cutler-hammer surge protection.pdf

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Contents

Surge Protection & Power Conditioning Products35

Ref. No. 1285

SurgeProte

ction&Pow

er

C

onditioningProduc

ts Description PageSurge Protection & Power Conditioning ProductsOverview

The Power Quality Pyramid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.0-2

Surge Protection Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.0-3

Voltage Sags/Regulation & Power Conditioning Overview . . . . . . . . . . . 35.0-4

Surge Protection Products TVSS

An Industry Breakthrough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1-1

Clipper Power System (CPS) Visor Series . . . . . . . . . . . . . . . . . . . . . . . 35.1-2

Visor Display Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1-4

Clipper Power System Retrofit Installation . . . . . . . . . . . . . . . . . . . . . . 35.1-8

Clipper VL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1-14

Whole Home Surge Protector (CHSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1-16

AEGIS Powerline Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1-17

Reflective Wave Trap (RWT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1-19

Datacom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1-21Specifications

For complete product specification in CSI format seeEatons Cutler-Hammer Product Specification Guide

Clipper Power Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 16671A

AEGIS Powerline Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 16671B

Reflective Wave Trap (RWT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 16671C

Datacom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 16671D

Surge Protection & Power Conditioning Products Family

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Surge Protection & Power Conditioning Products

5

Overview

General DescriptionRef. No. 1286

The Power Quality Pyramid

When evaluating a power qualityissue, the Power Quality Pyramidshould be used as the basis for analyz-ing a solution. This simple, yet proven

methodology will provide the mostcost-effective approach to ensuringreliable operation of electronic loadswithin a facility.

As shown in Figure 35.0-1

, groundingrepresents the foundation to any powerquality solution without it, othermitigating equipment will not functionproperly. Surge protection is the nextstage in the pyramid due to its lowoverall cost to facility-wide protection.

Sag correction or voltage regulation,harmonic filters and other solutionscan be employed where additionalreliability is necessary.

Figure 35.0-1.The Power Quality Pyramid

Figure 35.0-2.Surge Protection & Power Conditioning Applications (Commercial/Industrial Facility) These products can be applied either at the service entrance or branch location.

....................

The AEGIS family ofsurge filters: Providesprotection for PLCs forcritical loads.

DATACOM family ofsurge suppressors:For all telephone anddata communicationlines.

Clipper Power System(CPS): TVSS integrated& retrofit in MCCs,panelboards andswitchboards.

The above illustration identifies possible locations for:Voltage sag correction or regulation solutions (power conditioners). AC surge protection.

Telephone, cable and data line surge protection.

Motor protection from reflective wave spikes.

480V

12.47kV

120V

....................

....................

Production Floor

Office Panel

PBX(TelephoneSwitch)

AEGIS

ReflectedWave Trap

Motor

Motor

Copier

Printers

Server Lamp Fax

ElectronicLoad

PLC

.

.

.

.

PC

CPS

Note: All incoming data, telephone,4-20 mA,and signal lines require protection.

Utility Service

Small hpMotors

Welder

AFD Motor

AEGIS

WorkStation

AEGIS

RT

SurgeP

rotection

Datacom

Datacom

Sag Ride Through (SRT)corrects voltage sags.Electronic VoltageRegulator (EVR) correctsvoltage regulation(brownout) problems.

PowerConditioning

Motor Control

Center

AC Power

Service

Entrance

Telephone&DataServiceEntrance

R

W

T

SRT/EVR

Reflected Wave Trap (RWT):Motor protection againstreflected wave spikes.

CPS

AEGIS

RWT

DATACOM

SRT/EVR

AEGIS

AEGIS

CPS

CPS

Eaton's Cutler-Hammer business offers the most comprehensiveand effective facility-wide, power quality solutions.

SRT/EVR

SRT/EVR

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35January 2003

Surge Protection & Power Conditioning ProductsOverview

Surge ProtectionRef. No. 1287

The Problem

Voltage Transients andHigh Frequency Noise

The quality of power feeding sensitive

electronic loads is critical to the reliableoperation of any facility. In modernoffices, hospitals and manufacturingfacilities, the most frequent causesof microprocessor-based equipmentdowntime and damage are voltagetransients and electrical noise.

Electrical loads and sensitive micro-processor-based equipment arehighly susceptible to both highand low energy transients.

High Energy Transients

Sources of high energy transientsinclude lightning induced surges,power company switching and short

circuits. These high energy transientscan destroy components instantly.

Low Energy Transients andHigh Frequency Noise

More frequently the electrical systemexperiences low energy transients andhigh frequency noise that originatefrom the basic nature of AC current.Continuous or momentary surgesources from 250 to 3000 volts canbe present from the operation orswitching of electric motors, airconditioner compressors, or otherinductive loads.

The effects of continual low energytransients and high frequency noisecan cause erratic equipment perfor-mance or sudden failure of electroniccircuit board components.

The SolutionNote:Surge Protective Devices (SPD) arealso called TVSS or Transient Voltage SurgeSuppressors.

Eaton Corporation has an extensivefamily of surge protection productsfor any facility or application. Usingour products will ensure that thequality of power required to maximize

productivity in todays competitiveenvironment will be supplied in themost reliable, safe and cost-effectivemanner.

The Cutler-Hammer business hasdeveloped specific surge protectionsolutions for commercial, industrial,institutional, telecommunication, mili-tary, medical and residential applica-tions both for U.S. and internationalapplications.

Other Application and TechnicalInformation

Please contact your Cutler-HammerSales Engineer for copies of thefollowing surge protection/powerquality information not contained

in this catalog:s Technotes on surge protection.

s Surge Protection MarketSegment Application Matrix.

s Questions and Answers Surge Protective Devices.

s Independent Test Reports onthe CPS System.

s Installation manuals.

s Technical Specifications on DatalineProtectors (communications,telephone lines).

s Sales literature.

s Video Benefits of Integrated

Surge Protection.s International surge products.

s Typical specifications for AEGIS,CHSP, RWT and other products.

s Telecommunication and WirelessBase Station Protection Manual.

s TC TelecommunicationPower System.

s Surge strip product information.

s Lightning Response Investiga-tion and Power Quality Audit.

Applicable Standards:

s IEEE C62.41 (1991): Guide toSurge Voltages in Low Voltage AC

Power Circuits.s IEEE C62.45 (1992): Guide to

Surge Testing.

s IEEE Emerald Book (ANSI/IEEEStandard 1100).

s UL 1449: Underwriters LaboratoriesStandard for TVSS Devices.

s CSA: Canadian Safety Standards.

s NFPA: National Fire ProtectionAssociation.

s IEC 1024-1: Protection of StructuresAgainst Lightning.

s IEC 1312-3: Protection AgainstElectromagnetic Impulse.

s

NEMA

LS-1: National EquipmentManufacturers Association.

In addition, you can contact yourlocal Cutler-Hammer office or visitwww.cutler-hammer.eaton.com toobtain the following items:

Articles

s Specifying the Right Ratingsfor Surge Suppressors.

s IEEE White Paper on FacilityWide Surge Protection.

s When Lightning Strikes.

s New Life for Old (and New) Motors:the Reflected Wave Trap.

s Panelboards DesignedSpecifically for WirelessTelecommunication Sites.

Technotes

s Summary of Applicable ULand IEEE Standards for SurgeProtection Devices.

s Surge Current Per Phase

(Industry Definition).s Facility-Wide Surge Suppression.

s Debunking the Surge Current Myth,Why Excessive Surge CurrentRatings are Not Required.

s Surge Arrestor vs. Surge Suppressor.

s SurgePlane The Foundation toEffective Surge Suppression.

s Benefits of Hybrid Filtering inSurge Protection Devices.

s Why Silicon Avalanche Diodesare Not Recommended for ACPowerline Suppressors.

s New UL 1449 Safety Standard

for Transient Voltage SurgeSuppressors.

