ERICO TDS-MOVTEC Surge Diverters User Manual

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SURGE DIVERTERS
INSTALLATION INSTRUCTIONS
Includes MPM Movtec Protection Module Instructions
www.erico.com
Handbook No:
Handbook No:
HB-HBCR-111
HB-HBCR-111
© Copyright
© Copyright
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INSIDE FRONT COVER
(Blank)
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CONTENTS
Page
1. Warnings ... ... ... ... ... ... ... ... ... ... ... 4
2. Introduction ... ... ... ... ... ... ... ... ... ... 5
3. Protection Concepts .. ... ... ... ... ... ... ... 7
4. Mounting and Cautions ... ... ... ... ... ... 9
5. Voltage Ratings .. ... ... ... ... ... ... ... ... 10
6. Protection Mode .. ... ... ... ... ... ... ... ... 13
7. Connection Method ... ... ... ... ... ... ... 15
8. RCD, ELCB ... ... ... ... ... ... ... ... ... ... 20
Page
9. Isolation and Fusing ... ... ... ... ... ... ... 20
10. Status Indication and Alarms
... ... ... 22
11. MPM, Movtec Protection Module ... ... 24
12. Maintenance and Testing .. ... ... ... ... 27
13. Extended Warranty ... ... ... ... ... ... ... 28
14. Six Point Plan ... ... ... ... ... ... ... ... 29
15. Use of Mimic Panels ... ... ... ... ... ... 30
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GLOBAL LIGHTNING TECHNOLOGIES
1. WARNINGS
• Prior to installation ensure that the Movtec is of the correct voltage and frequency, and is the type recommended for the local power distribution, and for the equipment being protected.
• Hazardous voltages may exist internally to the units. The units should be installed (and replaced) only by qualified personnel in accordance with all relevant Electricity Safety Standards.
• Do not power MPMs and three phase connected Movtecs (Ph-N) without the upstream neutral connected. Failure to do so may damage the Movtecs and/or the load.
• Where the MPMs/Movtecs are connected to an earth, this must be a low impedance earth (<10 ) for correct operation.
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• X1-X4 connections may be at phase voltages dependant upon connection method.
• If connecting to the Movtec alarm outputs do not exceed the maximum permissible ratings as damage may occur.
• Movtecs must be installed in an enclosure or panel, ensure this does not cause their environmental ratings to be exceeded.
• Do not “Megger” or “Flash Test” circuits with Movtecs installed.
• The DINLINE Surge Counter (DSC) should not be used in voltage sensing mode with TDS-Movtecs. Voltage sensing mode is not compatible with TDS-Movtecs.
• All instructions must be followed to ensure correct and safe operation.
• Diagrams are illustrative only, and should not be relied on in isolation.
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DINLINE INSTALLATION INSTRUCTIONS
2. INTRODUCTION
Movtecs are designed to protect mains powered equipment from the damaging effects of lightning and transients. They are ideal for point-of-entry shunt protection applications where robustness and high surge ratings are required.
The Movtec family is designed to suit many distribution systems including TN-C, TN-S, TN-C-S and TT. They can be selected for use with distribution systems with nominal voltages of 110/120V, 220/240V and 277Vrms at frequencies of 50/60 Hz.
The TDS Technology (Transient Discriminating Suppressor) units are specifically designed for distribution systems that may feature poor voltage regulation where the actual supply voltage may exceed the nominal ratings for extended periods.
This Installation Manual details the preferred procedure for the installation of the family of Critec Movtec™ Surge Diverters.
The Critec Movtec family includes:
• Critec Movtec, Single Mode, enhanced MOV technology units eg. (MT275V-135K-A)
• Critec TDS-Movtec, Single Mode, TDS technology unit featuring high over-voltage withstand for added robustness (TDS-MT-
277)
• Critec TDS-Movtec, Three Mode, TDS technology unit featuring high over-voltage withstand for added robustness (TDS-MTU)
TDS-Movtec units are coloured blue for easy identification, while enhanced MOV technology units are coloured red.
In this manual, reference to “ Movtec” also includes “TDS-Movtec”.
