INSTALLATION AND OPERATING INSTRUCTIONS€¦ · Installation & Operating Instructions Warnings PAGE...

TSG SERIESSURGE REDUCTION FILTERS (TSG-SRF)

INSTALLATION AND OPERATING INSTRUCTIONS

CRITEC products are designed and manufacturedby ERICO ABN 70 078 495 646Technopark, Dowsings Point, Tasmania, Australia

Telephone: 61 (03) 6237 3200 Facsimile: 61 (03) 6273 0399 Handbook No:HB-HBCR-140

Issue 1

March 2001

Contents TSG Series Surge Reduction Filters

TABLE OF CONTENTS

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

2. Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5

3. Installation Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6

4. Identify the Distribution System . . . . . . . . . . . . . . . . . . . . . .Page 8

5. Mounting the Surge Reduction Filter ( SRF ) . . . . . . . . . . . . .Page 12

6. Optimising Performance . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13

6.1. Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13

6.2. Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14

6.3. Output Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17

6.4. Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 18

6.5. Connection of Alarm Circuits . . . . . . . . . . . . . . . . . . . . .Page 19

6.6. Installation Arrangement for Australian MEN Systems . . .0

6.7. TSG-SRFs on Sub-Circuits . . . . . . . . . . . . . . . . . . . . . . . .Page 21

7. Servicing & Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . .Page 23

8. Non-Standard Products & Accessories . . . . . . . . . . . . . . . . .Page 24

9. Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 25

10. Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 27

IntroductionInstallation & Operating Instructions

PAGE 3

1. INTRODUCTION

The CRITEC Triggered Spark Gap SurgeReduction Filter (TSG-SRF) from ERICO incor-porates high energy clamping devices andspecial filtering circuitry. TSG-SRFs areinstalled in series with the circuit, usually atthe point of entry to the building or structure.They are available in single or three-phaseconfigurations for load currents from 40A to2000A per phase.

The purpose of a TSG-SRF is to filter andprotect against lightning induced transients.The SRF provides a clean, filtered supply ofelectricity to all output connected equipmentwhen installed in accordance with the manu-facturers’ instructions.

Protection is achieved via a three-stage circuit.This includes the internal CRITEC TriggeredSpark Gap unit as the primary surge diverter,a purpose designed low pass filter network

and a secondary, Transient Discriminating (TD)diversion stage to further clamp the transientenergy to safe levels. This allows the TSG-SRFto:

• Provide filtering to the clamped waveform in order to reduce the rate of voltage rise.

• Provide a secondary stage of surge diver-sion to protect equipment from transients which may be induced onto the SRF output cables or be caused by the load itself.

The use of this combination of technologieshas resulted from considerable advances intechnology which have negated previousdisadvantages associated with spark gaps.

The use of spark gaps has not been practicalin the past due to the high initiation voltagesrequired to activate such devices and alsotheir poor follow-current performance.

Introduction TSG Series Surge Reduction Filters

PAGE 4

Both issues have been addressed with theCRITEC TSG, a spark gap surge diverter incor-porating a triggering device which enablesthe TSG to operate on much lower voltagesthan was previously possible. Additionally, theTSG is able to extinguish the spark and returnto the peak mains voltage as soon as thetransient event has passed, thereby greatlyimproving follow-current performance.

These considerable technological advancesmean that the TSG can be utilised as theprimary shunt diverter within the new SRF,exploiting the performance benefits of sparkgap diverters.

Incorporating TSG technology into a surgereduction filter has allowed a fundamentalbreakthrough in the overall design of thefilter. Ferrite cored inductors, which are muchsmaller than non-saturating air-cored induc-tors required in MOV based surge reductionfilters have been used in the CRITEC SRF.

The use of ferrite-cored inductors is possiblebecause the let-through voltage from a TSGremains high for only a few microseconds(µs). In comparison, the let-through voltagefrom a MOV based device remains atanywhere between 600V and 1000V for theduration of the surge. This time can rangefrom 30µs to 400µs and above for longer tailpulses and determines how much energy theinductor has to store before reaching satura-tion and becoming ineffective.

The combination of TSG and TD technologyprovides the benefits of high surge capability,low let through voltage and considerablyreduced dv/dt. This applies to both surgeperformance and over-voltage withstand fromshort and long duration high-energy surges.

TD technology has been developed specifical-ly to cater for abnormal over-voltage condi-tions that may occur on sites with poor volt-age regulation, or due to wiring or distribu-tion faults. TD and TSG technologies featurean extremely high over-voltage withstand.This eliminates heat build up that can occurwith standard technologies when the protec-tion devices start to clamp on the peak ofeach abnormal mains cycle.

Traditional MOV technology is not suitable inapplications where sustained over-voltageconditions can be experienced. The range ofCRITEC TSG-SRFs, with a higher abnormalover-voltage withstand, are preferred in theseenvironments.

WarningsInstallation & Operating Instructions

PAGE 5

2. WARNINGS

• PRIOR TO INSTALLATION. Ensure thatthe TSG-SRF is of the correct voltage,current, phasing, and frequency, and is ofthe type recommended by the manufactur-er for the equipment and power distribu-tion system in use.

• DO NOT MEGGER. This unit containsover-voltage protection components.