Datacom Application Guides

s Water Treatment Facility.

s Control Room.

s Alarm Systems.

s Intercom Systems.

s Control Systems.

s Isolated Loop Circuit Protector.

s Secondary Protectors.

s Data Line Correct Application.

s The Ground Window Concept.

s Instrumentation and Signal Lines.

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5

Overview

Power ConditioningRef. No. 1288

Voltage Sags/Regulation& Power Conditioning

The Problem

Voltage Sags and Brownouts

The ability of a plant to ride throughvoltage sags can have a significantimpact on operations and competitive-ness. In the United States, voltage sagscost billions of dollars in lost produc-tion, interruption, damaged materials,retooling and scrap. In addition, sagscan cause: increased operating costs,the need for product reworks, safetyhazards, equipment damage and/orfailure, reduced product quality,increased clean-up, additional laborcosts, increased scrap material andcosts associated with investigationsinto the problem.

Figure 35.0-3.Deep, Single-Phase Sag

Todays industrial and large commercialelectricity customers are becoming moresensitive to power disturbances and aredemanding better electric quality. How-

ever, the quality of power grids is notsignificantly improving. Customers stillexperience power quality problems thataffect plant operations and profitability.

Definition of Voltage Sag

A voltage sag is a sudden, momentarydecrease in supply voltage. It can lastfrom a cycle to several seconds. Voltagesags are most often caused by faults onthe electrical transmission or distribu-

tion system. They can be caused bylightning strikes, animal contact, start-ing of large motors or an internal faultwithin a customers facility.

Depending on the proximity to thefault, which can be hundreds of milesaway, the voltage during the sag istypically 40% to 90% of nominal utilityvoltage. The operation of circuit break-ers, fuses and reclosers limits mostsags to less than 15 cycles.

Voltage sags are experienced 10 to20 times more frequently than com-plete outages. However, voltage sagsare equally disruptive to sensitive

equipment.

Figure 35.0-4.Voltage Sags

Regularity of Voltage Sags

EPRI conducted a two-year study ofpower quality levels on distributionsystems in the United States. Avariation event was recorded everytime the voltage dropped below 90% of

the nominal. The results are shown inthe graph below (Figure 35.0-5).

A typical distribution system customerexperiences about 50 events per year,when the voltage drops below 90%,and only about two events per yearwhen the voltage drops below 30% ofnominal. The utility study concludedthat sags represented almost all of theevents experienced at a typical facility.

Brownouts

In the United States, most facilitieshave sufficient voltage regulation.However, in some U.S. locations andmany developing countries, regulation

problems occur because of over-stressed utility distribution systems.

Figure 35.0-5.Events per Year

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35January 2003

Surge Protection & Power Conditioning ProductsOverview

Power ConditioningRef. No. 1289

Figure 35.0-6.ITIC Curve Voltage Tolerance Envelope

In some cases, due to the excessivedemand on the utility system, voltagemay be below 10% of nominal (-10%)during the day. This condition is calleda voltage regulation or brownout.Customers may notice dim lights andreduced power. During the evening,voltage may rise above 10% of nomi-nal (+10%) because large facilities andloads are shut down. This shutdownreduces the power demand on the gridand results in a voltage increase.

The IEEE defines voltage regulation asovervoltage or undervoltage. Voltageregulation events last from a few min-

utes to many hours with voltage vary-ing by +/- 20%. Long-term regulationproblems differ from short durationsags and dips, which are much deepervoltage drops.

For facilities or processes thatrequire high operating reliability, aSag Correction Device will likely berequired to correct deep voltagesags. These random events occur onaverage 50 times per year at a facilitydue to faults in the utility system. Thesolution would be a Sag Ride Through(SRT) unit.

To obtain additional product information

and specifications on the Sag RideThrough and Electronic VoltageRegulator, contact the Cutler-Hammerbusiness.

The SolutionPrior to installing an expensivesolution, Eaton Corporations Cutler-Hammer business encourages cus-tomers to monitor incoming voltageto determine if voltage regulation is aproblem. The local utility may also beable to provide information on voltageexpected at the facility.

Using a meter, it can quickly be deter-mined if a voltage regulation problemor brownout condition exists. The appro-priate solution would be an ElectronicVoltage Regulator (EVR). EVRs can beinstalled at the service entrance, branch

panel or at critical loads.

SafeRegion

Duration of Disturbances in Cycles and Second(s) on a 60HzBasis

1S 1MS 3MS 20MS 0.5S 10S Steady State

Sag RelatedDisturbances

Brownouts

500

400

300

200

100

0

EquipmentDisruptionorDamage Region

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Ref. No. 1290

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35January 2003

Surge Protection & Power Conditioning ProductsSurge Protection Products TVSS

General Description Clipper Power System Visor SeriesRef. No. 1291

An Industry Breakthrough

Eatons Cutler-Hammer businesswas the first to introduce the directbus bar connect SPD that providescustomers with the lowest system

let-through voltage at the bus barwhen compared to traditional cableconnected surge protectors.

By utilizing a direct bus bar connectionthe Clipper Power System VisorSeries achieves the industrys lowestlet-through voltage effectively sup-pressing both high and low energytransient events providing protectionfor all connected electronic loads. Thisdesign provides superior suppressionratings and eliminates poor perfor-mance that results from cable connec-tions and/or long lead lengths.

Other ProductsOther surge suppressor manufacturersmeasurements are made at the SPDmodule or the suppressors terminals,not at the electrical distribution equip-ments bus bar. The distance betweenmodule or suppressor terminals andthe distribution equipment bus bar isoften 14 inches (355.6 mm) or more.The impedance associated withcabling required to connect the surgesuppressor to the electrical distribu-tion equipment (also referred to aslead length) significantly effects theoverall performance of the surge sup-pressor and results in an increase inlet-through voltage.

Pow-R-Line 3a Panelboard with integratedCPS120 and direct bus bar connection.Visor can also be integrated into Pow-R-Line 1a and 2a Panelboards. Disconnectoption also available.

Figure 35.1-1.120V/208Y Panelboard

1. Visor Series Hybrid Surge Filter.

2. Direct Bus Bar Connection.

3. Visor Monitor Diagnostic System.

4. Integral Molded Case Switch Disconnect.

Pow-R-Line C Distribution Switchboardwith integrated CPS250 and direct bus barconnection, and standard model caseswitch for disconnect means.

Freedom 2100 or Advantage MCC Bucketswith integrated CPS120 for retrofit and newinstallations.

208Y/120V Panelboard

0 5 10

800

Time (microseconds)

Let-Through

Voltage

at

BusBar

Based on IEEEC62.41 (1991)Combination WaveForm Category B3/C1

(6000V, 3000A;8x20 s) using #10AWG wire.

Integrated Clipper Power System

Cable Connected TVSS(14-Inch Cable Lead Length to Bus Bar)

400

1

2

3

4

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Clipper Power System Visor Series

Visor Series Retrofit and Integrated Versions

General Description

Eatons Cutler-Hammer leading-edgesurge suppression system for retrofitapplications offers the widest variety ofsurge current rating, monitoring fea-tures, and enclosure options. The VisorSeries is the most up to date and

respected line of surge protectiondevices in the industry due to its excep-tional technology and performance.

With over two decades of experiencein the surge suppression industryand extensive R & D initiatives, theCutler-Hammer business is considereda world leader in surge protectivedevice (SPD) manufacturing.

When installing a surge suppressor ina retrofit environment, it is importantto mount the suppressor as close tothe electrical equipment as possible.Keep the wiring (lead length) betweenthe electrical equipment and the sup-

pressor as short as possible, and twistor wire tie the conductors to reduceinductive effects.

Installation lead length reduces theperformance of any surge suppressor.For each inch of wiring (installationlead length), add 15 to 25 volts to thesurge suppressors published let-throughvalue (e.g., suppressor let-through at400V and installation of 3 feet (.9 m) ofcable = 1000V installed rating).

