the fuse characteristics and, if applicable,
results in the following conditions for overcurrent protection equipment tailored to each other, so that the
dimensioning the connecting cables of ensures that in the event of the failure curves are not affected (Fig. 54 and 55).
SPDs (based on PVC-insulated copper of the SPD (e.g., a short circuit), the F1 In areas with short-circuit currents,
cables): upstream overcurrent protective device they must have a sufficient time interval,
• The minimum cross sections for does not trigger and that the supply to so that the respective downstream
the SPD connecting cables first of the equipment to be protected is not overcurrent protective device can
all result from the requirements for interrupted. In this case, however, the address the other and switch off.
installing surge protective devices, equipment is no longer protected from A similar scenario applies in the
depending on the active conductor subsequent overvoltage events. event that a circuit breaker should
connection or the main grounding In the second case, the F1 upstream represent the overcurrent protection
busbar/the protective conductor overcurrent protective device takes on for the SPD as F1, without a separate
(PE(N)) as well as the type of the the overcurrent protection in the event F2 overcurrent protective device.
SPD: that the SPD fails. The failure of the Then, the switching- off characteristics
– Connection cross section of the supply is hereby accepted, so that no of the switch must be compared with
active conductor for type 1 SPDs: damage can be caused by subsequent the characteristics of the maximum
min. 6 mm2 overvoltage events. overcurrent protection specified for
– Connection cross section of the When dimensioning the overcurrent the SPD by the manufacturer. This
active conductor for type 2 SPDs: protection, the following points should must not be exceeded in the range for
min. 2.5 mm2 be kept in mind: short- circuit currents.
– Connection cross section of the • Selectivity of the respective
main grounding busbar or the overcurrent protective device to
36 PHOENIX CONTACT
The basics of surge protection | Areas of application
Circuit
Fuse breaker
1h Circuit breaker 1h Fuse
Trigger Trigger
time 10 min time 10 min
1 min 1 min
10 s 10 s
1s 1s
100 ms 100 ms
10 ms 10 ms
1 ms 1 ms
1 ms 1k 10 k 100 k 100 1k 10 k 100 k
Current (A) Current (A)
Fig. 54: Switching-off characteristics of a circuit breaker (F1) and a selective Fig. 55: Switching-off characteristics of a circuit breaker (F1) that is suitable
gG fuse (F2) as an upstream overcurrent protective device for an SPD with a maximum
backup fuse of 315 A gG
PHOENIX CONTACT 37
The basics of surge protection | Areas of application
Impact-free and durable type 1 spark gap and type 2 varistor the voltage level of the supply, there are
A consistent surge protection concept arrester in a confined space. All products various SPD types and circuit versions.
requires a powerful type 1 lightning in the SEC portfolio are pluggable, If, for example, it is a three- phase
current arrester. Conventional making maintenance a great deal easier. 230/400 V AC TN-C system, the
type 1 line follow currents load the FLT-SEC-P-T1-3C-350/25-FM is ideal
installation with high line follow 6.1.11 Multi-level protection (Fig. 58).
currents that can lead the upstream concepts Alternatively, the protective device
overcurrent protection to trigger. combination of FLASHTRAB SEC T1+T2
The SEC technology lightning current Thanks to the SPDs from the SEC range, (Fig. 59) can also be used here. This
arresters are the first to feature multi-level protection concepts can be directly coordinated combination of a
spark gap technology with no line very easily put together for standard type 1 SPD on a spark-gap basis and a
follow current. The avoidance of line installations. Parameters such as the type 2 SPD on a varistor basis provides
follow currents benefits the entire maximum continuous voltage, voltage many advantages when used directly in
installation. This means that not only protection level, and discharge current, the main distribution.
the protected equipment, but the entire are ideally tailored to one another. In the further sub-distributions of
supply, including the SPD, are placed the production system, for machine
under minimal load by the discharge Industrial production system with halls and office rooms, the protective
external lightning protection
process. Maximum system availability is zone transition is provided by 1 2,
system
guaranteed because the fuse protection thanks to a type 2 SPD from the
upstream is not triggered. The protective zone transition 0A 1 VALVETRAB SEC product range.
is provided by a type 1 SPD from the A supply as a TN-C system, as
Backup-fuse-free solution for every FLASHTRAB product range at the point assumed in this example, is generally
application where the supply lines enter the building already converted into a TN-S
The powerful lightning current arresters in the area of the low-voltage main system in the main distribution, so
and surge protective devices with Safe supply. Depending on the grid system, that the remaining installation is
Energy Control technology provide the connection type to be selected, and implemented with separately laid
a solution without separate arrester
backup fuse for all common applications.