• TSG-SRFs contain capacitors. Disconnectpower at least 1 minute prior to removingthe escutcheon panel. Check voltage priorto working on SRF internals.

• TSG-SRFs must be connected to a lowimpedance earth (<10Ω) for correct opera-tion.

• TSG-SRFs must be installed in accordancewith ALL relevant national electrical andsafety codes.

• The power supply to the TSG-SRF shouldalways be turned off (and locked) beforethe escutcheon panel is removed for any

purpose. Internal circuit breakers do notfully isolate the filter.

• Check all TSG-SRF terminals for tightconnections. (Some terminals may becomeloose during transport).

• Ensure all input and output cabling, onceinstalled, is tightened to the correct torquesettings (see table 3)

• Do not disconnect upstream Earth orNeutral connections supplying the SRFwhile power is still applied, as this maydamage the SRF or load.

• No combustible items should be storedwithin the SRF during operation.

• Do not leave this manual behind theescutcheon panel after applying power tothe SRF. Retain this manual for future refer-ence.

• Failure to heed instructions or warningsmay result in personnel injury, equipmentdamage or ineffective transient protection.

HAZARDOUS VOLTAGES EXISTWITHIN THE TSG-SRF ENCLOSURE.THIS UNIT SHOULD BE INSTALLED &SERVICED ONLY BY QUALIFIEDPERSONNEL AND IN ACCORDANCEWITH RELEVANT NATIONAL ELEC-TRICAL & SAFETY CODES.

ALL INSTRUCTIONS MUST BEFOLLOWED TO ENSURE CORRECTAND SAFE OPERATION OF THE SRF.

Installation Cautions TSG Series Surge Reduction Filters

PAGE 6

3. INSTALLATION CAUTIONS

CAUTIONS:

• Transient protection devices are usuallyrated to protect against non-repetitivepulses from sources such as direct orinduced lightning energy.

• They are not designed to provide protec-tion against repeated cyclic anomalies suchas those caused by motor speed controlnotching (variable speed controls, etc).

• SRFs are not designed to provide protec-tion against sustained over-voltage condi-tions where the supply voltage exceeds,for an extended period of time, the nomi-nal rating of the protection equipment. iecontinuous over-voltages from poorly regu-lated generators or distribution systems.

• Smaller power generation equipment doesnot always conform to the same standardsof voltage regulation that is in place formains power reticulation. A large numberof smaller or cheaper generators have avoltage waveform that approximates240Vrms (often poorly regulated), butmore importantly, which often containssignificant higher order harmonics andmay exhibit a peak voltage on each halfcycle far in excess of the normal 340V(peak). Such machines are usually capaci-tive excitation induction generators, asopposed to synchronous generators. Theproblem is usually increased when thegenerator is lightly loaded.

• Harmonic voltages may also be present indistribution systems that do not featuregenerators. This is normally where non-

ELCBor

RCD

Avoid repetitive voltages in excess of SRF rating

275 Vrms240 Vrms

240 Vrms275 Vrms

SRF

Avoid high harmonic voltages

275 Vrms

SRF SRF

Avoid upstream Earth Leakage Circuit Breakers (ELCB’s) or

Residual Current Devices (RCD’s)

orGenerator

Generator

Generator

SRFSRF

BypassSwitch

NON PREFERRED NON PREFERRED PREFERRED

Bypass Switches compromise protection

SRF

Generator

MAINS / GENERATOR CHANGE-OVER SWITCH CONNECTION

SRF

Figure 1. Seek specialist advice with the above installations.

Installation CautionsInstallation & Operating Instructions

PAGE 7

linear loads are used, such as UPSs, recti-fiers, switch-mode power supplies andmotor speed controls. The harmonic volt-ages may have peak voltages in excess ofthe protective clamping voltages, causingproblems such as excessive heat build up.Because the harmonic waveforms containhigher order frequencies, capacitive leak-age currents may increase to aboveprescribed limits and shorten the life of theSRF. It should be noted that in sites withlarge harmonic voltage distortion, the SRFcapacitance may dramatically affect thepower factor.

• Seek the manufacturers’ advice beforeinstalling any SRF into a circuit whichfeatures a total harmonic voltage ratioabove 5%.

• With large transients, significant energymay be passed by the SRF diverters backto the source or to earth. This may, undersome circumstances, cause upstream earthleakage circuit breakers or residual currentdevices (ELCBs & RCDs) to nuisance trip.Where possible, these devices should beinstalled after the SRF in order to reducethis possibility.

• Transient protection devices often haveminimum requirements for upstreamfusing to ensure proper operation. Seesection 6.1 for fusing requirements.

• By-pass switches are not recommendedto be used with SRFs as they compromisethe protection offered. The connection ofthe by-pass switch compromises the inputto output separation requirement by bring-ing the SRF input and output wiring intoclose proximity at the switch. Due to thehigh reliability of the SRF and, provided

that spare fuses are on hand (for SRFs of125A and larger), it is deemed to beunnecessary to provide a means by whichto bypass the SRF. If these situationscannot be avoided, contact your localERICO office to assess the possibility of aspecial design.

Identify the Distribution System TSG Series Surge Reduction Filters

PAGE 8

4. IDENTIFY THE DISTRIBUTION SYSTEM

A number of different power distributionsystems are employed in various countriesaround the world. It is important to identifythe distribution system in use prior to installa-tion of the SRF, and confirm that the SRF isthe model recommended by the manufactur-er for that distribution system.