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This manual also details the installation of the MPM (Movtec Protection Module). The MPM is a supplied enclosure with three Movtecs and a high energy neutral to earth protection device for three phase protection. The MPM is often used where Movtecs can not be fitted in an existing switchboard and must be mounted externally. Therefore the Movtec installation instructions are also applicable to the MPM. Section 11 gives details which are specific to the MPM.
Two standard MPMs are available:
• Critec TDS-MPM, Single Mode, TDS Technology unit (uses 3 x TDS-MT-277)
• Critec MPM-275V, Single Mode, Enhanced MOV Technology unit (uses 3 x MT275V­135K-A)
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Alarm Contact Terminals
T2 Terminal
X3-X4 For A-N/A/N-E configeration option
Status Indicator
X1-X2 For connection to optional Mimic Panel (Ref. Section 15)
SINGLE MODE
MOVTEC
T1 Terminal
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DINLINE INSTALLATION INSTRUCTIONS
Alarm Contact Terminals
Phase Terminal
Status Indicator
Earth Terminal
THREE MODE
MOVTEC
Neutral Terminal
3. PROTECTION CONCEPTS
To optimise effectiveness of installed protection a concept of “Unprotected” and “Protected” wiring should be followed.Wiring from the transient source to the Movtec should be considered “Unprotected” and kept remote from all other wiring (approximately 300mm) where possible. Wiring on the equipment side of the Movtec should be considered “Protected”.
The separation of “Protected” from “Unprotected” wiring is recommended in order to minimise the risk of transients conducted on “Unprotected” wiring cross coupling on to “Protected” circuits, thus compromising the level of protection available from the Movtec.
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GLOBAL LIGHTNING TECHNOLOGIES
Keep other cables and equipment away from this area.
Unprotected zone Protected zone
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DINLINE INSTALLATION INSTRUCTIONS
4. MOUNTING & CAUTIONS
The performance of surge diverters can be dramatically affected by the method of connection (refer section 7). Where possible select a mounting method that allows the Movtec to be connected in the “Preferred Connection Method”.
Failure of a Movtec under severe AC over­voltage, such as 11kV on 240V mains, can result in the generation of significant heat. Consideration should be given to ensure that Movtecs are not installed in close proximity to combustible materials.
Units must be installed in an enclosure or panel to provide the appropriate degree of electrical and environmental protection.
Only use enclosures that:
• Do not cause the Movtec temperature to exceed 60 deg C
• Provide adequate electrical and safety protection
• Prevent the ingress of moisture and water
• Allow Movtec Status Indication to be inspected
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5 VOLTAGE RATINGS
The TDS (Transient Discriminating Suppressor) technology has been specifically developed to cater for abnormal over-voltage conditions that may occur on sites with poor voltage regulation, or due to wiring or distribution faults. The TDS units feature an extremely high over-voltage withstand to eliminate heat build up that can occur with standard technologies when the protection devices start to clamp on the peak of each abnormal mains cycle.
Traditional MOV technology (eg MT-275V/ 135K/A) is not suitable in applications where sustained over-voltage conditions can be experienced.
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Examples of poorly regulated voltage environments include:
• Smaller power generation supplies
• Sites with large earth currents
• Variable motor speed control circuits
• High harmonic voltage environments (non-
linear loads)
The TDS range of Movtecs with a higher over-voltage withstand may be able to be used in these environments following advice.
Transient protection devices are usually rated to protect against non-repetitive pulses from such sources as direct or induced lightning strikes. They are not designed to provide protection against repeated cyclic anomalies. Nor are they designed to provide protection
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DINLINE INSTALLATION INSTRUCTIONS
Generator Generator
Avoid repetitive voltages in excess of rating
EQUIPMENT
Over-Voltage Rating
240 Vrms
240 Vrms Over-Voltage
Rating
Avoid high harmonic voltages
or
MOVTECMOVTECMOVTECMOVTEC
MOVTECMOVTEC
Over-Voltage Rating
Over-Voltage Rating
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GLOBAL LIGHTNING TECHNOLOGIES
against sustained over-voltage conditions where the supply voltage exceeds the protection equipment’s nominal rating for an extended period of time, ie continuous over-voltages
from poorly regulated generators or distribution systems.