For applications where protecting the
installation is the top priority, type 1 and
type 2 SPDs can be used for main fuse
ratings of 315 A gG without separate
11 12
38 PHOENIX CONTACT
The basics of surge protection | Areas of application
FLASHTRAB SEC
The type 1 SPDs from the availability, as upstream overcurrent
FLASHTRAB SEC family all use protection systems are not triggered
the spark gap technology that is as part of the discharge process.
free of line follow currents. They
thereby guarantee maximum system
Fig. 58: FLT-SEC-P-T1-3C-350/25-FM
FLASHTRAB SEC T1+T2
The unique SPD combination on the • Varistor arrester to limit dynamic
market, FLASHTRAB SEC T1+T2, surge voltages
optimally protects sensitive equipment • Optimum energy distribution
by means of: between the protective levels
• Powerful spark gap to discharge
direct lightning currents Fig 59: FLT-SEC-T1+T2-3C-350/25-FM
VALVETRAB SEC
The VALVETRAB SEC T2 impresses up to 315 A gG. It is also possible to
above all due to the powerful, internal operate it at the location installation
thermal disconnect device, in addition with prospective short-circuit
to the narrow design – just 12 mm currents up to 50 kA.
per pole. The SPD can therefore be
used without a further backup fuse Fig. 60: VAL-SEC-T2-3S-350-FM
PLUGTRAB SEC
The PLUGTRAB SEC T3 has enables connection in branch wiring
integrated surge-current resistant without separate backup fuse,
fuses. As such, it can be used with irrespective of the nominal current
end devices operated with both and the protection of the circuit.
alternating current and direct current.
The integrated overcurrent protection Fig. 61: PLT-SEC-T3-230-FM
PHOENIX CONTACT 39
The basics of surge protection | Areas of application
The operating behavior of different Selecting surge protective devices • Nominal voltage of the DC power
direct current systems with linear source Selecting SPDs for direct current source(s)
characteristics can vary greatly from one systems is generally significantly more • Number, type, and operating behavior
to another. It is therefore impossible to complex than for alternating current of the DC power source(s)
easily select surge protective devices power supply systems. • Maximum and minimum prospective
without precise knowledge of the In the case of AC power supply short-circuit current at the SPD
respective systems. This particularly systems, there is often only one power installation location
applies to systems with limited or low source; for DC systems, however, there
short-circuit currents. are often multiple power sources with Protective circuits for grounded
and non-grounded DC systems
Direct current power supply systems different operating behaviors. This
with linear source characteristics are particularly applies to battery-operated The preferred circuits for SPDs in DC
mainly used for: DC systems. systems conform to the CT1 connection
• Loads with low direct current power In the majority of AC systems, the type (refer to Fig. 50) and are either
supply, e.g., programmable logic minimum short-circuit current is high designed with one or two poles.
controllers or telecommunication enough to cause upstream overcurrent A 2+0 circuit is also required for
systems protective devices to trigger in a few grounded TN systems if the installation
• Mobile loads, e.g, fork-lift trucks or milliseconds. In the case of DC systems location of the SPDs is far away from
onboard power systems with limited or low short-circuit the system's grounding point (Fig. 64).
• Battery storage in UPS systems currents, however, it is very important
• Computer centers that even minimal prospective short-
• Rail vehicles circuit currents at the SPD installation
Typical power sources of direct current site are detected, in order to meet basic
power supply systems with linear source safety requirements.
characteristics are: Significant design criteria for the
• Controlled and non-controlled selection of SPDs and corresponding
rectifiers with or without smoothing overcurrent protective devices in DC
• Regulated power supply units systems are:
• Charging power supply units
• Battery sets
F1 F1
L+ L+
F1 F1
L+ L- L-
F2 F2 F2 F2 F2
SPD
SPD
SPD
SPD
SPD
L-
PE PE PE
Fig. 62: 1+0 circuit for grounded TN systems at Fig. 63: 2+0 circuit for IT systems Fig. 64: 2+0 circuit for grounded TN systems
the grounding point that are far away from the grounding point
40 PHOENIX CONTACT
The basics of surge protection | Areas of application
The increasing number and variety typical behavior of the photovoltaic The combination of switching and
of versions of photovoltaic systems system are carried out. This is because, limiting components in series and parallel
presents a new challenge in terms of under almost all operating conditions, arrangements is also taken into account.
safety and reliability. This applies to all the panels of a photovoltaic generator Table 6 provides the required values for
photovoltaic systems, such as rooftop provide an almost constant current that the discharge capacity of voltage-limiting
systems on single-family dwellings, off- is at the same time close to the short- and combined SPDs that are switched in
grid systems or free-standing systems. circuit current of the system. series in structural systems.
Photovoltaic systems are often Voltage-limiting components or
subjected to tough weather conditions, CLC/TS 50539-12 installation combined SPDs can thereby function as
such as the effects of lightning, due to directive varistors or varistors and gas-filled surge
their exposed location. In order for In addition to the product standard, protective devices in series connection
the systems to be able to continue to there is also the CLC/TS 50539-12 [13] (Fig. 65).
operate safely and profitably, installing installation directive. This provides
lightning and surge protection is key information for the installation of
recommended. Thanks to special photovoltaic systems in the field. The
standards and installation directives, it directive differentiates between free-
is possible to optimally plan and install standing systems and structural systems
photovoltaic systems. (rooftop systems).