To identify the distribution system in use,consult reputable and knowledgeable sourcessuch as:

• The local power supply authority

• Local electrical engineers

• Applicable regulatory bodies or standardsassociations

Alternatively, confirm the type of distributionsystem used by personal inspection. By visual-ly tracing the neutral and earthing conductorsfrom the load equipment or sub-distributionpoint back to the point of entry (and perhapsto the supply transformer), the type of distri-bution system should be identifiable with theaid of the following diagrams (figures 2-6).

These are prescribed in local regulations anddescribe the relationship between the source,exposed or conductive parts of the installationand earth. Amongst these, the TN-C, TN-S,TN-C-S and TT systems are most commonlyencountered. Note that supplies such as thoseused in industry and mining may often use adifferent distribution system to that of thelocal supply authority.

SRF

MAIN DISTRIBUTION

LOADEQUIPMENT

SRF

MAIN DISTRIBUTION

LOADEQUIPMENT

EXPOSEDCONDUCTIVE

PARTS

CONSUMERSINSTALLATIONS

SOURCE OF ENERGY

SOURCEEARTH ADDITIONAL

SOURCEEARTH

L1L2L3COMBINEDPROTECTIVE AND NEUTRALCONDUCTOR PEN

Regulations differ between countries. Check compliance with appropriate authorities.

Figure 2. TN-C system: In this system, the neutral and protective earth conductor combine in a single conductorthroughout. All exposed conductive parts are connected to the PEN conductor.

IIdentify the Distribution SystemInstallation & Operating Instructions

PAGE 9

SRF

MAIN DISTRIBUTION

LOADEQUIPMENT

EXPOSEDCONDUCTIVE

PARTS


SOURCE OF ENERGY

SOURCEEARTH

L1L2L3NPROTECTIVE CONDUCTOR PE

SRF

MAIN DISTRIBUTION

LOADEQUIPMENT

* *

Regulations differ between countries. Check compliance with appropriate authorities.* Use of earth where allowed will enhance protection.

SRF

MAIN DISTRIBUTION

LOADEQUIPMENT

SRF

MAIN DISTRIBUTION

LOADEQUIPMENT

EXPOSEDCONDUCTIVE

PARTS


SOURCE OF ENERGY

SOURCEEARTH ADDITIONAL

SOURCEEARTH

L1L2L3COMBINEDPROTECTIVE AND NEUTRALCONDUCTORPEN


Figure 3. TN-S system: In this system, a separate neutral and protective earth conductor are run throughout. The protec-tive PE conductor can be the metallic sheath of the power distribution cable or a separate conductor. All exposed con-ductive parts of the installation are connected to this PE conductor.

Figure 4. TN-C-S system: In this system, a separate neutral and protective earth functions combine in a single PEN con-ductor. This system is also known as a Multiple Earthed (MEN) system and the protective conductor is referred to as thecombined neutral earth (CNE) conductor. The supply PEN conductor is earthed at a number of points throughout thenetwork and generally as close to the consumer’s point of entry as possible. All exposed conductive parts are connectedto the CNE conductor.

Identify the Distribution System TSG Series Surge Reduction Filters

PAGE 10

L1

GROUND

L2

SOURCE OF ENERGY

SPLIT PHASE SUPPLY

SRF*

MAINDISTRIBUTION

LOADEQUIPMENT


CRITEC TSG-SRFs provide protection forequipment on TN-C, TN-S, TN-C-S, TT, deltaor split-phase distribution systems whenselected, installed and earthed in the specifiedmanner.

The TSG-SRFs are designed to be used indistribution systems that provide a separateearth and neutral connection. TSG-SRFsshould not be used in IT distribution systems.(Refer Figure 7).

Specialist application advice should be soughtin the protection of delta supplied three-phase systems (refer Figure 8) before thepurchase of the protection equipment.

SRF

MAIN DISTRIBUTION

LOADEQUIPMENT

SRF

MAIN DISTRIBUTION

LOADEQUIPMENT

EXPOSEDCONDUCTIVE

PARTS


SOURCE OF ENERGY

SOURCEEARTH

L1L2L3N


Figure 5. TT system: A system having one point of the source of energy earthed and the exposed conductive parts ofthe installation connected to independent earthed electrodes.

Figure 6. Split-phase distribution systems.

Identify the Distribution SystemInstallation & Operating Instructions

PAGE 11

The diagrams are provided as a guide to iden-tifying and distinguishing the distributionsystem in use. Metering, over-current protec-tion, and other details have not been shown.

As electrical wiring and safety regulationsdiffer from country to country. It is importantto ensure that the installation complies withall regulations applicable to the location.Please seek further assistance if uncertain.

L1

L2

L3

SOURCE OF ENERGY

DELTA SUPPLY

SRF*

MAINDISTRIBUTION

LOADEQUIPMENT

*SEEK SPECIALIST ADVICE BEFORE SELECTING PROTECTION TYPE


SRF*

MAINDISTRIBUTION

LOADEQUIPMENT

SRF*

MAIN DISTRIBUTION

LOADEQUIPMENT

EXPOSEDCONDUCTIVE

PARTS


SOURCE OF ENERGY

SOURCEEARTH

L1L2L3

*SEEK SPECIALIST ADVICE BEFORE SELECTING PROTECTION TYPERegulations differ between countries. Check compliance with appropriate authorities.