Smaller power generation equipment (particularly capacitive excitation induction generators) does not generally conform to the same standards of voltage regulation that are in place for mains power reticulation. A large number of smaller and/or cheaper generators have a voltage waveform that is “loosely” 240Vrms (often poorly regulated), but more importantly, often contains significant higher order harmonics. These generators may exhibit a peak voltage on each half cycle far in excess of the normal 340V. The problem is usually worse when the generator is lightly loaded.
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Whilst electrical equipment may tolerate this over-voltage for a period of time, the clamping elements in the power protection devices will begin to conduct on the peak of each 50Hz cycle, as their voltage threshold is reached (typically 400V peak for a traditional 275V diverter). This will cause slow degradation and ultimate failure of the clamping device (time dependent upon how poor the waveform is).
Harmonic voltages may also be present in distribution systems that do not feature generators. This is normally where non-linear loads are used, such as UPSs, rectifiers, switch mode power supplies and motor speed controls. The high harmonic voltages in certain applications may have peak voltages in excess of the protective clamping voltage causing problems as described above. Seek the manufacturer’s advice before installing any
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DINLINE INSTALLATION INSTRUCTIONS
product into a circuit which features a total harmonic voltage ratio above 5%.
Model Nominal Maximum
Voltage Permissible
Abnormal
Over-Voltage
TDS-MT-277 220-277V 480V
TDS-MTU 220-277V 480V
MT275V-135K-A 220-240V 275V
Ensure that the correct voltage rating unit is installed. Exceeding the nominal rating while transient events occur may affect product life.
Note: Other voltage rating Movtecs are available. Refer
to Movtec table for actual ratings.
6. PROTECTION MODES
Movtecs are available in Three Mode and Single Mode configurations. This refers to how the internal protection is arranged and applied to the circuit to be protected.
Three Mode units provide protection between the Phase-Neutral*, Phase-Earth* and Neutral-Earth circuit within one Movtec.
Single Mode units provide protection between two conductors connected to the terminals marked T1 and T2. These units can be connected to provide protection from Phase­Neutral* or Phase-Earth* or Neutral-Earth. To allow the status indication and alarm circuitry to operate, a neutral connection is required for Phase-Earth* configured units, and a Phase* connection is required for
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Neutral-Earth configured units. Connection details for single mode units are detailed on page 15. Warning - this connection link can be at mains potential.
* Note. Some users may be used to the
terminology “Active” or “Line”, in place of “Phase”. For consistency “Phase” is used throughout this documentation.
Model Modes
TDS-MTU Three Mode
TDS-MT-277 Single Mode
MT275V-135K-A Single Mode
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SINGLE MODE THREE MODE
T1
Terminal
Status
Electronics
T2
Terminal
X4
X3
Neutral
Terminal
Earth
Terminal
Status
Electronics
Phase
Terminal
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DINLINE INSTALLATION INSTRUCTIONS
SINGLE MODE CONNECTIONS OPTIONS
Ph
T1
T2
N
PHASE
NEUTRAL
PROTECTION
LINK X3-X4
Ph
T1
X4
T2
N
EE E
PHASE
EARTH
PROTECTION
Ph
N
T1
T2
NEUTRAL
EARTH
PROTECTION
7. CONNECTION METHOD
To optimise transient performance, attempt to connect the Movtecs in the “Preferred” fashion as depicted on pages 16 and 17. This is recommended for cable sizes between 6mm and 16mm2. Take care not to run the protected and unprotected wire parallel or in close proximity.
Where this is not possible due to layout or
X4
conductor size, use the “Non-preferred” “T” connection method as depicted on pages 16 to
18. With this connection method, the “T” lead
should be between 6mm2 and 16mm2. The connection should be as short as practicable (less than 100mm).
Cable sizes less than 6mm2 should not be used without specialist advice.
