SURGE SUPPRESSOR © Copyright · Standard AS3008.1-1989 it is permissible to rate the protection...

INSTALLATION INSTRUCTIONS

Handbook No:HB-HBCR-109

© Copyright

ISSUE: 3 April 2003

Includes TDS-AR Alarm Relay and TDS-SC Surge Counter

SURGE SUPPRESSOR

www.erico.com

INSIDE FRONT COVER

(Blank)

CONTENTS

Page

1. Warnings ... ... ... ... ... ... ... ... ... ... ... 4

2. Introduction ... ... ... ... ... ... ... ... ... ... 5

3. Quick Installation Guide ... ... ... ... ... ... 5

4. Protection Concepts .. ... ... ... ... ... ... ... 6

5. Mounting ... ... ... ... ... ... ... ... ... ... ... 7

6. Voltage Ratings ... ... ... ... ... ... ... ... ... 8

7. Protection Modes .. ... ... ... ... ... ... ... ... 8

8. Conductor Sizes ... ... ... ... ... ... ... ... ... 10

9. Conductor Length ... ... ... ... ... ... ... ... 11

10. RCD, ELCB ... ... ... ... ... ... ... ... ... ... 14

Page

11. Isolation and Fusing .. ... ... ... ... ... ... 15

12. Status Indication ... ... ... ... ... ... ... ... 17

13. Maintenance & Testing .. ... ... ... ... ... 18

14. Alarm Relay (TDS-AR) .. ... ... ... ... ... 19

15. Surge Counter (TDS-SC) ... ... ... ... ... 26

16. Typical Domestic Installation ... ... ... 29

17. Extended Warranty ... ... ... ... ... ... ... 30

18. Six Point Plan ... ... ... ... ... ... ... ... ... 31

D S D I N S T A L L A T I O N I N S T R U C T I O N S

1. WARNINGS

• Prior to installation ensure that the unit isof the correct voltage and frequency, and isthe type recommended for the local powerdistribution, and for the equipment beingprotected.

• Hazardous voltages may exist internally tothe modules. The units should be installed(and replaced) only by qualified personnelin accordance with all relevant ElectricitySafety Standards.

• Do not power three phase connected unitswithout the upstream neutral connected.Failure to do so may damage the units and/or the load.

• Where the unit has an earth terminal, thismust be connected to a low impedance earth(<10 Ω) for correct operation.

• If connecting to the TDS Opto-coupleralarm outputs do not reverse the +/-connections or exceed the maximumpermissible ratings as damage may occur.

• Use only the TDS-AR Alarm Relay withTDS-DINLINE.

• Use only TDS-SC Surge Counter with TDSDINLINE.

• Units must be installed in an enclosure orpanel, ensure this does not cause the unitsenvironmental ratings to be exceeded.

• Do not “Megger” or “Flash Test” circuitswith TDS-DINLINE units installed.

• All instructions must be followed to ensurecorrect and safe operation.

• Diagrams are illustrative only, and shouldnot be relied on in isolation.

2. INTRODUCTION

This Installation Manual details the preferredprocedure for the installation of TDS-DINLINE™ SURGE SUPPRESSORS andoptions.

The TDS-DINLINE SURGE SUPPRESSORSare available in a variety of surge ratings,which are packaged in the 2M, 4M and 8M“DIN 43 880” compliant enclosures. They aredesigned to suit many distribution systemsincluding TN-C, TN-S, TN-C-S (MEN) and TT.They can be selected for use with distributionsystems with nominal RMS voltages of 110/120, 220/230/240V or 277V at frequencies of50/60 Hz.

Recommended installation and connection ofthe ALARM RELAY (TDS-AR) is detailed in

Section 14. Installation and connection of theSurge Counter (TDS-SC) is detailed in section15.

3. QUICK INSTALLATION GUIDE

Install in the following manner:

1. Ensure that power is removed from the areaand circuits to be connected.

2. Install the DIN mounting rail, if not fitted.

3. Snap lock the Surge Suppressor to the rail.

4. Connect wiring to the indicated terminals.

5. Ensure compliance with suppliedinstructions.

6. Apply power and observe correct operationof Status Indicators, and alarm facilities ifutilised.


4. PROTECTION CONCEPTS

To optimise effectiveness of installedprotection a concept of “Unprotected” and“Protected” wiring should be followed. Wiringfrom the transient source to the SurgeSuppressor should be considered“Unprotected” and kept remote from all otherwiring (approximately 300mm) where possible.Wiring on the equipment side of the SurgeSuppressor should be considered “Protected”.

The separation of “Protected” from“Unprotected” wiring is recommended in orderto minimise the risk of transients conducted on“Unprotected” wiring cross coupling on to“Protected” circuits, thus compromising thelevel of protection available from the SurgeSuppressor.

Keep other cables andequipment awayfrom this area.

Unprotected zone Protected zone

5. MOUNTING

Surge Suppressors are designed to clip to35mm top hat DIN rails (to StandardEN50022). Unless otherwise mechanicallyrestrained, use horizontal DIN rails with the

Surge Suppressor fixing clip to the bottom, ielabel text the correct way up.