Figure 7. IT system: A system having no direct connection between live parts and earth, but having all exposed conduc-tive parts of the installation connected to independent earthed electrodes. CRITEC Surge Reduction Filters should NOT beused in IT systems without specialist advice.

Figure 8. Delta connected three-phase systems.Although delta connected systems are “IT” systems,special mention is made due to their frequent use inmining and industrial applications. Standard CRITECSurge Reduction filters may not be suitable for someapplications.

Mounting the Surge Reduction Filter TSG Series Surge Reduction Filters

PAGE 12

5. MOUNTING THE SRF

Before mounting the SRF, refer to Table 4(weights and dimensions on last page of thismanual) which provides dimensions and unitweights. Ensure that appropriate lifting equip-ment is used when installing the larger SRFs.When installing the SRF, consideration shouldbe given to future service needs. Ensure thata clear view of the status indicators is provid-ed. The SRFs should be mounted away fromother electrical apparatus (300mm minimum)and in a position that avoids close proximityto combustible materials.

TSG-SRFs of 630A capacity and smaller aredesigned to be wall mounted. Mountingbrackets (as shown in Figure 9) are supplied.Larger units are anchored through holesprovided in the rear of the SRF enclosure.

The cabling and upstream over-currentprotection requirements and all instructionsprovided in this manual, should be taken intoconsideration before mounting the SRF.

• To preserve the IP rating, TSG-SRF units from40A to 200A must be installed in accor-dance with figure 9 and section 6.2.

• Larger SRF units from, 400A to 2000A areventilated and should be mounted in a dustand moisture-free, ventilated environment.

• All TSG-SRFs should be installed in a dry,well-ventilated area. Avoid sites subject tomoisture ingress.

• SRFs are not intended for use in harsh orcorrosive environments.

Where the SRF is to be enclosed in a switch-board cubicle, models are available without theproprietary enclosure. These backplane unitsare denoted by the model number suffix ’BP’.

FIBRE WASHER

MOUNTING BRACKET

METAL WASHER

MOUNTING BOLT

PROVIDE M10ANCHOR BOLT

SUITABLE WALLANCHORING

SPECIALLY SHAPED SLOTIN BRACKET ALLOWS FORPARTIAL INSERTION OFMOUNTING BOLT INTO WALLFOLLOWED BY "HANGING"THE SRF OVER THE BOLTS

BRACKET ROTATES 90ß TOALLOW FOR HORIZONTALPOSITIONING.

SEE PAGE 26 FORMOUNTING DIMENSIONS

SRF MOUNTING KIT ASSEMBLED IN ORDER SHOWN

Figure 9. Typical mounting arrangement for wallmounted CRITEC Surge reduction Filters (40-200A).

Optimising Performance/FusingInstallation & Operating Instructions

PAGE 13

6. OPTIMISING PERFORMANCE

The protection equipment must be earth-ed and installed in accordance with allrelevant national electrical and safetystandards. The term "point of entry" protec-tion, is a general descriptive concept of zonalboundary protection, as detailed in standardssuch as IEC 1024. Some local wiring regula-tions will allow the protection equipment tobe mounted directly at the point of entry,while other countries require protectionequipment to be installed after the meteringor main circuit isolators or over-currentprotection.

The following installation points requireattention to ensure that optimal protec-tion is provided by the protection equip-ment. This information is provided as aguide only. Compliance with local electri-cal and safety regulations must beensured.

6.1 FUSING

Over-current and short-circuit protection mustbe provided in order to protect the SRF andassociated wiring if a fault develops. Theover-current protection should be installed insuch a manner as to provide a means ofisolating the SRF from the mains supply. Thisis an important safety consideration. Over-current protection provided within theSRF is not designed to act as a means ofisolation. Over-current protection within theSRF does not necessarily isolate all TSG-SRFcomponents.

To allow the TSG, (the internal primary divert-er) to operate correctly, it is essential that theminimum requirements for upstream fusingor circuit breakers be adhered to.

Table 1 summarises the minimum require-ments for upstream fusing or circuit breakersrequired to prevent nuisance tripping, oroperation of fusing when the TSG activates.Upstream fusing and cabling may need tobe of higher capacity than the appear-ance or size of filter would suggest.Fusing of smaller capacity may experienceoccasional nuisance tripping during surge andtransient conditions.

Max supply Typical supply Minimum Minimumfault transformer circuit fuse sizecurrent rating breaker

10kA 500A 100A 40A

15kA 750A 100A 63A

20kA 1000A 125A 80A

43kA 2000A 160A 100A

Table 1.

The table above summarises the minimumrequirements for upstream fusing or circuitbreakers necessary to prevent nuisance trip-ping or operation of fusing when the TSGprimary surge diverter activates.

Cabling TSG Series Surge Reduction Filters

PAGE 14

6.2 CABLING

The cabling and earth wires connected to thefilter input should always be run separately,with a minimum clearance of 300mmbetween them and all other cables or sensi-tive equipment (as shown in Figure 11). Theinput cable and earth wire will carry the tran-sient energy, while the "protected" outputcable can be considered to be a "cleanfiltered" supply.