2
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PREFERRED CONNECTION METHOD
CORRECT
Separate wires
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INCORRECT
NON-PREFERRED "T" CONNECTION METHOD
Keep Short
Keep Close
Keep Short
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DINLINE INSTALLATION INSTRUCTIONS
PREFERRED CONNECTION METHOD EXAMPLES
NEUTRAL
EARTH
LINE LOAD
SINGLE MODE UNITS
LINE LOAD
PHASE
THREE MODE UNITS
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GLOBAL LIGHTNING TECHNOLOGIES
NON-PREFERRED "T" CONNECTION METHOD EXAMPLES
NEUTRAL
2
6-16 mm
The inductance of branch connections increases the clamp
voltages seen by
the load.
LINE LOAD LINE LOAD
EARTH
PHASE
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SINGLE MODE UNITS
THREE MODE UNITS
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DINLINE INSTALLATION INSTRUCTIONS
CORRECT
RCD
ELCB
Protected
Equipment
RCD
ELCB
INCORRECT
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8. RCD, ELCB
Where RCDs/ELCBs (Residual Current Devices / Earth Leakage Circuit Breakers) are fitted the Movtecs should be installed in the circuit prior to these devices (ie upstream). Where this can not be avoided and RCDs/ ELCBs are installed upstream, nuisance tripping of the RCD/ELCB may occur during transient activity.
Contact your local ERICO agent for advice if upstream RCDs/ELCBs can not be avoided.
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9. ISOLATION AND FUSING
Overcurrent and short circuit protection must be provided to protect the Movtec and associated wiring if a fault develops. The overcurrent protection should be installed in such a manner to also provide a means of isolating the Movtec module from the mains supply. This is an important safety consideration and is required in the event that any future maintenance or testing is needed.
The Movtec uses disconnection devices to isolate internal segments that have reached the end of their service life. In order for this disconnection to occur correctly, Movtecs should be only used on circuits with fuse or circuit breaker ratings of 32A or greater. (Nuisance operation of the overcurrent protection may occur during transient activity on smaller capacity circuits.)
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DINLINE INSTALLATION INSTRUCTIONS
Ph
Supply
N
OVERCURRENT PROTECTION
F1 >100A
Install F2 when F1 exceeds 100A
*HRC - High Rupture Capacity
F2 =100A HRC*
Equipment to be protected
Ph
N
OVERCURRENT PROTECTION
Ph
F1 >100A
Upstream Fuse
Supply
N
Suitable connection method when upstream
Fuse/Supply capacity does not exceed 100A
Ph
Equipment to be protected
N
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On circuits with a capacity of greater than 100A, the Movtecs should be installed in series with a 100A HRC fuse being placed prior to the Movtec, as detailed in the diagram on page 21. This will require the Movtec to be installed in a similar manner to the non­preferred “T” connection method. Care must be taken to keep “T” connections as short and straight as possible. Note that this fuse may rupture under surge events exceeding 60kA, thereby disconnecting the protection circuit. Under such conditions it is important that suitable monitoring of the alarm contact should be carried out to detect this possible occurrence.
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10. STATUS INDICATION AND ALARMS
A characteristic of all transient and surge protection devices is that they degrade in proportion to the magnitude and number of incident surges to which they have been subjected. Status indication should be periodically monitored to determine if replacement is required.
Each Movtec features 5 protection segments. The status for each of these sectors is provided by way of a 5 segment LED bar graph. If any sector is damaged due to excess surge activity, a LED will extinguish. The LEDs extinguish in a sequential order (100% LED out first, 80% LED out next etc.) irrespective of which sector has sustained damage.
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DINLINE INSTALLATION INSTRUCTIONS
When mains voltage is applied to the fully functional Movtec, the alarm contacts will be closed. Should the surge handling capacity fall to below the alarm threshold, these contacts will open. The contacts are “fail-safe” in that, if power to the unit fails, the contacts will also revert to the open condition.
For Single Mode units (TDS-MT-277 and MT275V-135K-A)
• The voltage free alarm contacts are activated (opened) as soon as the primary protection status displays 60% or less and indicates that the Movtec unit should be replaced.
For Three Mode units (TDS-MTU)
• The voltage-free alarm contacts are activated (opened) as soon as the protection status displays 80% or less. This indicates that damage has been sustained to the protection
of one of the three modes and that the TDS­Movtec unit should be replaced.