In the installation directive, there is a
IEC 61643-31 – requirements and differentiation between voltage-switching
test methods for surge protective and voltage-limiting components.
devices in photovoltaic systems
Thanks to the IEC 61643-31 [8] product
standard, it is possible to qualify lightning
and surge protective devices according
to their operating behavior and thereby
guarantee the quality and safety of
these products. The standard describes
testing procedures for SPDs for use in
photovoltaic systems and takes into
MOV MOV + GDT in series
account the peculiarities of the DC
voltage and its properties. Among other
things, special tests that replicate the Fig. 65: Examples of voltage-limiting components or combined SPDs in series connection
Table 6: Values for I10/350 and I8/20 for voltage-limiting and combined SPDs
(voltage-switching and limiting components in series)
PHOENIX CONTACT 41
The basics of surge protection | Areas of application
Table 7: Values for I10/350 and I8/20 for voltage-switching and combined SPDs
(voltage-switching and limiting components in parallel)
PE
42 PHOENIX CONTACT
The basics of surge protection | Areas of application
III or IV 150 kA 5 kA 10 kA 15 kA 30 kA 10 kA 20 kA
Table 8: Values for I10/350 and I8/20 for SPDs to protect a photovoltaic free-standing power system with several grounding points and a meshed grounding
system
PHOENIX CONTACT 43
The basics of surge protection | Areas of application
Building installation the external lightning air-terminal. units, comprehensive protection is just
Across the world, many photovoltaic Connect module frames to the as important and should be taken into
systems are installed; among them, separate ground potential. account at the planning stage. Here,
numerous rooftop systems (Fig. 68). During installation it is important that slight surge voltages can couple in and
Often when it comes to rooftop the existing system is not disturbed damage the inverter or evaluation unit.
installation, it is a case of integration and that it is sufficiently protected from
into the existing electrical building external influences. This relates to the Free-standing systems
system. The following specifications must entire installation, from the module Today, large free-standing systems
be observed here: right through to the inverter on the DC (Fig. 69) are mainly used as a source
• Do not route the photovoltaic lines side and of course from the inverter of income. To reduce system costs,
in parallel or close to the lightning to the main connection on the AC increasing the system availability and
conductor of the external lightning side. In order to enable lightning and minimizing the failure quota is important.
protection system. surge protection, photovoltaic systems To this end, all components must be
• Avoid the effects of lightning on the are connected to the equipotential carefully selected and correctly installed.
protective conductor by means of bonding strips in the main distribution. As such, surge protective equipment
a galvanic connection in which the As a consequence of this, the lightning that has been developed according
lightning surge protective devices are effects can enter via the DC and AC to the valid product standard,
installed upstream of the device to be side in the non-protected state. For this IEC 61643- 31 [8] for SPDs for use in
protected. reason it is crucial that the entire system photovoltaic installations, should be
• Observe the separation distances is considered and devices at risk are installed.
between the module frame and protected. For data and communication For the majority of constellations, a
type 2 SPD that is directly installed at
the DC input of the inverter is sufficient.
For effective protection, the data and
communication lines of the inverter
must also be protected in addition to
the DC and AC side.
44 PHOENIX CONTACT
The basics of surge protection | Areas of application
New design for system voltages up with a smaller cross section, and thereby cost- effective and efficient. However,
to 1500 V DC achieve cost savings in terms of cabling. this is only possible if all the components
In times in which solar subsidies are In total, the balance of system (BOS) are designed for these voltages.
being drastically reduced, it is essential costs can be reduced through fewer
to minimize system costs accordingly string combiner boxes and lower cabling
to ensure an acceptable return. Thanks expenses. Inverter manufacturers also
to an increased voltage of up to 1500 benefit from this. With a system voltage
V DC, this is perfectly feasible. Due to of 1500 V, the inverter performance
the associated lower string currents, in can be increased by up to 20%. This
practice this means customers use lines makes the photovoltaic system more
VALVETRAB-MB-...-DC-PV
To keep pace with this trend, the What's more, the new product range
new surge protective devices of completely fulfils the product standard
the VAL- MB product range were requirements and the installation
developed for voltages up to directive for Lightning Protection
1500 V DC and with a total discharge Levels III and IV.
capacity of 12.5 kA ITotal (10/350 μs).
PHOENIX CONTACT 45
The basics of surge protection | Areas of application
SPD
high level of availability of the signals
C1
SPD
C2
SPD
transmitted. However, these are exposed D1
to an increasingly active electrical
environment. This particularly applies to
weak measured values that are delivered
by sensors. If the measured values are
low voltages or electric currents that
must be securely transmitted, carefully
conditioned or evaluated, then there is
an increase in the electromagnetic and Fig. 71: Lightning protection zones and classification of protective devices for MCR and IT systems
high-frequency interference they are according to IEC 61643 22 [7]
exposed to.