By separating these cables, any incomingtransients will not be induced from the inputcables onto nearby "clean" cables. This clear-ance will reduce the possibility of arc-overfrom input to output cables. Where cablesneed to run closer together due to spacerestrictions, input and output cables shouldcross at right angles and not be installedparallel to each other. Cabling should be sizedin accordance with all relevant wiring stan-dards to ensure that the full load current canbe safely supplied. All cabling or busbarsconnected to the protection equipmentshould be securely anchored to preventundue stress being applied to theinput/output terminals.

Input and output terminal requirements aredetailed in Table 2.

Cable terminal torque requirements aredetailed in Table 3.

• Cable glands (of an appropriatedesign) must be used for all input andoutput cables to preserve the IP ratingof the 40A – 200A TSG SRFs.

• To protect input and output cablinginsulation from sharp edges aroundthe cable entry knockouts, suitablecable glands or grommets must beinstalled. An alternative is to extendthe cable conduit through the knock-out.

CablingInstallation & Operating Instructions

PAGE 15

SRF SRF

• EXPOSED

• OUTDOOR

• EXTERIOR

• LINE

• DIRTY

OUTPUT

• SAFE

• FILTERED

• LOAD

• CLEAN

• PROTECTED

• EQUIPMENT

INPUT

40-200A

200+A

SRF

SRF LABE L S PHYSICAL CONNECTIONS

OUTPUT ONBOTTOM

INPUT ON TOP

SRF

INPUT ONBOTTOM

OUTPUT ON TOP

Figure 10. Identification of SRF input and output terminals.

SRF

INPUTLINE

OUTPUTLOAD

Right anglecrossingOK

Keep cablesand equipmentaway from thisarea

300 mm

300 mm

300 mm

Safe area

Hazardous area

Figure 11. Maintaining clearance between input and other cabling.

Cabling TSG Series Surge Reduction Filters

PAGE 16

Filter Rating Maximum Accepted Cable Size

Phases(s) Neutral Earth

Termination Size Termination Size Termination SizeMethod Method Method

Single Phase

40A Input Screw Clamp 50mm2 Screw Clamp 50mm2Output Screw Clamp 35mm2 Screw Clamp 35mm2 Stud* 8mm

63A Input Screw Clamp 50mm2 Screw Clamp 50mm2 Stud* 8mmOutput Screw Clamp 35mm2 Screw Clamp 35mm2

125A Input Stud 8mm Stud 8mm Stud* 8mmOutput Stud 8mm Stud 8mm Stud* 8mm

Three-Phase



125A Input Bolt 8mm Bolt 8mm Stud 8mmOutput Bolt 8mm Bolt 8mm Stud 8mm



630A Input 6 x Bolt 10mm 6 x Bolt 10mm Stud 8mmOutput 6 x Bolt 10mm 6 x Bolt 10mm Stud 8mm

1250A Input 6 x Bolt 12mm 6 x Bolt 12mm 2 x Stud 8mmOutput 6 x Bolt 12mm 6 x Bolt 12mm 2 x Stud 8mm

2000A Input 6 x Bolt 12mm 6 x Bolt 12mm 2 x Stud 8mm Output 6 x Bolt 12mm 6 x Bolt 12mm 2 x Stud 8mm

* Input and output earths on 40 and 63A TSG-SRFs use a common earth stud.Table 2. Termination details for TSG-SRFs.

Bolt/Screw Recommended Torque Location

M6 4.2 Nm ( 3.1 ft.lbs) TSG-SRF140, 163, 340, 363 input terminals

M6 3.5 Nm ( 2.6 ft.lbs) all locations except as above

M8 14.0 Nm ( 10.3 ft.lbs) TSG-SRF1125, 3125 phase input terminals

M8 8.5 Nm ( 6.3 ft.lbs) all locations except as above

M10 44.0 Nm (32.0 ft.lbs) TSG-SRF3200, 3400, 3630 phase input terminals

M10 17.0 Nm (12.5 ft.lbs) all locations except as above

Table 3. Recommended tightening torques.

Output DistributionInstallation & Operating Instructions

PAGE 17

6.3 OUTPUT DISTRIBUTION

As the output of the SRF is considered to be a"clean filtered" supply it should not besubjected to situations where further tran-sients can be introduced. The "clean" supplyshould not be run external to the facility, ie toprovide power to an external building ortower lighting. From the aspect of transientprotection, to do so would create possible"points of entry" for transient energy to theprotected zone.

A similar scenario exists where the output ofthe SRF is fed to an electrically "noisy" load.Any transients developed by this load mayalso be fed to other equipment connected tothe same supply.

Electrically noisy equipment should ideally besupplied from a separate SRF and all cablingshould be run in isolation to other cables.

SRF

AIRCRAFTWARNING LIGHT



INCORRECT CONNECTION

WRONG

SRF

ALTERNATIVE CONNECTION

RIGHT

SRF SRF

REVERSE CONNECTED SRF

PREFERRED CONNECTION

RIGHT

SRF

WRONG

RIGHT

SRF

Figure 12. Connection of circuits outside the protectedzone.

Figure 13. Isolation of sensitive equipment from noisysources.