MOVTEC MODEL TERMINALS ALARM OPERATES
WHEN
TDS-MT-277 X5 & X7 MOVTEC displayed
capacity =< 60%
MT275V-135K-A X5 & X7 MOVTEC displayed
capacity = <60%
TDS-MTU X5 & X7 MOVTEC displayed
capacity = <80%
Contact Rating 250Vac, 10A resistive, 1A inductive Contact connection Multi-stranded wire with CSA not
greater than 1.5mm
2
Where multiple Movtecs are used, such as in three phase distribution systems the alarm contacts may simply be connected in series to provide a common alarm output connection.
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11. MPM, MOVTEC PROTECTION MODULE
The MPM utilises a high energy Neutral to Earth spark gap to provide robust protection against earth potential rise problems. Care is required to ensure co-ordination of this device
MPM
Supply Equipment to
PREFERRED CONNECTION METHOD
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be protected
Supply Equipment to
NON PREFERRED
"T" CONNECTION METHOD
if any other voltage limiting device is connected either upstream or downstream in the Neutral to Earth circuit. Contact your
local agent for further information if other N-E protection devices are installed and co-ordination may be affected.
MPM
(Refer section 7)
be protected
Supply Equipment to
CONNECTION METHOD ON
CIRCUITS GREATER THAN 100A
MPM
100A HRC Fuses in phase lines
be protected
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DINLINE INSTALLATION INSTRUCTIONS
INSTALLATION PROCEDURE FOR MPM
1. Remove the cover from the MPM.
2. Select the MPM mounting position to ensure optimum electrical connection method (refer Section 7) and in accordance with all given instructions.
3. Position and mark the mounting position of the MPM on the wall.
4. Depending on the mounting surface, prepare suitable anchoring holes for the marked position.
5. Snap the mounting spacers, supplied, into the rear of the back of the MPM as shown in Figure 1. (see inside back cover P31)
6. Mount the unit to the wall. To ensure the IP33 rating is preserved, the MPM should be mounted to the wall using the spacers provided and one of the fixing methods as shown in Figure 1. (see inside back cover P31)
7. Prepare the appropriate cable glands. It is recommended that a nylon cable gland (typically rated at IP66) be used.
8. Install wiring, taking care to support cabling directly connecting to the MPM unit, and tighten all terminals.
9. Check that the MPM is installed in accord­ance with all instructions, and relevant electrical safety codes.
10.Replace MPM cover, then apply power.
11.Correct operation of the MPM unit is estab­lished by checking that all 5 LED’s on each MOVTEC bar graph are lit, and that power is correctly being supplied to the load(s).
INSTALLATION ARRANGEMENT FOR AUSTRALIAN MEN SYSTEMS
Under Australian Standards classification, MPMs are considered a piece of equipment to
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be connected to the mains supply. The MPMs are not intended for use as, nor are they, a ‘switch
board’, ‘distribution board’ or other equipment. As MPMs are classified as ‘electrical equipment’ (ie: a product), AS 3000 Wiring Regulations apply to the installation and operation of the units.
In the multiple earth neutral (MEN) distribution system, the MPM equipment should be installed as clos e as possible after the MEN point and after both the main disconnect switch/ overcurrent protector and any metering equipment.
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TYPICAL CONNECTION DETAIL FOR MPM POINT-OF-ENTRY INSTALLATION
IN MEN DISTRIBUTION SYSTEM
NEUTRAL
EARTH
1
2
3
METERING
MAIN
DISTRIBUTION
M.E.N. LINK
MPM
SUB
DISTRIBUTION
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DINLINE INSTALLATION INSTRUCTIONS
12. MAINTENANCE & TESTING
Before removing any unit from service ensure that power to the device is isolated. Replacement of any Movtec units should only be undertaken in accordance with all relevant Electricity and Safety Standards by suitably qualified personnel.
Movtecs should be inspected periodically, and also following any periods of lightning or transient activity. Check the status indicators and replace if in the “Alarm” condition as detailed in Section 10 -STATUS INDICATION.
For high transient exposure sites or those of a critical operational nature, it is recommended that the alarm outputs be monitored to provide an additional warning of reduced capacity (refer Section 10).