Reasons for this are:
• An increasing number of electrically level, surge protective devices with is not usually separated at every zone
operated components in all combined protective circuits or with transition, helping to reduce installation
performance classes, especially individual components are used. These work. Multiple protection levels are
motors operated via frequency are installed directly upstream of the generally combined in one MCR surge
inverters and other actuators. signal inputs to be protected. The protective device. As a practical solution,
• The increasing miniaturization and circuits of the surge protective devices this protective module can be installed
packing density of device components. to be used are adapted to the various upstream of the device to be protected
• A growing volume of wireless signal types. (e.g., controller input)
communication and control
equipment. Divisions within the standard
• Digital systems that work with ever The requirements and assignment to
higher transmission frequencies. protective zones are described in detail
Insufficient attention given to the in standards IEC 61643-21 [7] and
above disturbance variables, incorrect IEC 61643-22 [16]. The performance of
adjustments or lack of planning can protective modules for MCR technology
all affect interference-free signal is described by IEC categories D1, C2,
transmission. and C1. (Fig. 71) Zone transition 0A 1 1 2 2 3
Surge voltages that are influenced Table 9 explains the correlations
by the effects of lightning can also have between lightning zone transitions and
a negative impact on the functioning the IEC category of the MCR protective Corresponds to
SPD type D1 C2 C3
and availability of electronic modules in devices in comparison to the power
measurement and control technology. supply protective devices. IEC-61643-21
Damage caused by surge voltages in In contrast to installing SPDs for
Corresponds to
MCR technology systems can, however, power supply systems, a surge protective SPD type 1 2 3
be effectively prevented by using device does not have to be installed IEC-61643-11
tailor-made surge protective devices. at every zone transition in the case of
Depending on the potential for risk MCR signals (refer to IEC 61643-22). In Table 9: Lightning protection zone transitions and
and the requirements of the protection practice, the signal cabling from the field corresponding SPD types
46 PHOENIX CONTACT
The basics of surge protection | Areas of application
Choosing surge protective devices insulated from the ground potential voltage protection level.
Selecting surge protective devices for for interference immunity. A frequently The special functioning of the
MCR technology depends on several encountered application of this type protective circuit with decoupling
factors. The product required is is the 4 ... 20 mA current loop for resistors is described in detail below.
primarily determined by the type of transmitting measured values. In cases where the decoupling
signal circuit to be protected. To ensure insulation in the application resistors in the common mode paths
Typical signal transmissions are: does not fail going forward, the are damaging, it makes sense to choose
• Binary signals surge protective devices are designed a circuit version without decoupling.
• Analog loops accordingly. Gas-filled surge protective This may be the case with the Pt 100
• Temperature measurements (two-, devices (gas discharge tubes, GDT) have two-conductor measuring circuits.
three-, and four-terminal sensing) a corresponding insulation behavior.
• Multi-polar binary signals When operated, they guarantee
insulation between the signal wires and
Other factors involved in selection are: the ground potential. In the event that
• Signal voltage of the signal to be a surge voltage is applied, the GDT
transmitted effectively discharges the transients to
• Surge withstand capability of the end ground and limits the voltage so that
device interface to be protected the dielectric strength of the end device
• Transmission frequency of the signal is not exceeded. The typical dielectric
strength of the end device is 1.5 kV. Surge protection for all signal
types
6.4.1 How the In addition to protecting the dielectric
circuits work strength, the protection between the The huge variety of different signal
signal wires and thereby the electric types, field buses, and interfaces
Basic circuits strength is particularly important in the requires a tailor-made product
In measurement and control technology, area of MCR surge protection. The end and a wide product range. When
there are different applications and types devices are often much more sensitive choosing the right MCR SPD,
of signal. Various protective circuits are to potential differences of this nature, the STOP-IT (Selection Tool
therefore available that are specially as sensitive semiconductor components of Protection for Information
optimized for the application. First of in the terminal device are directly Technology) selection guide is
all, a distinction is made between signal affected. Often, the corresponding invaluable. It is available online on
types that are designed as a closed electric strength of the devices is below the Phoenix Contact website.
circle (loop) and signals with a common 100 V. The protection stage affected in
reference potential or a shared return the surge protective device implements
conductor. a fast-responding suppressor diode
The stand-alone closed circles (loops) (transient voltage suppressor diode,
are often designed so that they are TVS diode), with a correspondingly high
Signal Signal
Ground Ground
Fig. 72: Basic circuit for insulated signal circuits Fig. 73: Basic circuit for insulated signal circuits (without coupling resistors)
PHOENIX CONTACT 47
The basics of surge protection | Areas of application
Signal 1
Signal 1
Signal 2
Signal 2
Reference
Ground
Ground
Fig. 74: Basic circuit for applications with common reference potential, Fig. 75: Basic circuit for applications with common reference potential,
directly grounded indirectly grounded
48 PHOENIX CONTACT
The basics of surge protection | Areas of application
PHOENIX CONTACT 49
The basics of surge protection | Areas of application
SPD
In most cases, transient overvoltages
arise on signal lines due to indirect
couplings. Systems that are particularly
SPD
at risk are those that are very extensive
and those that have high numbers of
lines laid through the free-standing area
(LPZ 0) (strong meshing) (Fig. 78).