Applications

s The Visor can be integrated intoSwitchboards, Switchgear, MotorControl Centers, Panelboards andBusway.

s The Visor can also be externallymounted to existing distribution

equipment.s Standard NEMA 1/3R retrofit

enclosure.

s NEMA 4X and NEMA 12 enclosureavailable as an option.

s Enclosures with disconnect switchavailable as an option.

s The Visor is available from 100to 500 kA/phase units.

Remote Mounting Kits

The monitoring display panel can beremotely mounted on the Visor usingeither ribbon cables or DB15 connectorcable. Both optional kits can be ordered

separately. Cable supplied in the kitscomes in different lengths. Refer toTable 35.1-1.

Table 35.1-1.Remote Mounting Kits

Consult factory for availability.

Style Number Type

TBATBATBA

Ribbon cableDB15 cable 4 ft. (1.2 m)DB15 cable 8 ft. (2.4 m)

Features, Functions and Benefits

Standard Features

s 200 kAIC internal fusing system.

s Thermo-Dynamic Fusing System.

s Standard NEMA 1/3R enclosure.

s AdVisor monitoring package, whichis loaded with features. An audiblealarm with reset button, Form Cdry contacts and phase operatingstatus lights.

s Remote mountable display panel.

Optional Features

s SuperVisor and NetVisor monitoringpackages.

s Different enclosure packages.

s For OEM packages, contact factory.

Industry Leadership

s The Visor is an intelligent surge

suppression device that offersadvanced monitoring options.

s It offers improved safety andreliability from a new patentpending technology Thermo-Dynamic Fusing.

s Independently tested by lightninglaboratories to ensure performance,long-term reliability, and qualitystandards are met.

s Installation flexibility for all lowvoltage distribution equipment.

s Worldwide customer, engineering,and application support.

Application Flexibility

s 100, 120, 160, 200, 250, 300, 400 and500 kA/phase ratings are available.

s All units utilize our low impedanceSurgePlane suppression platformto ensure surge currents are equallydiverted to all suppression compo-nents, therefore extending lifeexpectancy.

Figure 35.1-2.SurgePlane Technology

SurgeCurrentEquallyDivertedNeutral

CopperSurgePlanes

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35January 2003



Comprehensive Diagnostics

s Maintenance-free surge suppres-sion. (No external test set or routinemaintenance required.)

s The NetVisor, our premium display,allows you to monitor your surge

protective device from across theplant or across the world.

s All monitoring display panels arecompletely removable and can beinstalled horizontally or vertically,offering four mounting positions.

s AdVisor and SuperVisor monitoringdisplay panels are completelyremovable and can be installed hori-zontally or vertically, offering fourmounting positions.

Visor Monitoring Options

s Our patent pending Thermo-Dynamic Fusing System providesboth safety and performance. Thistechnology uses a fuse trace on eachindividual metal oxide varistor (MOV)that can sustain high surge currents

and provide the necessary interrup-tion of high fault currents (kAIC).

s Thermo-Dynamic Fusing System alsoincludes a thermal fuse spring (TFS)that provides the needed disconnec-tion from low level fault currents.

Components of the Thermo-DynamicFusing System

Standards and Certifications

s All Clipper units have been tested byUL and meet the requirementsunder UL 1449 2nd Edition for surgesuppression devices.

s All Clipper units have been testedas per NEMA LS-1 and ANSI/IEEEC62.45.

s Category A3 Ringwave (6 kV opencircuit, 200A short circuit currentat 100 kHz).

s Category B3 Ringwave (6 kV opencircuit, 500A short circuit currentat 100 kHz).

s Category C1 Combination Wave(6 kV 1.2/50us open circuits, 3 kA8/20us short circuit current).

s Category C3 Combination Wave(20 kV 1.2/50us open circuits, 10 kA8/20us short circuit current).

s UL 1020 (standard for safety for

thermal cutoffs for use in electricalappliances and components).

s UL 1283 listed for EMI/RFI noiseattenuation filtering (50 db at 100kHz). CSA C22.2.

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Display Packages

Table 35.1-2.Visor Series

Note: = Yes$ = No = Not Applicable

Description AdVisor SuperVisor NetVisor

Diagnostics Package

Status Indicator Lights Red/GreenForm C ContactsAudible Alarm with Reset Button

Transient CounterPush-to-Test Button

Power Consumption in Watts

$

$

0.5W

1.2W

3.0WRemote Mounting Kits

Ribbon CableDB15 Cable

PQ Meter $

Adjustable Set PointsNon-Volatile MemoryWeb EnabledDate Stamped

$

$

$

$

$

Communication PortModbus and Ethernet

$

$

Communication Speed (10Base-T)

TemperatureStorageOperating

-40 C to +60 C-40 C to +60 C

-40 C to +60 C-20 C to +60 C

-40 C to +60 C-20 C to +60 C

Humidity (Relative) = 5% 95%Remote Mountable Display

Dimensions (4.2-inch W x 4.2-inch H x 0.4-inch D)(106.7 x 106.7 x 10.2 mm)

Power Quality (PQ) Metering

% Life Remaining% THD (Voltage)

Event Storage (9999 Events)LCD (2 x 16)

Event CaptureSag Counter

Counter:s -10% System Voltages 23 Cycless Fixed Set Points

Meter:s User Defined Set Points for

Voltage Triggers 1 Cycle

Swell Counter Counter:s +10% System Voltages One Cycles Fixed Set Points

Meter:s User Defined Set Points for

Voltage Triggers 1 Cycle

Outage Counter Counter:s Zero Voltage

s 2 Cycless Fixed Set Points

Meter:s >10% System Voltage

s 1 Cycles Fixed Set Point

Surge Counter Counter:s Sensitivity Minimum 104s 8x20 vs. Waveform

Meter:s Sensitivity Minimum 104s 8x20 vs. Waveform

Voltage MeterL LN G

$

Accuracy 5% 5%

Resolution 8 bit 8 bit

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A Facility-Wide ProtectionApproach Should be Employed toAddress Power Quality Issues

Why Coordinated (Cascaded)Facility-Wide Protection?

As recommended in the IEEE EmeraldBook, a cascaded or staged protectionapproach should be employed toreduce external/internal impulse wave-forms to harmless levels. An SPD filtershould be installed at the main serviceentrance and key distribution or branchpanelboards to eliminate ringing andimpulse disturbances as well as highfrequency EMI/RFI noise.

All Visor units are coordinated towork on a system basis. Visor unitsinstalled at each level in the systemwork together to isolate and removeexternal/internal generated distur-

bances, creating superior facility-wideperformance and reliability. IntegratedVisor units are available in switch-boards, switchgear, panelboards,MCCs, automatic transfer switches,and retrofit.

Benefits of Visor SeriesFacility-Wide Protection

s High amplitude lightning impulsesreduced to negligible levels.

s The industrys lowest systemlet-through voltage (under 200volts using ANSI/IEEE Category C3Combination Waveform 20 kV, 3 kA).

s The electrical distributions noiseattenuation is significantly enhanced.

The coordinated design ensures effec-tive current sharing between main andbranch SPD devices.

Figure 35.1-3.Cascaded Performance

Incoming LVSubstation

Service EntranceSwitchgear orSwitchgear CPS250

SPD Bus Plug CPS120

LV Busway

SwitchboardCPS120

Motor Control Center CPS120

Panelboard CPS100

Clipper Power System

Visor Series

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Figure 35.1-4.IEEE Emerald BookRecommends a Cascaded (or Two-Stage) Approach

SPD

480V SPD120/208V

Stage 1 Protection(Service Entrance)CPS250 Recommended

Stage 2 Protection(Branch Entrance)CPS200 Recommended

ComputerSensitiveLoads

System Test Parameters:IEEE C62.41 and C62.45 test procedures using C3 impulse480V main entrance panels;100 feet (30 m) of 3-phase wire;480V/208V distribution transformer; and

120V/208V branchClipper Power System Visor Series

0

25S 50S

400

800

10,000

20,000

Let-ThroughVoltage(V)

Time (Microseconds)

High Energy TransientDisturbance Input at Main PanelIEEE Category C3Impulse (Combination)Waveform,20,000V,10,000A

Best Achievable Performancewith Single TVSS at 480Volt

a n ane age

Two Sta e use ofCPSs(Cascade Approach)Achieves BestPossible Surge Protection (Stage 2)

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Table 35.1-3.Service Entrance Applications

Note:The CPS Surge components can be integrated into Safety Switches, Automatic Transfer Switches (ATS) and other assemblies.Contact your local Eatons Cutler-Hammer sales office.