Earthing TSG Series Surge Reduction Filters

PAGE 18

6.4 EARTHING

The earths for all site equipment should beintegrated (preferably deploying a single pointearthing approach) and an equipotential earthplane should be created. Integral to this is theelimination of earth loops. It is common, butincorrect from the point of lightning protec-tion, for there to be separate earths for vari-ous services, ie electricity mains, telephone,computer equipment and other building serv-ices.

For sites where the interconnection of theseearths is difficult, either for practical or regu-latory reasons, the use of a Transient EarthClamp (TEC) is recommended. The TECbehaves as an open circuit under normaloperation, but under surge conditions it acti-vates to effectively clamp individual pointstogether.

The effectiveness of an SRF is intimately relat-ed to the impedance presented by the earth-ing system to which it is connected. A lowimpedance route to the earth is required (less

than 10Ω). This can be achieved by ensuringthat the earth electrode system at the sitepresents a low surge impedance with respectto the ground. Additionally, the interconnect-ing cabling must be of adequate crosssectional area and be routed to provide asshort and direct a path as is practical. Ideallythe earthing system impedance should bemeasured using a meter which simulates thetypical wave shape of a lightning transient.ERICO can provide this service.

The earth conductor for the SRF should besized according to local regulations but with aminimum size of 6mm2. Every attempt shouldbe made to limit the cable length to under 5metres.

By selecting the most direct route, with theminimum possible number of bends to theearth point or internal earth bar, the risk ofside flashing and excessive voltage rise acrossthe equipment is reduced. Figure 14 depictsthe correct earthing concept as describedabove.

Earth bar

Single centralearthingsystem

SRF UPS

Rooftopmicrowave

All power and data cables enter or leave the building on the same side(to avoidearthloops)

3 PhaseLV electricitysupply

R. F.Communications

Equipment

Communications& ComputingEquipment

DatalineProtector

CoaxialProtector

Peripheralsearthed to the central earth viaequipment

Figure 14. Preferred approach toequipotential bonding.

Connection of Alarm CircuitsInstallation & Operating Instructions

PAGE 19

6.5 CONNECTION OF ALARM CIRCUITS

The TSG-SRF secondary surge diverters arecontinuously monitored and their internalprotection status is identified by a twosegment LED indicator for each phase.

Reduction in surge handling capacity activatesa set of voltage free alarm contacts which canbe used to shut down the load or to activatean external warning. Once an alarm situationis registered, there is a three-second delayprior to the alarm contacts opening.

This three-second alarm delay is provided toeliminate the possibility of nuisance alarmsthat may be attributed to brief supply voltagevariations.

When mains voltage is applied to the TSG-SRF and the surge diverters are fully function-al, the alarm contacts will be in the energisedor normal state. The NC contact will be in

short circuit with the COM contact. Shouldthe surge handling capacity fall to below thealarm threshold, these contacts will be in thede-energised or alarm state and the NOcontact will be in short circuit with the COMcontact.

The contacts are "Fail-Safe" in that, if powerto the unit fails, the contacts will revert to thede-energised or alarm state.

The alarm contacts should only be connectedby an appropriately qualified person owing tothe possibility of mains voltage being presentin the TSG-SRF cabinet. Care should be takento route the alarm wiring away from theinput circuit and any other current-carryingconductors.

Alarm contact ratings:

• 2A @ 30Vdc• 600mA @ 110Vdc• 600mA @ 125Vac

Installation arrangement for AustralianMEN Systems

TSG Series Surge Reduction Filters

PAGE 20

6.6 INSTALLATION ARRANGE-MENT FOR AUSTRALIAN MENSYSTEMS

Under Australian Standards classification, SRFsare considered a piece of equipment to beconnected to the mains supply. They are notintended for use as switchboards, distributionboards or other equipment. As these devicesare classified as "electrical equipment" AS3000 Wiring Regulations apply to the installa-tion and operation of the units.

AS 3000 specifies minimum requirements forelectrical equipment that is connected toswitch boards or distribution boards.

For a point of entry application in the multipleearth neutral (MEN) distribution system, theSRF equipment should be installed as close aspossible after the MEN point and after boththe main disconnect switch/over-currentprotector and any metering equipment. TheSRF therefore, may not be installed at thephysical "point of entry" of the mains powerto the building. It must be earthed andinstalled in accordance with all other applica-ble electrical and safety standards. As theprotection equipment is hardwired, the instal-lation must be inspected by an appropriatelyauthorized electrical authority official prior tocommissioning.

Figure 15. Typical connection detail for SRF point ofentry installation in MEN system.

METERING MAIN DISTRIBUTION SRF

∅ 1

∅ 2

∅ 3

SUB DISTRIBUTION

INPUT

OUTPUT

NEUTRAL

EARTH

M.E.N.LINK

TSG-SRFs on Sub-CircuitsInstallation & Operating Instructions

PAGE 21

6.7 TSG-SRFs ON SUB-CIRCUITS

Where SRFs are installed to protect equip-ment on a particular sub-circuit, it is stronglyrecommended that additional protection beinstalled at the power point of entry. Primaryshunt protection at the poin of entry shouldbe used to divert the peak surge currentsaway from the sub-circuit. This will reduce therisk of cross-coupling of transients onto adja-cent circuits and will reduce the risk offlashover between the locally grounded chas-sis and the earth circuit.