Be aware that the hazards must be
made clear at both end points of the Fig. 79: Surge protection in the field and the control center
lines. It is therefore recommended
that the surge protection is taken into
account both in the field as well as in applies to surge protective devices that such applications, take note of the
the control center (Fig. 79). are used in these types of application. corresponding approval.
Systems often contain signal circuits
Today's requirements with Ex i protection (intrinsic safety) Zone 0
The surge protection products that according to IEC/EN 60079-11. A circuit Area in which a hazardous explosive gas
are mounted on a DIN rail often, is described as intrinsically safe if the atmosphere is present for continuous,
in line with today's state-of-the-art current and voltage are limited to such frequent or long periods. These
technology, have an installed, galvanic an extent that no spark or thermal conditions are usually present inside
conductive base contact that is designed effect can cause a potentially explosive containers, pipelines, apparatus, and
to discharge the transients to ground. atmosphere to ignite. No special tanks.
This means that the connection to the authorization (e.g., fire certificate)
equipotential bonding on the DIN rail is required for the maintenance of Zone 1
can be made to ground. For installation intrinsically safe circuits. The cables Area in which a hazardous explosive
in the field, special designs are available of the intrinsically safe circuits can be gas atmosphere is to be expected only
that can be directly attached to the short circuited or interrupted without occasionally during normal operation.
threaded screws on the measuring having to de-energize the system. On This includes the immediate area
transducers or actuators. The protective top of this, the equipment may be surrounding zone 0, as well as areas
circuits are enclosed in a stable metal installed in EX zone 0, depending on close to filling and emptying equipment.
housing and have an IP protection class the respective protection level. If surge
which enables direct use in open areas. protective devices are to be used in
In this case, the discharge to ground
takes place via the local equipotential
bonding connection on the field device.
Certified protective devices
for potentially explosive areas
6.4.4 Surge protection
in explosion-proof areas With the PLUGTRAB,
TERMITRAB, and SURGETRAB
Explosive atmospheres can frequently product ranges, Phoenix Contact
occur in the chemical and petrochemical provides solutions that have ATEX
industries due to industrial processes. approval according to directive
They are caused, for example, by gases, 94/9/EC and that can be installed
fumes or vapors. Explosive atmospheres in intrinsically safe circuits up to
are also likely to occur in mills, silos, and Zone 1.
sugar and fodder factories due to the
dust present there. Therefore, electrical
devices in potentially explosive areas are Fig. 80: Surge protection for direct mounting on
subject to special directives. This also field devices, SURGETRAB
50 PHOENIX CONTACT
The basics of surge protection | Areas of application
Zone 2
Area in which a hazardous, explosive
gas atmosphere is not expected during
normal operation; however if it does Zone 2
occur, it is only for a short time.
Zone 2 includes areas that are used
exclusively for storage, areas around pipe
connections that can be disconnected, Zone 1
and generally the intermediate area
surrounding Zone 1.
Fig. 82: Typical area of application: gas compression station Fig. 83: Installation example based on an
insulated flange
PHOENIX CONTACT 51
The basics of surge protection | Areas of application
Communication via data networks is gas- filled surge protective devices. Where to Cat. 6 and Cat. 7, and in the future
a part of daily life in all areas of the required by the circuit technology, ohmic will work according to Cat. 8.1 or
company. resistors decouple the two protection Cat. 8.2.
The interfaces operate with low signal stages. Protective devices with RJ45
levels at high frequencies. This makes connection, where all eight signal paths
them particularly sensitive to surge 6.5.1 Ethernet and token ring are protected, are universally suited to
voltages and can lead to the destruction interface the Ethernet, Profinet, and token ring
of electronic components in IT systems. interfaces.
In addition to protection that is tailored The architecture or structure of a
to these systems, SPDs must also exhibit network installation and the type of Power over Ethernet (PoE)
high-quality signal transmission behavior, data transfer between the terminals in Power over Ethernet (PoE) is a process
as otherwise malfunctions are to be the data network are referred to as the in which the auxiliary energy for the
expected in the data transmission. This topology. connected devices is also transmitted via
aspect is becoming ever more important In local networks, they have been the Ethernet data cable.
in the face of constantly increasing data tried and tested as bus, ring, and star The auxiliary power is either applied
transmission rates. To this end, when topologies that can also be combined. to the unused wire pair (mode b, Fig.