Switchboard Switchgear Motor Control Centers

Features:s The Visor can be integrated into any

switchboard.

s Specifiers have the flexibility to install the Visorin any location within the switchboard.

s Disconnect switch is a standard feature.

s Unique design minimizes installationimpedance.

Features:s Available on all switchgear designs.

s Disconnect switch is a standard feature.

s Unique design minimizes installationimpedance.

s CPS250 ideal for critical industrialswitchgear applications.

Features:s Ideal protection for PLCs, sensors, drives,

electronic starters, or other digital equipment.

s Visor is designed to fit in Freedom 2100 andAdvantage MCCs in a standard (2X) size12-inch (304.8 mm) compartment.

s May be used in new/aftermarket applications.

s Ideal for water treatment, petrochemical andother industrial applications.

Safety Standards:

s UL 891 (Switchboard)s UL 1449 2nd Edition (Surge Suppressor)

s UL 1283 (EMI/RFI Filter)

s CSA C22.2 Certified (Suppressor)

Safety Standards:

s UL 1558 (Switchgear)s UL 1449 2nd Edition (Surge Suppressor)



Safety Standards:

s UL 845 (MCC)s UL 1449 2nd Edition (Surge Suppressor)



Panelboards Busway Retrofit

Features:s The Visor is used extensively on branch

panelboards for computer rooms, laboratories,schools, hospitals, and industrial applications.

s 200% rated neutral is provided for non-linearloads.

s Cost-effective branch protection (assumesmain panel protection employed).

Features:s Ideal for busway fed distribution systems.

s Easy to install Visor units, fit in standard busplug assembly.

s Full diagnostic and monitoring capabilities.

s Isolates critical busway sections from nearbydisturbance producing loads.

s Designed for new and existing facilities.

s Integral disconnect.

Features:s TVSS Filters can be externally mounted to

existing distribution equipment.

s Standard NEMA 12 enclosures.

s Requires field installation.

s Visor Retrofit 100 to 500 kA/phase units.

s Clipper VL 50, 80 and 100 kA/phase units.

Safety Standards:s UL 67 (Panelboards)

s UL 1449 2nd Edition (Surge Suppressor)



Safety Standards:s UL 857 (Busway)

s UL 1449 2nd Edition (Surge Suppressor)



Safety Standards:s UL 1449 2nd Edition (Surge Suppressor)



>

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14/28

5.1-8


January 2003


5



Retrofit InstallationRecommendations to ReduceLet-Through Voltage

When installing a surge suppressorin a retrofit environment, it is impor-

tant to mount the suppressor as closeto the electrical equipment as possible,keep the wiring (lead length) betweenthe electrical equipment and the sup-pressor as short as possible [lessthan 14 inches (355.6 mm) is recom-mended], and twist/wire tie the con-ductors to reduce inductive effects.

As shown in Figure 35.1-5 below,installation lead length reduces theperformance of any surge suppressor.For each inch of wiring (installationlead length), add 15 to 25 volts tothe surge suppressors publishedlet-through value (e.g., suppressorlet-through at 400V and installationof 3 feet (.9 m) of cable = 1000Vinstalled rating).

Retrofit Installation Recommendations

Visor Series Retrofit

Figure 35.1-5.Let-Through Graph

Wire Size

14 AWG

10 AWG

4 AWG

3 ft (.9 m) Lead Length 1 ft (.3 m) Lead Length

Twisted Wires

Installation Criteria Order of Importance:

1) Lead Length 75% reduction

2) Twisting Wires 23% reduction

3) Larger Wire minimal reduction

AdditionalLet-ThroughVoltage

(AdditionaltodeviceLetThrough) 1000

900

800

700

600

500

400

300

200

100

0

209V (23%)

673V (75%)

Twisted WiresLoose Wiring

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15/28


35January 2003



Visor Series Ordering Guidelines

Table 35.1-4.Retrofit

Table 35.1-5.Integrated

Valid for 220/415 and 240/415 per IEC standards.

Diagnostics Packages

A = AdVisor c/w Status indicator lights on eachphase, Form C, Audible Alarm Enable/Disable.

S = SuperVisor c/w Status indicator lights on eachphase, Form C, Audible Alarm Enable/Disable,Transient Counter, Push-to-Test, PQ Meter(no date stamp).

N = NetVisor c/w Status indicator lights on eachphase, Form C, Audible Alarm Enable/Disable,Transient Counter, Push-to-Test, PQ Meter (datestamp), Modbus and Ethernet Communication Port,% Life Remaining, % Voltage THD.

CPS 100 480Y S K

Surge Ratings

100 = 100 kA/phase120 = 120 kA/phase160 = 160 kA/phase200 = 200 kA/phase250 = 250 kA/phase300 = 300 kA/phase400 = 400 kA/phase500 = 500 kA/phase

Enclosure Cross Reference

K = Standard (NEMA 1, 3R)L = Flushmount (NEMA 1)M = Standard (NEMA 1, 3R)

c/w Disconnect SwitchN = NEMA 4XO = NEMA 4X c/w Disconnect SwitchP = NEMA 12Q = NEMA 12 c/w Disconnect Switch

Voltage Code 120/208

127/220240V

230/400

400V

277/480

480V

347/600

600V

220/127 Three-Phase Wye (4W+G) (Mexico)120/240 Single Split Phase (3W+G)Three-Phase Delta High Leg (4W+G)Three-Phase Wye (4W+G)Three-Phase Delta (3W+G)

220Y240S240H208Y240D

400Y

480Y480D

600Y600D

Diagnostics Packages

A = AdVisor c/w Status indicator lights on eachphase, Form C, Audible Alarm Enable/Disable.

S = SuperVisor c/w Status indicator lights on eachphase, Form C, Audible Alarm Enable/Disable,Transient Counter, Push-to-Test, PQ Meter(no date stamp).

N = NetVisor c/w Status indicator lights on eachphase, Form C, Audible Alarm Enable/Disable,Transient Counter, Push-to-Test, PQ Meter (datestamp), Modbus and Ethernet Communication Port,% Life Remaining, % Voltage THD.

CPS 100 480Y S C

Surge Ratings

100 = 100 kA/phase120 = 120 kA/phase160 = 160 kA/phase200 = 200 kA/phase250 = 250 kA/phase300 = 300 kA/phase400 = 400 kA/phase500 = 500 kA/phase

Enclosure Cross Reference

A = Panelboards (PRL1A, 2A, 3A, 4)B = Remote Monitor Display

(PRL4, Switchgear, Busway)C = MCC VersionD J = Warranty Versions,

Consult Factory.

