Sophisticated and highly susceptible microprocessor-based electronics and data communication networks are integrated across every sector of today’s fast paced business world. Preserving these mission-critical systems from the damages of surges, spikes, and transients ensures that these systems are protected from equipment destruction, disruption in service, and from costly downtime. How to properly stage these surge protective devices (SPDs) can be as important as actually making the decision to purchase them.

Much like the Great Oz who manipulates the Emerald City from behind a curtain, various types of drives are used to control motors in these systems. The purpose of a drive is to increase the efficiency or to manage the speed of the motor being controlled. Through various processes and control mechanisms, the drive often reshapes the sine wave to provide a signal to the motor that allows for greater efficiency or varies the frequency of the signal to control the speed of the motor.

Due to the action of the drive, the power quality of the electrical environment can be compromised. That is, the drives can create voltage surges and harmonics on the system. (Imagine the Great Oz’s master control panel being zapped by an electrical surge!)

The good news is that in the real world, there are various technologies available that aid in correcting issues such as surges, spikes, and transients. This article focuses on applying surge protective devices (SPDs) to a drive system to mitigate the damage that can occur due to voltage surges while considering the effects of the harmonics on the surge protective device.

Follow the Yellow Brick Road
Much like the yellow brick road leading to the Emerald City, Figure 1 shows a typical drive layout and a path of 5 opportunities to protect the typical drive system is described below.

Figure 1. One line diagram of a typical drive layout.

The incoming power is usually delta configured (3 phases and ground). Often the incoming voltage is 480 V, but other voltages may be used. The incoming power is usually stepped down to a lower voltage (typically 120 Vac) that provides power to the control circuit. The control circuit contains sensitive electronics. Once the power is acted upon by the drive the output is fed to the motor.

Path 1: Drive Input. Protecting the drive input is an essential step in protecting the drive system. Providing protection at this location prevents surge damage due to events propagated on the electrical system from upstream sources, external events such as lightning and switching surges created by the utility, and the interaction of multiple drives on the same system.

At this location, a parallel connected, voltage responsive circuitry device is appropriate (one without frequency responsive circuitry). Frequency responsive circuitry is not recommended for this location due to the fact that this location is typically more susceptible to impulse transients as opposed to ring wave transients.

Path 2: Inverter Input. The inverter input is one of the most sensitive and critical areas of the drive itself. It is at this location that care must be taken and the proper survey conducted. You may install a parallel connected, frequency responsive circuitry device provided you have confirmation that within this drive that no additional capacitors have been installed to mitigate harmonic currents.

If they have, then at this location, a parallel connected, voltage responsive circuitry device is appropriate (one without frequency responsive circuitry). Frequency responsive circuitry would not be recommended for this location due to the high harmonic content that necessitated the installation of additional capacitors. Installation of frequency responsive circuitry devices at this location will lead to failure of the SPD.

Path 3: Control Circuit. The control circuit contains sensitive electronics that can be damaged by the environment created by the drive or by surges from external sources. Protection at this location is essential. Since this circuit is isolated by a step down transformer and it feeds sensitive electronics, a series connected SPD with frequency responsive circuitry is recommended for this location.

Path 4: Drive Output. Protecting the immediate drive output is recommended when the length of the connection between the drive and the motor is longer than 50 ft (15 m) or if the connection is routed along an external wall or outdoors.

One reason for protecting at the immediate output when the length of the connection to the motor is long is due to reflected waves that can occur as the signal (often higher frequency) from the output of the drive reaches the motor and is then reflect back and forth between the drive and the motor. This action can create (ITALICS)voltage piling;(END ITALICS) the reflected voltage adds to the nominal voltage and other reflected waves. The SPD will aid in reducing the voltage peaks of the reflected waves.

More importantly, if the connection between the drive and the motor extends outdoors, along a path that is exposed to the environment or close to the building's steel structure, protection at this location is important to diminish the effects of direct lightning or induced voltage surges due to nearby lightning. These surges can cause damage to the drive, even if protection is provided at the motor input.

At this location, a parallel connected, voltage responsive circuitry device is appropriate (one without frequency responsive circuitry). Frequency responsive circuitry is not recommended for this location due to the high harmonic content of the signal due to the normal operation of the drive. Installation of frequency responsive circuitry devices at this location will lead to failure of the SPD. Utilizing a voltage responsive circuitry device at this location will eliminate this possibility.

Path 5: Motor Input. Protecting the motor input is an essential step in protecting the drive system. Providing protection at this location prevents surge damage due to events propagated from the drive output to the motor input. Providing protection at this location aids in extending the life of the motor as the SPD helps to prevent damage to the windings and bearings of the motor due to surges.

Further, if the connection between the drive and the motor extends outdoors, along a path that is exposed to the environment or close to the building's steel structure, protection at this location is important to diminish the effects of direct lightning or induced voltage surges due to nearby lightning. These surges can cause damage to the motor, even if protection is provided at the drive output.

At this location, a parallel connected, a voltage responsive circuitry device is appropriate (one without frequency responsive circuitry). Frequency responsive circuitry is not recommended for this location due to the high harmonic content of the signal due to the normal operation of the drive. Installation of frequency responsive circuitry devices at this location will lead to failure of the SPD. Utilizing a voltage responsive circuitry device at this location will eliminate this possibility.

There's No Place Like Ohm
Overall, properly installed surge protective devices reduce the magnitude of random, high energy, short duration electrical power anomalies. These occurrences are typically caused by atmospheric phenomena (such as lightning strikes), utility switching, inductive loads, and internally generated overvoltages. (At least, there are no Wicked Witches of the West to handle.) Alas, good will prevail when you take action to ensure SPD are properly placed. All fiction aside, remember, the ultimate goal of a sound protection approach is to keep sites and systems operating safely and reliably.

Endnote: PowerTrip® Surge Protection Devices incorporate Frequency Responsive Circuitry technology years ahead of any other devices on the market today. Utilizing proprietary electro-chemical encapsulation, PowerTrip® SPDs dissipate large amounts of surge energy to prolong service life.

About the Authors

Beth Chittum is the Marketing Director of Alltec Corporation and has worked in the power quality industry for 3 years. Alltec offers a complete facility protection approach to solving lightning protection, surge suppression, and grounding related problems. For more information, visit www.allteccorp.com.

Dan Latham is the Surge Protection Product Specialist at Alltec Corporation and has more than 25 years of experience in the power quality industry. For more information, visit www.allteccorp.com or contact Dan at dlatham@allteccorp.com. 

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