developing new SPDs for IT systems, To transmit information in data networks, 86) or is supplied between the signal
the focus is on implementing high-quality twisted pair or fiber optics are used. wire pairs as phantom power (mode A,
signal transmission behavior. It is Fig. 85). In line with IEEE 802.3af, a
evaluated based on the ISO/IEC 11801 Data transmission requirements maximum power of 13.5 W can be
or EN 50173 standards. Ethernet and token ring interfaces transmitted using this procedure. The
Furthermore, in this area of have been used for years. Ethernet following IEEE 802.3at standard already
application, a wide range of connection systems have prevailed, however, due to enables 25.5 W with PoE. POE++ is
technology is encountered. For their transmission speed and compact being debated, with which even higher
this reason the protective devices connectors. The transmission behavior transmission capacities will be able to be
must correspond to the electrical of the Ethernet system is defined in achieved.
specifications and also be adapted to standard IEEE 802.3. The transmission
the interfaces to be protected. The SPD speed is up to 10 Gbps. 6.5.2 Serial interfaces
versions often differ only in their design The transmission speed (Table 5.1.1a)
and connection technology. is defined according to the power Serial interfaces are used to exchange
The protective circuits usually categories (Cat. 5 - Cat. 7). data between computers and peripheral
combine fast-responding, low-capacitive New systems with a higher devices. In the event of serial data
suppressor diodes with powerful, transmission frequency work according transmission, the bits are transmitted
DT-LAN-Cat.6+
1 2 3 6 OUT 4 5 7 8
The DT-LAN-CAT.6+ protective
device optimally protects sensitive
equipment, as quickly reacting
protective components are used
for the data cabling as well as for
the PoE system.
1 2 3 6 IN 4 5 7 8
52 PHOENIX CONTACT
The basics of surge protection | Areas of application
33
receive signal are each transmitted via a
66 pair of signal wires. In addition, a ground
7 is routed as a reference potential, so
50 V 50 V that defined voltage conditions prevail at
up to 57 V 8
up to 57
(30 W) V (30 W)
4 the connected interfaces.
1 5
1
TTY interface
2
2 The TTY interface works serially and
symmetrically via two signal wire pairs.
Fig. 85: Transmission of auxiliary power by means Fig. 86: Transmission of auxiliary power by means When a signal voltage of up to 24 V
of phantom supply (mode A) of phantom supply (mode B) occurs, a current signal is analyzed.
Here, 10 – 30 mA is the logical 1 and
0 – 1 mA the logical 0. Standard data
over a cable (in series), one after the D-SUB attachment plugs for DIN transmission rates are 9.6 kbps or
other. Particularly common are: rail mounting or DIN rail modules with 19.2 kbps.
screw terminal blocks are frequently
RS-485 and PROFIBUS interfaces used as protective devices.
The RS-485 serial interface is used on
the Intel bitbus and is closely related V.24 interface
to the RS-422. This symmetrical data The V.24 or RS-232 serial interface
transmission generally functions via a works with an asymmetrical signal
pair of signal wires. Versions with two transmission. One transmit and one
pairs of signal wires and a ground are receive signal each have a common
also used. reference potential (ground). In
In older systems, the signal voltage of addition, up to five control signals can
this interface amounts to ground -7 V be transmitted. This yields a maximum
and +12 V. In newer systems, a version of eight active signals including ground.
with TTL level, e.g., +/- 5 V is used. Connection is usually via D-SUB 25,
The PROFIBUS interface is a further D-SUB 9 or screw terminal blocks.
development of the RS-485 interface.
It uses the physical characteristics of V.11 interface
the RS-485, but with transmission rates The V.11 or RS-422 serial interface
of up to 12 Mbps. These interfaces are works on the basis of symmetrical signal
used for other applications in the time transmission. The transmission path
and machine data acquisition device field. can be up to 1000 m. The transmit and
PHOENIX CONTACT 53
The basics of surge protection | Areas of application
DT-TELE-RJ45
RJ 45
RJ 12
RJ 45
RJ 11
RJ 12
RJ 11
Plug
Plug
54 PHOENIX CONTACT
The basics of surge protection | Areas of application
Transceiver systems are generally advantage in this technology is achieving to sport and leisure facilities. The
considered to be particularly susceptible a very good (low) voltage protection permanent availability of this monitoring
to surge voltages. level, as the protective device functions equipment requires suitable surge
Antenna cables which extend beyond as a short circuit in the frequency range protective devices. As a general rule,
the building and are generally particularly of surge voltages. However, it must be coaxial attachment plugs are used as
long, as well as the antennas themselves, taken into account that the cable that is protective devices, with BNC or TNC
are directly exposed to atmospheric connected to the Lambda/4-protective connectors.
discharges. For this reason, cables device cannot use a DC power supply.