Voltage Code 120/208127/220

240V

230/400400V

277/480480V

347/600600V

220/127 Three-Phase Wye (4W+G) (Mexico)120/240 Single Split Phase (3W+G)

Three-Phase Delta High Leg (4W+G)Three-Phase Wye (4W+G)Three-Phase Delta (3W+G)

220Y240S

240H208Y240D

400Y

480Y480D

600Y600D

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5.1-10


January 2003


5


Dimensions Clipper Power System Visor SeriesRef. No. 1300

Standard Dimensions Retrofit Only

Figure 35.1-6.NEMA 1 Flushmount up to 200 kA (480V or Less)

Figure 35.1-7.NEMA 1/3R up to 200 kA (480V or Less)

Figure 35.1-8.NEMA 1 Flushmount 250 kA and up(480V or Less/600V, 100 kA 500 kA)

Figure 35.1-9.NEMA 1/3R 250 kA and up(480V or Less/600V, 100 kA 500 kA)

CLIPPER POWER SYSTEM

15.0 (381)

20.0 (508)16.0 (406)

3.9 (98)

11.0 (279)

16.0 (406)


3.9 (98)

17.0 (432) 3.9 (98)

22.0 (559) 18.0 (457)



13.0 (330)

18.0 (457)

3.9 (98)

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17/28


35.1January 2003


Dimensions Clipper Power System Visor SeriesRef. No. 1301

Standard Dimensions Retrofit Only (Continued)

Figure 35.1-10.NEMA 4X up to 500 kA (All Voltages)

Figure 35.1-11.NEMA 1/3R c/w Disconnect Switch(Up to 500 kA/All Voltages)

Figure 35.1-12.NEMA 4X c/w Disconnect Switch(Up to 500 kA/All Voltages)

16.0 (406)

18.0 (457)


8.6 (219)


14.1 (359)

22.6 (575)

5.2 (132)


18.0 (457)

21.9 (556)

10.4 (264)

>

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18/28

5.1-12


January 2003


5


Technical Data Clipper Power System Visor SeriesRef. No. 1302

Table 35.1-6.Eatons Cutler-Hammer Clipper Power System Visor Series Specifications

Guide for applying the appropriate surge suppressor based upon life expectancy and performance.

CPS250 recommend for service entrance. CPS120 recommended for branch locations using IEEE recommended cascade approach. Optional sizes to meet competitive specifications. All CPS have been independently tested to verify all suppressor components can survive published

surge current ratings. Test documents are available upon request.

CPS Models CPS100 CPS120 CPS160 CPS200 CPS250 CPS300 CPS400 CPS500

Surge Current Per Phase 100 kA 120 kA 160 kA 200 kA 250 kA 300 kA 400 kA 500 kA

Surge Current Mode

L-N (Line-to-Neutral)L-G (Line-to-Ground)N-G (Neutral-to-Ground)L-L (Line-to-Line, Delta, andUngrounded Applications Only)

50 kA50 kA50 kA

50 kA

60 kA60 kA60 kA

60 kA

80 kA80 kA80 kA

80 kA

100 kA100 kA100 kA

100 kA

125 kA125 kA125 kA

125 kA

150 kA150 kA150 kA

150 kA

200 kA200 kA200 kA

200 kA

250 kA250 kA250 kA

250 kA

Single Pulse Surge Current TestBased on IEEE C62.41 8x20 microsecond

waveformYes Yes Yes Yes Yes Yes Yes Yes

Modes of Protection3-Phase Wye System3-Phase Delta System

All76

All76

All76

All76

All76

All76

All76

All76

Filter Attenuation(Based on MIL-STD-220A) at 100 kHz 50 dB 50 dB 50 dB 50 dB 50 dB 50 dB 50 dB 50 dB

Surge Withstand CapabilitiesANSI/IEEE C3 Wave (10 kA) 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000

Thermo-Dynamic Fusing SystemOvercurrent Protection (Thermal Fuse Spring)200 kAICIndividual Fused MOVs

YesYesYes

YesYesYes

YesYesYes

YesYesYes

YesYesYes

YesYesYes

YesYesYes

YesYesYes

Monitoring Display OptionsSuperVisor (Standard)AdVisorNetVisor

YesOptionalOptional

YesOptionalOptional

YesOptionalOptional

YesOptionalOptional

YesOptionalOptional

YesOptionalOptional

YesOptionalOptional

YesOptionalOptional

Direct Bus Bar Connection Yes Yes Yes Yes Yes Yes Yes Yes

Warranty Clipper Power System Visor Series 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years

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35.1January 2003


Technical Data Clipper Power System Visor SeriesRef. No. 1303

Exceptional Let-Through Performance

Let-through voltage is the key perfor-mance measure for a suppressiondevice. NEMA LS 1-1992 and ANSI/IEEE C62.41 and 45 recommend test-ing TVSS devices using high energy

combination waveforms (i.e., CategoryC3 and C1) and internally generatedringwave surges (i.e., Category B3).

Eatons Cutler-Hammer Visor designoffers superior performance on allANSI/IEEE recommended waveformsbecause of our unique low impedance3D SurgePlane, matched MOVs on

each mode and phase, tuned suppres-sion filter, and high quality construc-tion/manufacturing process.

Figure 35.1-13.IEEE C62.41 Test Waveforms

Table 35.1-7.Visor Series Let-Through Ratings

Indicates dynamic test method.

Operating SystemVoltage

Wye System Delta System

L-G L-N N-G L-L L-G L-L

ANSI/IEEE Category C3 Combination Wave (20 kV, 10 kA) 8 x 20 s

120/240V; 208Y/120V; 240V Delta480Y/277V; 480V Delta600Y/347V; 600V Delta

70012001500

600900

1800

80012002000

1000800

2500

100018002500

100018002500

ANSI/IEEE Category C1 Combination Wave (6 kV, 3 kA) 8 x 20 s


400800

1000

400800

1000

450900

1300

68016002000

80015002000

80015002000

UL 1449 2nd Edition (6 kV, 500 Ampere)


400800

1000

400800

1000

400800

1000

80015002000

80015002000

80015002000

2010-10 03020100

6,00010,000

8,000

6,000

4,000

2,000

0

SurgeVoltage(V)

SurgeCurrent(A)

4,000

2,000

0

-2,000

-4,000

Time (Microseconds) Time (Microseconds)

12,000 8,000

Cat. C1 (6 kV,3 kA) Impulse

Cat. C3 (20 kV,10 kA) Impulse Cat. B3 (6 kV,100 kHz) Ringwave

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20/28

5.1-14


January 2003


5


General Description Clipper VL SeriesRef. No. 1304

Clipper VL

Eatons Cutler-Hammer Clipper VL isa commercial grade and light indus-

trial Surge Protection Device (SPD)that combines surge suppressioncomponents and EMI/RFI filtering toprovide effective protection for sensi-tive electronic loads. Surges (alsoknown as transients) due to lightning,utility grid switching, switching ofexternal/internal inductive or capaci-tive loads and other sources travelon power line conductors throughoutthe electrical distribution system thatcause system operating problemsand equipment downtime.

Three surge current ratings are avail-able to meet a variety of applications

the CVL050 (50 kA/phase), CVL080(80 kA/phase) and CVL100 (100 kA/phase).

Service Ratings

s 120/240V AC(1-phase 3-wire + ground).

s 208Y/120, 480Y/277, 600Y/347V AC(3-phase 4-wire + ground).

s 240, 480, 600V AC(3-phase 3-wire delta).

Panel Mounted Surge Protection Device Commercial and Light Industrial Applications

Surge Current Per Phase

s 50, 80 and 100 kA.

s Independently tested at lightninglaboratories to verify publishedsurge current ratings.

s SurgePlane technology to ensurereliability and performance by usinga low impedance copper platform.

s All Clipper VL units have beentested per NEMA LS-1 and ANSI/IEEE recommended high energyimpulses (Category C3, 20 kV,10 kA), and internally generatedringwave surges (Category B3, 6 kV,500A, at 100 kHz).

s UL 1449 2nd Edition listed, UL 1283listed, CSA approved, CE marked.

EMI/RFI Filters The UL listed filter protects against

ringing transients and EMI/RFI noisedisturbances. The tuned suppressionfilter achieves 0 40 dB attenuation at100 kHz (IEEE Category B3 Ringwave).

Monitoring and Diagnostics

s No external test set or routine main-

tenance costs are required.s Status indicator lights to monitor

supply power, surge suppressioncomponent status and fusing.

s Individually fused surge suppressioncomponents.

s Can be remotely monitored usingForm C contacts c/w AudibleAlarm.

Enclosure

s NEMA 1 surface mounting isstandard.

s NEMA 3R outdoor enclosure isan option.

Table 35.1-8.Specifications

Contact the Cutler-Hammer business for let-through voltage ratings for other system voltages. AllCVLs have been independently tested to verify all suppressor components can survive publishedsurge current ratings. Test Documents are available upon request.