Figure 16 details the role of point of entryprotection in these instances. The cablessupplying the input to the SRF and theconnection to the earthing system will carry aproportion of the surge energy which hasbeen let through the primary point-of-entryprotector.

Care should be taken therefore, in the routingof these cables to ensure that this energy willnot couple onto adjacent circuits.

Figure 16. Operation of primary shunt protection andSRFs on sub-circuit.

SRF

LIGHTS NON CRITICAL LOADSAIR CONDITIONING

Sub-Circuit only protected

SRF

LIGHTS NON CRITICAL LOADSAIR CONDITIONING

Sub-Circuit protection combined with point of entry shunt protection

SHUNTONLY

DEVICE

TSG-SRFs on Sub-Circuits TSG Series Surge Reduction Filters

PAGE 22

In some instances it will be necessary toprovide a separate earth electrode for the SRF(subject to compliance with relevant wiringregulations), particularly where the filter is tobe installed on a sub-circuit some distancefrom the existing earth electrode. In thisinstance, the new electrode should be locatedas near as possible to the SRF. This secondaryelectrode must be electrically bonded to theexisting earthing system via the most directroute possible, using flat copper tape andshould be buried to an appropriate depth.

SRFNEUTRALNEUTRAL

MAX

LEN

GTH

5M

BENDS AND LOOPS TO BEAVOIDED WHERE POSSIBLE

LOCAL EARTH ELECTRODE

TO LOADS

EARTH

EARTHEARTH

PHASE CONDUCTORS IN/OUT

EXISTING EARTHELECTRODE

INPUT

OUTPUT

This earthing arrangement is depicted inFigure 17. If a secondary earth cannot beinstalled, or the earth impedance through thesub-circuit to the earth is significantly above10Ω, special care must be taken. The risk offlashover between the locally grounded chas-sis and the earth circuit may exist.

Careful attention must be paid to equipoten-tial bonding of the protected equipment.

Figure 17. Earthing of an SRF remote from MEN point. (Subject to compliance with relevant nationalstandards). Care is needed to avoid earth loops within protected environment.

Servicing & Trouble ShootingInstallation & Operating Instructions

PAGE 23

7. SERVICING and TROUBLE SHOOTING

HAZARDOUS VOLTAGES EXIST WITHINTHE SRF ENCLOSURE. THE SRFSHOULD ONLY BE SERVICED BY QUAL-IFIED PERSONNEL, IN ACCORDANCEWITH RELEVANT NATIONAL ELECTRI-CAL & SAFETY CODES.

Do not disconnect upstream earth or neutralconnections supplying the TSG-SRF whilepower is applied to the unit, as this maydamage the TSG-SRF or load.

Only replace the primary TSG or secondary TDSsurge diverters with an identical type.

Voltage-free alarm contacts are activated (aftera three-second delay) should the secondaryprotection status fall below a pre-determinedlevel.

Fault Checks

All indicators, alarms and surge counters(where fitted) should be checked on a regularbasis.

Should any of the display indicators fail to illu-minate, check for the following conditions:

• Is power available to the TSG-SRF?

• Check the input voltage by measuring thevoltage between active and neutral

• Has the line fuse blown or upstream circuitbreaker or fuse tripped?

Surge reduction filters of 1250A capacity andabove, have fuses installed in series with theTSG primary surge protection.

If these fuses are open circuited for any reason,or if the fuse ruptures, then the primary surgeprotection is removed from circuit.

• For SRFs utilising input fuses, spares ofthe correct type and rating should beheld on site.

The TSG-SRFs are essentially maintenancefree, although periodic inspection is recom-mended to ensure that the ventilation louvres(where fitted) do not become clogged withdust. In high humidity areas, dust should beregularly vacuumed from the enclosures toprevent the possibility of voltage tracking.

Indicators

If power is being supplied to the TSG-SRF andthe indicators still fail to illuminate, then it ispossible that either the primary TSG orsecondary TDS devices have exhausted theirsurge capacity. In such circumstances, theparticular devices should be replaced as amatter of urgency as they are no longerproviding optimum protection.

A single status indicator is provided on eachTSG surge diverter to indicate the surgecapacity of the primary TSG surge diverter(s).When power is applied and full surge capaci-ty is available, the status indicator will be illu-minated. Should the indicator fail to illu-minate, the TSG should be replaced, asoptimum protection is no longer provid-ed. It should be noted that the status indica-tor will not illuminate (regardless of TSGsurge capacity) if power is not available.

The TSG-SRF employs TD technology as thesecondary protection stage on both singleand three-phase models. The integrity andsurge capacity of this stage is indicated by atwo-segment LED display per phase, locatedon the escutcheon panel of the TSG-SRF.Should one or both of the secondary stageLED indicators fail to illuminate a reductionin surge handling capacity has occurred.In this event the affected surge divertermodule should be replaced.

Non-Standard Products & accessories TSG Series Surge Reduction Filters

PAGE 24

8. NON-STANDARD PRODUCTS &ACCESSORIES

This document details the installation proce-dure for our current range of standard TSG-SRFs. Non-standard units are also manufac-tured to suit specific customer requirements.This manual is likely also to be supplied withthese units. The following are details for someof the non-standard variations and optionsavailable.