with a coaxial structure and therefore Relatively wide bandwidth signals Radio link and mobile phone
systems
favorable EMC properties are used. The (e.g., 0.8 – 2.25 GHz) can be transmitted
shield of the antenna cable can be either by means of HF-optimized Lambda/4 Radio link technology enables wireless
grounded or floating, depending on the protective devices. Fig. 88 shows a transmission of data. The radio waves
system conditions. However, the risk of typical design of a protective device with produced are transmitted in multiplex
surge voltage coupling in antenna cables Lambda/4 technology. mode using panel antennas with a carrier
is not completely eliminated. Surge The most common applications for SPDs frequency of between 1 and 40 GHz.
voltages can even reach the sensitive in telecommunications are: Common types of antennas are parabolic
interfaces of transceiver systems via this reflectors, shell antennas, and horn
cable path. Antenna connection of television antennas. The nominal frequencies of
and radio receivers
The high frequencies of wireless useful signals in this range are between
transmission require the use of The protective devices for radio and 0.8 GHz and 2.7 GHz. N, SMA or 7/16
protective devices with low self- television devices are generally mounted connectors are used as the connection
capacitance or low insertion loss with between the antenna wall connection technology for the protective devices.
good impedance matching. Nevertheless, and the outgoing antenna cable. For
a good level of protection is required satellite receivers, there are multi-
with high discharge capacity. For this channel protective devices for wall
reason, most protective devices are mounting. Broadband cable and antenna
equipped with powerful gas-filled surge connections generally have TV and RF
protective devices or with the Lambda/4 connectors according to DIN 45 325.
technology. The Lambda/4 technology Satellite receivers are connected via F
uses a short circuit between the inner connectors.
conductor and the shield. The length
of the cable between the short circuit Video communication
and the inner conductor matches The applications in video communication
the frequency that is allowed to pass extend from monitoring buildings,
through without attenuation. A great public areas, and institutes right through
CN-LAMBDA/4
Using the CN-LAMBDA/4-2.25
protective device, the widest
range of transmission systems
can be actively protected in the
λ/4 GHz range. This is achieved by
means of a broadband LAMBDA/4
technology.
PHOENIX CONTACT 55
The basics of surge protection | Glossary
7 Glossary
ATEX current parameter values with regard Nominal discharge current (In)
ATEX is a widely used synonym for the to probability, whereby the largest and Peak value of the current flowing
ATEX directive issued by the European smallest measured values in the event through the SPD with pulse shape
Union. The ATEX designation is derived of naturally occurring strikes cannot be (8/20 μs). The pulse shape (8/20 μs) of
from the French abbreviation for exceeded and the strikes can be safely a surge current is characteristic of the
“atmosphères explosibles”. discharged. Lightning Protection Level effects of an indirect lightning strike or
I thereby corresponds to the highest switching operation. The value of the
Binary signals measured values and the greatest nominal discharge current is used for
By binary signals, we mean digital signals probability of capturing a strike. The a variety of tests on an SPD, including
that only take on the state of “high” or values decrease accordingly, down to those used to determine the voltage
“low”. Generally, these signals relate to a Lightning Protection Level IV. protection level. Depending on the
common reference potential or a shared Lightning Protection Level assigned
return conductor. Lightning protection system to a lightning protection system, the
System consisting of interception rods, SPDs must have minimum values that
Dielectric strength protective devices, and grounding system correspond to this value.
Insulation strength of the electrical externally, as well as equipotential
circuits of a piece of equipment when bonding system and coordinated SPD Nominal load current (IL)
compared to withstand and surge system within the structural system Maximum r.m.s. value of the nominal
voltages with amplitudes above the to protect against damage caused by current, which allows a connected ohmic
maximum continuous voltage. surge voltages and surge currents from load to flow to one of the protected
lightning strikes. outputs of the SPD. This maximum
EMC value is specified by the parts carrying
EMC stands for electromagnetic Lightning protection zone operational current within the SPDs;
compatibility, the capacity of an A zone in which the electromagnetic these must be able to withstand the
apparatus, plant or system to work environment is determined with regard continuous thermal current load.
satisfactorily in an electromagnetic to risk of lightning. All the (supply) lines
environment, without causing that cross zone limits must be included Nominal voltage (UN)
electromagnetic interference itself that in the lightning protection equipotential The nominal value of the voltage of the
would be unacceptable for the apparatus, bonding by means of corresponding current or signal circuit based on the
plants or system in this setting. SPDs. The zone limits of a lightning zone use envisaged for the SPDs. The nominal
are not necessarily physical limits (e.g., voltage stated for an SPD corresponds
Gas discharge tube, GDT walls, floor or ceiling). to the system voltage of the typical SPD
Gas-filled surge protective device installation site for a standard three-
Lightning protection zone, LPZ phase system, e.g., 230/400 V AC. Lower
Insertion loss Lightning protection zone system voltages can also be protected by
The attenuation value is defined as the the SPD. In the event of higher system
ratio of voltages that occur immediately Maximum continuous voltage (Uc) voltages, it must be decided on a case-
before and after the insertion point of Maximum r.m.s. value of the voltage that to-case basis as to whether the SPD can
the protective device to be tested. The can continuously be applied to the mode be used and if there are restrictions to
result is expressed in decibels. of protection of the SPDs. The maximum observe.