CVL CVL50 CVL80 CVL100

Surge Current Per Phase 50 kA 80 kA 100 kA

Surge Current Per Mode 25 kA 40 kA 50 kA

Let-Through Voltage Rating

IEEE Category C3 Combination Wave (20 kV, 10 kA)IEEE Category C1 Combination Wave (6 kV, 3 kA)IEEE Category B3 Ringwave (6 kV, 500A, 100 kHz)UL 1449 2nd Edition (6 kV, 500 ampere)

(L-N mode: 120/208V)

655V440V380V500V

655V440V380V500V

655V440V380V500V

Filter Attenuation (MIL-STD-220A at 100 kHz) 40 dB 40 dB 40 dB

Multiple Surge Withstand Possibilities(IEEE C3 Wave 20 kV, 10 kA)

>1500 >1500 >1500

Circuit Construction SurgePlane SurgePlane SurgePlane

UL 1449 2nd edition, UL 1283 Listed, CSA Approved,CE Marked

Yes Yes Yes

EnclosureNEMA 1NEMA 3R

StandardOptional

StandardOptional

StandardOptional

Warranty 10 Years 10 Years 10 Years

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35.1January 2003


General Description Clipper VL SeriesRef. No. 1305

Table 35.1-9.Clipper VL Catalog Ordering Information

Table 35.1-10.Voltage Code

Use these codes to complete the model number. Valid for 220/380 and 240/415 per IEC standards.

Note:Contact factory for single-pole (2-wire plus ground) or for other configurations.Not suitable for resistive or underground wire systems.Refer to the Clipper Power System (CPS) for these applications.

Physical Specifications

Temperature

-40C to 60C.

Altitude

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22/28

5.1-16


January 2003


5


General Description Clipper VL Residential SeriesRef. No. 1306

Cutler-HammerWhole Home Surge Protector(CHSP)

Eatons Cutler-Hammer Whole Home

Surge Protector is an externallymounted unit that provides industriallevel surge protection in a residentialdesign. The CHSP is available in fourversions and provides protection forall residential electrical equipment.These units can be mounted to anymanufacturers breaker panel eitherinside or outside.

Figure 35.1-15.Cutler-Hammer Whole Home Surge Protection (CHSP) Residential Product Chart

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35.1January 2003


General Description AEGIS Series Protective DeviceRef. No. 1307

AEGIS Critical LoadProtection Hybrid SeriesSurge Filters

Eatons Cutler-Hammer AEGIS solu-

tions are specifically designed to pro-tect expensive electronics from thehazards that exist within a facility. Thiscritical load protection is effective atreducing harmful surges and noise.Applying this high performance seriespowerline filter at your critical loadsresults in clean power entering theelectronics and reduction of softerrors, operational malfunction, anddamage to components.

Typical Applications

The AEGIS is the ideal protectionsolution for your critical loadsand facilities.

Loads:

s Programmable controllers (PLCs).

s Scanning devices.

s ATMs (Automatic Teller Machines).

s Cash registers.

s Alarm systems.

s Microprocessor-controlledOEM products.

s Robotics.

s CAD/CAM systems.

s Control equipment.

s Medical electronics and devices.

Table 35.1-11.Let-Through Voltages (L-N)

Note:Based on ANSI/IEEE C62.41, 1991and C62.45, 1992.

AEGIS-HWHardwired Surge Filter thatProtects Critical Loads 3to 20 Amperes

Why Should Sensitive ElectronicLoads be Protected?

PLC manufacturers and service techni-cians recommend the use of surgesuppressors and filters to preventdowntime and equipment damage dueto surges and electrical line noise. Onestudy shows failure to protect sensi-tive electronic loads cost Americanmanufacturing, commercial, andservice industries over $39 billion peryear in lost time and revenue. Prevent-ing these losses is a major cost-savingopportunity.

AEGIS Powerline Filters ProtectAgainst the Full Spectrum ofTransient Disturbances

AEGIS filters the entire sine wave andis effective against both frequently

occurring low energy and occasionalhigh energy transients. High energytransients can create immediate dam-age, while low energy transients causemicroprocessor failure over time.

Cutler-Hammer products are designedin accordance with ANSI/IEEE C62.41(1991) recommended spectrum oftransient waveforms. The AEGISprotects against all ringwave andimpulse disturbances.

Figure 35.1-16.Installation Diagram

AEGIS-PRPlug-in Surge Filter for Loadsup to 15 Amperes with RJ-11Modem Protection

Figure 35.1-17.IEEE C62.41 (1991) TestWaveforms

AEGIS+Two Stage Filter for Loads up to100 Amperes

Description AEGIS(L, N, G version)

Category A3 Ringwave(6000V, 200A)

8V

Category B3 Ringwave(6000V, 500A)

8V

Category B3/C1 Ringwave(6000V, 3000A)

112V

Programmable

ControlsAEGIS

Motors

MiscellaneousLoads

RelayContactors

0

100

-100

-200

-300

-400

200

300

400

Volts

2 Microseconds/Division

0

1000

-1000

-2000

-3000

-4000

2000

3000

4000

5000

6000

7000

Volts


0

100

-100

-200

-300

-400

200

300

400

500

600

700

Volts


B3/C1 Combination (Impulse)

Wave (6000V, 3000A)

A3 Ringwave (Line to Neutral) (6000V, 200A)

After

Before

After

0

-2000

-6000

-4000

2000

4000

6000

8000

Vo

lts


Before

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5.1-18


January 2003


5


Technical Data and Selection Guide AEGIS Series Protective DeviceRef. No. 1308

Table 35.1-12.Specifications

Table 35.1-13.AEGIS-HW (Hardwire Application) Catalog Numbering System

Note:230V applies to 220V and 240V applications.

Table 35.1-14.AEGS-PR (Plug-in Receptacle) Catalog Numbering System

230L-HW only.

Note:230V applies to 220V and 240V applications.

Table 35.1-15.AEGIS Catalog Numbering System

400/230 valid for 380/220 and 415/240 per IEC. Contact factory for resistive ground applications.

Application AEGIS-HW3-Wire Grounded Systems

AEGIS-PR2-Wire Ungrounded Systems

AEGIS+1-, 2- and 3-Pole Systems

Input Voltage, single-phase

Amperage

Frequency

120, 220, 240V AC, single-phase

3, 5, 10, 15, 20 Amps

50/60 Hz

120, 220, 240V AC

15 Amps

50/60 Hz

120, 208, 240, 400, 480, 600V; Wye, Deltaand International Systems

20, 30, 50, 70, 100 Amps

50/60 HzProtection Modes

MCOVNoise Attenuation:

Normal Mode:Common Mode:

L-N, L-G, N-G

150, 320

75 dB at 100 kHz50 dB at 5 mHz

L-N, L-G, N-G

150, 275V

85 dB at 100 kHz50 dB at 5 mHz

L-N, L-G, and N-G modes (Wye system);L-L and L-G (Delta system)

150, 320, 420V

65 dB at 100 kHz40 dB from 60 kHz to 5 mHz

Filter BandwidthTotal Peak Surge CurrentOperating Temperature

10 kHz to 50 mHz45.5 kA/phase-40C to +50C

10 kHz to 50 mHz39 kA/phase-40C to +50C

10 kHz to 50 mHz40, 80 or 160 per phase-40C to +40C

Response TimeOptions

Agency Approvals

Less than 1 nanosecondForm C Relay Contacts

UL 1449, UL 1283, CSA

Less than 1 nanosecondHospital Grade Filter

UL 1363, UL 1449, UL 1283, UL 497A, CSA

Less than 1 nanosecondForm C Relay Contacts; NEMA 3R/4X Con-

tainer; Disconnect Switch; 40 kA or 160 kACE, UL 1449, (20 to 70 amperes, up to 480V)