Backplane unit:

Normally denoted by ‘BP’ in the modelnumber. These units are supplied without theproprietary enclosure and are intended to bemounted in a customer provided switchboard.

Low Voltage unit:

This is an alternative voltage version of thestandard TSG-SRF. This unit incorporatesprimary and secondary surge diverters specifi-cally designed for low voltage applications, ie110/120VAC.

Surge Counter:

Optional surge counter (available for the TSG-SRF three-phase 125A to 2000A models).

Benefits of having the surge counter installedare accurate and reliable monitoring of surgeactivity and predictive maintenance schedul-ing. Accidental erasure of the surge count isprevented by the use of a non-resetablecounter display.

The surge counter can be either factory orfield installed. The ordering information forthis option is detailed below.

• Factory installed - Add the following post-script to the part number of the product.

(eg TSG-SRF3125 /SC for a three-phase125A Surge Reduction Filter with factoryinstalled surge counter)

• Field installed - Order a TDS-SC from yournearest ERICO office or distributor. Wheninstalling the TDS-SC, please follow theupgrade installation instructions which areprovided with the counter.

Figure 18. Backplane unit, supplied for installation intocustomer provided switchboard.

Schmetic DiagramsInstallation & Operating Instructions

PAGE 25

9. SCHEMATIC DIAGRAMS

A

N

E

A

N

E

Circuit Breaker or Fuse

TSG PrimaryDiverter

40A + 63Amodels TSGconnectedprior to circuitbreaker

TSG Diverter

TD SecondaryDiverter

L1

C1

INPUT/LINE

Single-Phase SRF Models

OUTPUT/LOAD

Figure 19. Schematic diagram for Single-Phase Filters.

Schmetic Diagrams TSG Series Surge Reduction Filters

C1

Phase 1L1

INPUT/LINE OUTPUT/LOAD

C2

Phase 2L2

C3

Phase 3

N

E

N

E

L3

L4

Three-Phase SRF Models




Circuit Breaker or Fuse

Circuit Breakeror Fuse


TSG PrimaryDiverter




TSG PrimaryDiverter

TSG PrimaryDiverter

TSG Diverter


Figure 20. Schematic diagram for Three-Phase Filters.

Physical DimensionsInstallation & Operating Instructions

10. PHYSICAL DIMENSIONS

Table 4. Physical dimensions of CRITEC TSG-SRFs

TSG-SRF DIMENSIONS

TSG-SRF ENCLOSURE SIZE MOUNTING CABLE MASS

MODEL X1 Y1 FASTENER ENTRYW H D X2 Y2 DIAMETER

TSG-SRF132 300 400 170 260 477 Ø10 A 11377 360

TSG-SRF163 300 400 170 260 477 Ø10 A 11377 360

TSG-SRF1125 300 400 170 360 477 Ø10 B 13377 360

TSG-SRF340 400 500 170 360 577 Ø10 A 20477 460

TSG-SRF363 400 500 170 360 577 Ø10 A 20477 460

TSG-SRF3125 500 650 175 460 727 Ø10 C (Ø25mm) 38577 610

TSG-SRF3200 500 780 215 460 857 Ø10 C (Ø32mm) 52577 740

TSG-SRF3400 650 850 218 610 927 Ø10 GLAND PLATE 100*727 810

TSG-SRF3630 850 1150 235 (X3) 405 1227 Ø10 GLAND PLATE 120*927 1110

TSG-SRF31250 1200 1650 315 ON Ø12 GLAND PLATE 350*APPLICATION

TSG-SRF32000 1200 1650 315 ON Ø12 GLAND PLATE 400*APPLICATION

A

B

C

25mm

25mm

20mm

40mm

20mm

X2

X3 X3

W

X1

Y2

H Y1

D

* Indicative mass only. If exact mass is critical for these units,contact ERICO for confotmation.

For further advice on your electrical protection needs please contact your local ERICO office.

Surge Reduction Filters form an important part of a much larger lightning, surge and transient protection philosophy. From over 150 years of combined aggregate experience in the field, ERICO engineers have developed the Six Point Plan™ of Protection.

Capture the lightning strike to a known and preferred attachment point.

Safely convey this energy to ground.

Dissipate the energy into a low impedance grounding system.

Bond all ground points together to eliminate ground loops and create an equipotential plane.

Protect incoming AC power feeders.

Protect low voltage data/telecommunication circuits.

Power Protection deviceCommunications Line Protection device• Coaxial Surge Protector (CSP)• Telecommunications Line Protector (TLP)• Data Line Protector (DLP)• Data Equipment Protector (DEP)

The range of TSG-SRFs fulfill some of the requirements of point 5 of the plan. Careful consideration of each of the six interdependent disciplines of the Six point Plan is important to ensure the provision of optimal protection and long-term operational viability. The degree of protection required will be determined by the individual situation and the proper application of risk management principles.

©Copyright 2001 ERICO International Inc.

The ERICO Six Point Plan of Protection

INSTALLATION AND OPERATING INSTRUCTIONS€¦ · Installation & Operating Instructions Warnings PAGE...

Documents

Transcript of INSTALLATION AND OPERATING INSTRUCTIONS€¦ · Installation & Operating Instructions Warnings PAGE...