continuous voltage must be at least 10%
Lightning Protection Level higher than the value of the nominal Off-load voltage (UOC)
A regulatory division of lightning voltage. In systems with greater voltage Off-load voltage of the hybrid generator
protection systems into classes I to IV, fluctuations, SPDs with a greater difference at the terminal points of the SPD. A
which are based on a set of lightning between UC and UN must be used. hybrid generator creates a combined
56 PHOENIX CONTACT
The basics of surge protection | Glossary
surge; e.g., in off-load, it supplies a capacity indicates the prospective r.m.s. TVS
voltage pulse with a defined pulse shape, value of the short-circuit current at TVS stands for Transient Voltage
generally (1.2/50 μs), and in a short the installation location of a voltage- Supressor.
circuit, a current pulse with a defined switching SPD, up to which the SPD Overvoltage categoryDivision of
pulse shape, generally (8/20 μs). The once again transitions into a high ohmic equipment into categories I to IV
combined surge is characteristic of the state if the maximum Uc continuous depending on their surge voltage
effects of an induced surge voltage. voltage is being independently applied resistance. Overvoltage category
Depending on the protection class due to a surge current, without I corresponds to the lowest value
assigned to a lightning protection system, triggering an upstream overcurrent and consists of particularly sensitive
the SPDs must have minimum values that protective device. (end) devices. These values increase
correspond to this value. accordingly, up to overvoltage category
Short-circuit withstand capability IV. The values for the individual
Overcurrent protective device, (ISCCR) categories also depend on the voltage
OCPD Maximum uninfluenced short-circuit level of the power supply system.
Overcurrent protective device current of the electrical network, for
which the SPD is rated in conjunction Voltage protection level (Up)
Power over Ethernet, PoE with the upstream overcurrent Maximum voltage that can occur on the
Power over Ethernet is a process in protective device. The short-circuit connection terminal blocks of the SPD
which the auxiliary energy for the withstand capability indicates up to while loaded with a pulse of specific
connected devices is also transmitted via which prospective short-circuit current voltage steepness and a discharge surge
the Ethernet data cable. the SPD can be used at the installation current of specified amplitude and wave
location. The corresponding tests form. This value characterizes the surge
Pulse discharge current (Iimp) to determine this value are carried voltage protective effect of the SPD. In
Peak value of the current flowing out in connection with the upstream the event of a surge voltage phenomenon
through the SPD with pulse shape overcurrent protective device. In the within the performance parameters of
(10/350 μs). The pulse shape (10/350 event that the special surge protective the SPDs, the voltage is safely limited to
μs) of a surge current is characteristic devices for PV systems correspond to a maximum of this value at the protected
of the effects of a direct lightning the value ISCPV, this is the max. direct connections of the SPD.
strike. The value of the pulse discharge current short-circuit current of a system
current is used for special SPD tests up to which the the SPD may be used.
to demonstrate carrying capacity with
regard to high-energy lightning currents. Surge current
According to the Lightning Protection A pulse-shaped current that is
Level assigned to a lightning protection characterized by a significant rise in
system, the SPDs must have minimum current within a short period of time.
values that correspond to this value. Typical pulse shapes are (8/20 μs), with
which the voltage-limiting behavior of
Safe Energy Control technology, SPDs can be checked, and (10/350 μs),
SEC technology
with which the lightning current capacity
Technology for SPDs for protecting the of the SPDs can be tested.
power supply. SPDs with SEC technology
are characterized by the following: Surge protective device, SPD
• Impact-free and durable Surge protective device
• Backup-fuse-free solution for every
application Surge voltage
• Compact and consistent pluggable A pulse-shaped voltage that is characterized
design by a significant rise in voltage within a
short period of time. A typical pulse shape
Sequential current extinguishing is (1.2/50 μs). The response behavior of
capacity (Ifi) SPDs or the surge voltage resistance of
The sequential current extinguishing equipment can also be tested with this.
PHOENIX CONTACT 57
The basics of surge protection | Glossary
58 PHOENIX CONTACT
The basics of surge protection | References
8 References
PHOENIX CONTACT 59
Always up-to-date, always available to you. Here you‘ll find everything on our products, solutions and service:
phoenixcontact.com
Product range
• Cables and wires • Industrial communication technology • Protective devices
• Connectors • Industrial Ethernet • Relay modules
• Controllers • Installation and mounting material • Sensor/actuator cabling
• Electronics housings • Lighting and signaling • Software
• Electronic switchgear and • Marking and labeling • Surge protection and interference filters
motor control • Measurement and control technology • System cabling for controllers
• Fieldbus components and systems • Monitoring • Terminal blocks
• Functional safety • PCB terminal blocks and • Tools
• HMIs and industrial PCs PCB connectors • Wireless data communication
• I/O systems • Power supply units and UPS