Voltage Code

120N230L

Options

S = StandardC = Form C Contact

for Remote Monitor

Current Capacity

35

101520

AGSHW CH

AGSPR CH

Voltage Code

120N

230L

Options

HG = Hospital Grade FilterHW = Hardwire UnitXX = No Options

Current Capacity

15

Voltage Code

120N = 120 (1-Phase, 2W+G)208Y = 120/208Y (3-Phase, 4W+G)240S = 120/240 (1-Phase 3W+G)

230L = 230 (1-Phase, 2W+G)

240D = 240D (3-Phase, Delta 3W+G)

400Y = 400Y/230 (3-Phase, 4W+G)

480Y = 480Y/277 (3-Phase, 4W+G)480D = 480D (3-Phase, Delta 3W+G)600Y = 600Y/347 (3-Phase, 4W+G)600D = 600D (3-Phase, Delta 3W+G)

AGS+CH

Surge Current Ratings/Phase

40 kA80 kA

160 kA

Options (if Required)

CXX = Form C Contacts(remote monitor)

RSX = Standard NEMA1R4X = NEMA 3R/4X ContainerRSD = Disconnect Switch

(with NEMA 12 Container

Operating

Current

20A30A50A70A

100A

Enclosure/Container Size:

AEGIS-HW (X Enclosure): 4.4 x 2.9x 4.3-inch (111.8 x 73.7 x 109.2 mm)DIN-Rail/Flange Mounted

AEGIS-PR: 7.5 x 3.5 x 3.0-inch (190.5x 88.9 x 76.2 mm) RJ-11 Receptacle

AEGIS+: Single-Phase 10 x 4.5 x 5-inch(254.0 x 114.3 x 127.0 mm); Multiphase 15.0x 10.0 x 6.5-inch (381.0 x 254.0 x 165.1 mm)

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35.1January 2003


General Description Reflective Wave Trap (RWT)Ref. No. 1309

VFD Motor Protection AgainstReflected Wave Spikes

Reflected Wave Trap (RWT)

The Problem

Although Variable Frequency Drives(VFDs) improve the efficiency andoperational control, many operators,engineers and system integratorsreport an increasing number of motorfailures due to insulation failurecaused by reflective wave transients.

Also known as dV/dT, this phenome-non occurs with long cable lengthsbetween the IGBT (and BJT) drivesand motors. With todays high speed

drives, power cable and AC motorimpedances are not matched. Thiscauses significantly higher voltagespikes at the motor terminals. It iscommon to have reflective wavespikes over 1400 volts (greater than2 p.u.) causing premature motor fail-ure and costly production downtime.

Per NEMA MG1 Part 30 and VDE 530,motors rated for 600V or less aredesigned to withstand a peak voltageof only 1000V. Existing solutions arenot adequate for todays drive systemsbecause they:

s Have high energy losses.

s Operate at very high temperatures(over 160C).

s Are limited to 6 kHz or loweroperating speeds.

s Do not protect motors with leadsover 600 feet (183 m).

Figure 35.1-18.Reflective Wave TrapPeak Voltage

The Solution

Cutler-Hammer Reflected Wave Trap(RWT) is installed in parallel at themotor terminals to eliminate systemovervoltage transients. Resulting froma major research and developmentinitiative by the Eatons Cutler-Hammerbusiness, the patented RWT is ideal fordrive-motor systems operating at car-rier frequencies ranging from 2 kHz to12 kHz.

RWT Benefits:

s Performance: eliminates reflectedwave transients that reduce motorfailures and costly downtime.

s Faster: operates up to 12 kHz(compared to 2 to 6 kHz for other

designs).s Simplicity: universal solution meets

all of your needs (sizing to motorhorsepower is not required).

s Flexibility of operation: longer leadlengths between VFD and motoroffers greater flexibility.

s Safety: maximum surface tempera-ture of 80C eliminates the possibil-ity of serious burns.

s Easy to install: integral connectioncable allows for easy installationand can be installed up to 20 feet(6 m) away from the motor terminalswithout sacrificing performance.

s Matching of motor cable impedanceis not required.

s No voltage drops that result inreducing motor torque.

s No maintenance.

s Meets Class 1, Division IIrequirements.

Figure 35.1-19.Installation GuidelinesNote:Install RWT less than 25 feet (8 m) from the motor.

Reflected Wave Without RWT

1100

900

700

500

300

100

-100

-300

-500

With RWT

Microseconds

480V 5 hp Drive 1 hp Motor 550 Feet(168m)

0 20 40

Reflected Wave Trap

Indicator light

Reflected

Wave Trap

AdjustableSpeedDrive

U (T1)

V (T2)

W (T3)

G/PET (L1)

G/PE

R (L1)

S (L2)

Fuses

MayBeRequired

S (L2)

T (L1)

G/PE

R (L1)

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5.1-20


January 2003


5


General Description Reflected Wave Trap (RWT)Ref. No. 1310

Table 35.1-16.Performance Capabilities

Cable lengths vary for different motor/drive/loading parameters. Check installationand operating guide for recommendedmaximum drive/motor cable lengths.

The RWT should be used on all drivesystems when the lead length betweendrives/motors exceeds 60 feet (18 m).

One Size Fits All You no longerneed to worry about sizing the motorprotector to the type of drive system,manufacturer, horsepower rating, etc.Simply select the operating voltage

and install the RWT to the motorterminals (less than 20 feet (6 m) awayfrom the motor).

Compared to reactor-based solutions,the RWT does not create voltage dropsor torque reductions that affect drivesystem performance. The RWT is themost advanced solution for improvingdrive system reliability.

Table 35.1-17.Ordering Guidelines

Note:NEMA 4X Enclosure (Class 1,Division 2) T4 135C Groups A, B, C, D.

DriveFrequency

2 kHz 6 kHz 12 kHz

MaximumHeatsinkTemperature

90C 90C 90C

Maximum Cable Length (40C Ambient) Feet (m)480V Applications 750

(230)650(200)

500(150)

Application Enclosure

NEMA 1 NEMA 4X

208V to 480V RWTCHR1 RWTCHR4

Table 35.1-18.Features and Specifications

Figure 35.1-20.480 Volt Drive: Reflected Wave Protection Technology Comparison

Figure 35.1-21. Reflected Wave Solutions: Comparison of Heat Sink Temperatures

CSA is a registered trademark of the Canadian Standards Association. NEMA is theregistered trademark and service mark of the National Electrical ManufacturersAssociation. UL is a federally registered trademark of Underwriters Laboratories Inc.

Features/Specifications Capabilities

TechnologyOperating VoltageDrive Carrier FrequencyHeat Dissipation

Patented Zender Diode Trap208 to 480 Volts2 kHz to 12 kHz90 Watts Minimum

EnvironmentAmbient TemperatureStorage TemperatureElevationRelative Humidity

-40C to +40C-40C to +85C0 to 10,000 Feet (3,000 m)0 to 95% Non-condensing

PhysicalEnclosuresDimensionsWeightMountingApprovals

NEMA 1 or NEMA 4X Versions14.0 x 6.5 x 3.25 Inches (355 x 165 x 80 mm)23 Lbs (10.4 kg)Mounting Tabs ProvidedUL 508, CSA, CSA (NRTL)

Competitor

RWT (40 Ambient)

0100200300400500600700

8009001000

0100200300400500600700

8009001000

Drive Speed (kHz)

480Volt Drive

MotorLead

Length(Feet)

0 2 4 6 8 10 12

216

90

65

Temperature(C)

Cutler-Hammer RWT

NEMA 1 Enclosure

Cutler-Hammer RWT

NEMA 4X Enclosure

Competitor(Motor Connected RC Protector)

0

50

100

150

200

250

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35.1January 2003


General Description DatacomRef. No. 1311

Datacom

The Problem

Lightning induced surges and other transient disturbancesenter a facility by many different paths. Facilities andequipment are at risk without adequate surge protection ondata/communication lines, such as:

s Telephone lines feeding the telephone switch, faxmachines or modems.

s Telephone extension lines between buildings (isolated loop).

s Data communication lines (i.e.: 4 20 mA signal).

s Security lines (video cameras, cables, remote sensors).

s Speakers and public address systems.

s Antenna cables.