Movtecs are designed for optimum performance under severe transient activity. To provide this performance, electronic components in the Movtec are encased in a patented proprietary, shock and thermal absorbant compound. Units cannot be
serviced, they must be replaced.
Do not attempt to open or tamper with the units in any way as this may compromise performance and will void warranty.
Do not “Megger” or perform other types of electrical tests that apply voltages greater than the nominal operating voltage of the Movtec. The Movtec will attempt to limit these voltages thereby affecting the test result. Where these tests must be performed, remove the Movtec from circuit first.
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13. EXTENDED WARRANTY
This product has a limited warranty to be free from defects in materials and workmanship for a period of five (5) years from the date of dispatch from the Manufacturer. The Purchaser acknowledges that lightning is a natural event with statistical variation in behaviour and energy levels which may exceed product ratings, and 100 % protection is not offered and cannot be provided for. Therefore the Manufacturer’s liability is limited to the repair or replacement of the product (at the Manufacturer’s sole option) which in its judgement has not been abused, misused, interfered with by any person not authorised by the Manufacturer, or exposed to energy or transient levels exceeding the Manufacturer’s specifications for the product. The product must be installed and earthed (where applicable) in strict accordance with the Manufacturer’s specifications and all relevant national Electricity and Safety Standards. The Manufacturer and the
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Purchaser mutually acknowledge that the product, by its nature, may be subject to degradation as a consequence of the number and severity of surges and transients that it experiences in normal use, and that this warranty excludes such gradual or sudden degradation. This warranty does not indemnify the Purchaser of the product for any consequential claim for damages or loss of operations or service or profits. Customers should contact their nearest manufacturer’s agent to obtain a Product Repair Authorisation Number prior to making any claim under this warranty. This is only a summary of the warranty given by the Manufacturer. The full text of the warranty is set out in the Manufacturer’s Conditions of Quotation and Sale. The above limited warranty is additional to rights which arise in respect of the sale of industrial and technical products and services to knowledgable buyers under the Australian Trade Practices Act 1974 as amended.
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DINLINE INSTALLATION INSTRUCTIONS
14. SIX POINT PLAN
Critec Movtec surge diverters form an important part of the much larger ERICO lightning, surge and transient protection philosophy (ERICO Lightning Technologies “Six Point Plan”). The level of protection and the degree of attention dedicated to each of the six points will require careful consideration for each site. The degree of protection required is determined by the individual site location/exposure with the aid of risk management principals.
For further advice on your protection needs please contact your local representative.
Capture the lightning strike
Conduct the strike to ground safely
Dissipate the energy through a low impedance earth system
Eliminate earth loops and differentials
Protect equipment from surges on power lines
Protect equipment from transients on telecommunication and signal lines
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15. USE OF MIMIC PANELS
Movtecs are used in the Proline range of Surge Reduction Filters where superior protection is required for critical or sensitive electronic equipment. Some models of SRF use an electronic mimic panel to display in the
M
OVTEC
& M
front door the status of the internal Movtecs. The X1-X4 terminals on the Movtec are used for this purpose. If this Movtec is to be used with a mimic panel (possibly as a replacement for an existing Movtec in a SRF) please ensure compatibility as below.
IMIC COMPATIBILITY
Movtec Version Mimic Version
TDS-Mimic Hybrid Mimic Discrete Mimic
#300732 #300731 #300730
EA-SRFP-117 EA-SRFP-115 EA-SRFP-104
EA-117 EA-115 EA-104 TDS-MT-277 Yes Note 1 No MT-275V/135K/A #300867 Yes Yes Note 2 MT-275V/135K/A #300865/300866 Yes Yes Yes Note 1 Mimic will operate for supply voltages up to 275Vrms Note 2 Request Product Update 44 for further details
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Figure 1. MPM mounting spacers.
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SINGLE MODE CONNECTIONS OPTIONS
Ph
T1
LINK X3-X4
Ph
T1
X4
Ph
N
E
www.erico.com
T2
PHASE
NEUTRAL
PROTECTION
T2
N
E
PHASE
EARTH
PROTECTION
N
T1
X4
T2
E
NEUTRAL
EARTH
PROTECTION
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