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Foundation Fieldbus End User Council North America Meeting

San Ramon, California June 5, 2003

Surge and Lightning Protection For Foundation Fieldbus


Presented By: David Crandall MTL, Inc.

What are Voltage Transients and Surges and why should they concern me?

...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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Why consider Surge Protection for Foundation Fieldbus


Host Link Active Scheduler

Junction Box

One to One Bus with Spurs

Daisy-Chain

Chicken foot
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Failure Modes of Equipment


Catastrophic Failure Safe Operating Area Equipment Degradation

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Electrical Equipment has high MTBF Factors that will shorten equipment life are:
Temperature Extremes (Heat and Cold) Extraneous Matter (Dirt, Dust, Grease, etc.)

Surges

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Typical Degradation
Magnified view of 2 junctions in an IC chip

(+) 5 volt signal

Insulation Breakdown Point 50 volts

(-) Logic ground

IC Chip Failure due to junction breakdown


...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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Failure of a Bipolar Transistor

Transient Voltage Damage


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Damage to discrete Semiconductor devices

<10 J
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Damage to Integrated Circuits

<1 J
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Objective of Surge Suppression


Lower the voltage on all wiring connected to devices you want to protect to a manageable level Divert the surge current away from those devices Reset automatically to be ready for the next surge or transient

...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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How Surges Enter AC Power Wires


Motors

Contactors

Breaker Panels

UPS
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...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003

UPS Power is vulnerable to Surges

Any Inductive Load Power Tools Crossed Wires Induced Voltages

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What uses or is connected to power? Man-Machine Interfaces Controllers DC Bulk Power Supplies Power Conditioners Repeaters Field Instrumentation UPS Systems

Any of these components are vulnerable to surge damage


...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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Measured Ground Flash Density

>21 >16 >10 >8 >5 >3 >1

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Ground Potential Shifts

200 kV

12kV
3 kV 400 Distance
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15 kV 100
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PC Board Damage

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The solution: Surge Suppressors Surge Suppressors protect electronics from the effects of: Lightning strikes Electrical Faults Induced Voltages Each device needs to be evaluated for Surge protection Critical High Replacement Cost Overall impact if lost from a surge
...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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The Solution: Surge Suppressors


Protection should be considered for: Field Devices Power Supplies Foundation Fieldbus H1 trunks Repeaters Man-Machine Interfaces Comm ports such as: Ethernet

...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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Insulation Ratings of Equipment


Determines highest voltage equipment can withstand without damage

Bulk Power Supplies Industrial PCs Controllers Field Devices UPS systems

600 Volts 600 Volts 600 Volts 500-1500 Volts 1000-6000 Volts

Surge suppressors must reduce voltage to less than 600 Volts!


...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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Design Criteria for Suppressors Reduce surge voltage to a point that the residual voltage is low enough for connected equipment to survive Assume 20kV surge Divert Surge Current Assume 10kA 8/20 Sec Have minimal impact on the FF signals Reset after use for next surge event

...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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Field Device Protection

Can be applied to any FF field device Design should add minimal resistance to the lines Can be Installed in spare conduit entry or tee Some models mount internally 10kA Surge Current Capacity

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Trunk Protection

Designed to protect Communication Trunk Protects: H1 Card Power Conditioner Terminators Repeaters Series connection 20kA Surge Current Capacity

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AC/DC Power Surge Suppressor

Designed to protect incoming power lines to: Power Conditioners Bulk power supplies Panel mounted equipment AC or DC Single phase power protection Noise Filtering recommended

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Facility Power Protection


Located at the Service & Breaker Panels Protects UPS systems,

and equipment powered


from breaker panels

...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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AC Power Protection

H1 Controller

Service Entrance Control Power UPS System Bulk Power Supply Power Conditioner

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Trunk Protection

200 kV 12kV 15 kV 3 kV 400 Distance


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100
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Trunk Protection

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Spur Protection

200 kV

12kV
3 kV 400 Distance
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15 kV 100
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...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003

Summary
Equipment is vulnerable to Surge Damage: Protect all devices with incoming AC power

Install surge suppression on field devices


Protect equipment located on the segments
...dedicated to a single international fieldbus. FIELDBUS FOUNDATION END USER COUNCIL Meeting San Ramon, California June 5, 2003
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