Surge protection is required at the facility entrance and onincoming data communication lines subject to induced surges.

The Solution

Eatons Cutler-Hammer Datacom surge protection productsare designed for all industries and applications. The widerange of products offer rugged surge protection in conve-nient, easy-to-install configurations. Exceptional perfor-mance is achieved using three-stage hybrid technology:

s Gas tubes for shunting high energy.

s Silicon avalanche components for responsive, low let-through voltages.

s PTC resettable fuses for mitigating fault current.

Our modular design enables customers to protect completefacilities or individual loads. Customers also save significanttime and money due to our unique plug-in components andprotection modules.

Call the Cutler-Hammer business for the most completeapproach to facility-wide protection.

Datacom Applications Include:

Schools, water treatment plants, commercial buildings, agricultural facilities, industrial and manufacturing and OEM applications.

Table 35.1-19.Datacom Applications

Mounting Hardware purchased separately (see above).

Products Model Description

Modular Protection for Multi-Pair Applications

DAMP25P-XXX 25 Pair Line Protector. Uses AMP-TYPE25 cabling to reduce installation hardware and labor costs.Three versions: Central Office (CO), Analog Extension (AE), or Digital Extension (DE).

DMTEL-XXX Telephone Protection Modules (1 pair). For PBX/KEY telephone systems. Mounted on standard M1-50punch-down block. Three versions: Central Office (CO), Digital Extension (DE), or Analog Extension (AE).

DMP-XXX Data and Control Isolated Loop Protector (1 pair). Mounted on M1-50 Block orIndustrial punch-down block (ordered separately).

DMPB-XXX Intercom & Speaker Protection Module (1 pair). Mounted on M1-50 punch-down block.

DCAT5 Category 5 Protection Module (1 pair). UL Certified to Category 5. Module mounts in DLANBLK(mounting assembly).

Hardwire Connected (1 or 2 Pair Protectors)

DHW2P-XXX Data, Communication, and Telephone Protector (2 pair). Three-stage hybrid technologywith serial connector base (includes mounting connector).

DHW2PSPK-XXX Speaker, Bell, and Strobe Protector (2 pair). Designed for alarm and security systemswith up to 5 amperes operating current.

DDIN-XXX DIN Rail Mountable Protector (1 pair). Three-stage hybrid technology.Mounts to a standard 1.4-inch (35.6 mm) industrial DIN rail.

DPIPE-XXX 4 20 mA Protectors for Water Treatment Industry (1 pair). Units mounted in 3/4-inch (19.1 mm)stainless steel pipe nipple to survive severe environments. Can be ordered with/without shield.

Wiring Connectors DB9, DB25 & RJ11

DRS2329 RS232 Protector (9 pin) Plugs. In series with data cable at protected equipment (all pins protected).

DRS23225 RS232 Protector (25 pin) Plugs. In series with data cable at protected equipment(protects pins 2-8 and 20; pin 1 is chassis ground). If long cable or outdoor runs are present,additional protectors recommended at building entry.

DRJ11-XXXDRJ45-XXX

RJ-11, RJ-14, RJ45 Protector. For telephone or data line applications using male RJ connectors.8V, 15V, 30V

Coaxial Cable Protection

DCXD-XXX CCTV, Data and Audio Protectors. BNC or F connectors available.

DCXCAB-XXX CATV Protector. For cable TV and satellite systems using standard F connectors.

DCXRF-XXX Radio Communication Protector. For repeaters, duplex antennas and other radio typecommunication. Available in UHF or N connectors.

Mounting Hardware

DMH150 M1-50, 25 pair punch block assembly for protection modules.

DMHGR Ground rail for DM1-50 Block (requirement for all protector modules).

DMH89D Standoff for DM1-50 Block to facilitate wiring and mounting.

DLANBLK Category 5 mounting assembly designed to house up to 6 DCAT5 modules.

DMHI12 Industrial mounting assembly (12 pair) for modules; applications requiring stranded pair(26 to 14 AWG wire) using compression screws (Wire too large for M1-50 Block).

DMHI25 25 pair industrial mounting assembly (26 to 14 AWG).

DMTT Adapter for test kit.

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5.1-22January 2003


5


Selection DatacomRef. No. 1312

Data and Communication Line Surge Protectors

Application and Model Number Guidelines

Table 35.1-20.Data Communications and Control

Mounting hardware for all punch-down modules (M1-50 blocks, etc.) .

Table 35.1-21.Telephone Lines

Mounting hardware for all punch down modules (M1 50 blocks etc )

Table 35.1-22.Alarm, Speaker, Intercom, Horn, Strobe

Mounting hardware for all punch-down modules (M1-50 blocks, etc.).

Table 35.1-23.Coaxial Cable

Add N if N connectors required.

Cutler-HammerBase Model

Number

Model Extension

RS485; RS422;

RS423; TokenRing; ARC Net

RS232 4 20

mA

10 Base T;

E-Net

CAT5

100Base T

Multiple Pair Protection Modules (Telephone, Extension Lines, Alarms)

DAMP25P (25 pair)

DMTEL (tel. lines)

DMP (control lines) 036

DMPB (speakers)

DCAT (Cat 5 module) 5

Hardware Connected (1 or 2 Pair Protectors)

DHW2P (2 pair) 008LC 020 036 030LC

DDIN (DIN rail; 1 pair) 232 036

DPIPE (no shield)DPIPES (with shield)

03620362

DHW2PSPK

RJ-11, DB9, DB25 ConnectionDRS (DB9) 2329

DRS (DB25) 23225

DRJ14 (RJ45; 2 pairsprotected)



DCXD (CCTV)

DCXCAB (cable)

DCX (radio antenna)

Cutler-Hammer

Base ModelNumber

Model Extension

POTS (standard tel.lines w/ring voltage)

T1, Digital Ext.ISDN Lines

AnalogExt. Lines


DAMP25P (25 pair) CO DE AE

DMTEL (tel. lines) CO DE AE

DMP (control lines)

DMPB (speakers)

DCAT (Cat 5 module)


DHW2P (2 pair) T 060LC T

DDIN (DIN rail; 1 pair)


DHW2PSPK

RJ-11, DB9, DB25 ConnectionDRS (DB9)

DRS (DB25)


A D A


A D (48V),8, 15, 30V

A


DCXD (CCTV)

DCXCAB (cable)

DCX (radio antenna)

Cutler-HammerBase ModelNumber

Model Extension

Alarm24V

Horn, Strobe 24 VoltSpeaker

IntercomCall-in

70 VoltSpeaker24V 12V


DAMP25P (25 pair)

DMTEL (tel. lines)

DMP (control lines)

DMPB (speakers) SPK CLN

DCAT (Cat 5 module)


DHW2P (2 pair) 030LC



DHW2PSPK 043 043 043 SP70

RJ-11, DB9, DB25 Connection

DRS (DB9)

DRS (DB25)

DRJ14 (RJ45;2 pairs protected)

DRJ45 (RJ45;4 pairs protected)


DCXD (CCTV)

DCXCAB (cable)

DCX (radio antenna)

Cutler-HammerBase ModelNumber

Model Extension

CCTV HeadEnd (closedcircuit TV,cameras),

6V, BNCConnector

CCTV CameraEnd (Isolatedgroundshield);

6V, BNCConnector

CATVSatellitesDish

AntennaUHFConnector


DAMP25P (25 pair)

DMTEL (tel. lines)

DMP (control lines)

DMPB (speakers)

DCAT (Cat 5 module)


DHW2P (2 pair)



DHW2PSPK

RJ-11, DB9, DB25 Connection

DRS (DB9)

DRS (DB25)

DRJ14 (RJ45; 2pairs protected)

DRJ45 (RJ45; 4pairs protected)


DCXD (CCTV) 06BNCY 06BNCYI

DCXCAB (cable) 145A

DCX (radio antenna) RF, RFN

>

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