Units must be installed in an enclosure orpanel to provide the appropriate degree ofelectrical and environmental protection.

Only use enclosures that:

• Do not cause the internal temperature toexceed 55 deg C.

• Provide adequate electrical and safetyprotection.

• Prevent the ingress of moisture and water.

• Allow Surge Suppressor Status Indicationto be inspected.

1

2

35 mm DIN rail(EN50022)


6. VOLTAGE RATINGS

Ensure that the correct voltage rating unit isinstalled. Exceeding the nominal voltagerating under transient conditions may affectproduct life. Do not exceed the MaximumPermissible Abnormal Over Voltage rating.

MaximumModel Nominal Voltage Permissible

AbnormalOver Voltage

TDS XXX-120 110-120 Vac 240Vac

TDS XXX-208 208 Vac 260 Vac

TDS XXX-240 220-240 Vac 415 Vac

TDS XXX-277 220-277 Vac 480 Vac

7. PROTECTION MODES

Protection Modes refers to how the internalprotection is arranged and applied to thecircuit to be protected.

TDS-DINLINE Surge Suppressors are SingleMode units which provide protection betweentwo conductors connected to the terminalsmarked T1 and T2. These units can beconnected to provide protection from Phase-Neutral* or Phase-Earth* or Neutral-Earth.To allow the status indication and alarmcircuitry to operate, a neutral connection isrequired for Phase-Earth* configured units,and a Phase* connection is required forNeutral-Earth configured units.

* Note. Some users may be used to theterminology “Active” or “Line”, in place of“Phase”. For consistency “Phase” is usedthroughout this documentation.

T1 T2 X

StatusElectronics

Protection

SINGLE MODE UNITS

Ph-E ProtectionPh-N Protection N-E Protection Ph-Ph Protection

Terminals Ph-N Ph-E N-E Phx - Phy

T1 Ph E E Phx

T2 N Ph N Phy

X Ph N Ph Phx

CONNECTION OPTIONS

T1 T2 XT1 T2 X

E N PhE Ph NPh N Ph

T1 T2 X

Phx Phy Phx

T1 T2 X

PROTECTION MODE


Phase to Phase protection can also be providedby Surge Suppressors, provided that thenominal and maximum voltage ratings are notexceeded.

8. CONDUCTOR SIZES

Each Surge Suppressor terminal is designedto accept wire sizes from 1.5mm2 to 6mm2,solid or stranded conductor. Insulation shouldbe stripped back 8mm before terminating intothe tunnel terminal.

Where two conductors require termination inthe same tunnel terminal, conductors shouldbe limited to a maximum size of 4mm2.

Do not use excessive force when tightening theterminal.

Correct

Insulation cutback too far

Insulation not cutback far enough

8mm

1.5-6 mm2 conductor

9 CONDUCTOR LENGTH

To optimise transient performance, attempt toconnect units in the “Preferred” fashion asdepicted on pages 11 and 12. Some units havedouble terminals to facilitate this. Take carenot to run parallel “protected” and“unprotected” wiring.

Where this is not possible due to layout orconductor sizing, use the “Non-preferred” “T”connection method as depicted on page 13. Withthis connection method, the “T” lead lengthshould be kept as short as practicable (less than100mm) and wires should be bundled together.The “T” conductor should be equal in size to themain conductor, up to a maximum of 6mm2.

PREFERRED CONNECTION METHOD

Ph Ph Ph

Ph PhPh INCORRECT

CORRECT

Separate wiresNON-PREFERRED CONNECTION METHOD

T1 T2

INCORRECT

CORRECTKeepShort

Keep Close

T1 T2


TDS1160-8S

ProtectedEquipment

Maximumconductorsize 4mm2

Maximumconductorsize 2x4 mm2

or 1x6 mm2


PREFERRED CONNECTION METHOD EXAMPLE FOR Ph-E PROTECTION

TD140-2S

T2T1 X XT1T1 T2T2

SupplyPhNE

SupplyPhNE

ProtectedEquipment

Keep as shortas practical

Keep as shortas practical

SupplyPhNE

SupplyPhNE

Bundletogether

Bundletogether



NON-PREFERRED "T" CONNECTION METHOD EXAMPLE FOR Ph-E PROTECTION

TDS1160-8STDS 140-2S

ProtectedEquipment

ProtectedEquipment

T2T1 X T2T2T1 T1 X


10. RCD, ELCB

Where RCDs/ELCBs (Residual CurrentDevices / Earth Leakage Circuit Breakers) arefitted the Surge Suppressor units should beinstalled in the circuit prior to these devices

(ie upstream). Where this can not be avoidedand RCDs/ELCBs are installed upstream,nuisance tripping of the RCD/ELCB may occurduring transient activity.

Contact your local representative for advice ifupstream RCDs/ELCBs can not be avoided.

RCDELCB

ProtectedEquipment

CORRECT

RCDELCB

INCORRECT

PhPh

11. ISOLATION AND FUSING

Overcurrent and short circuit protection mustbe provided to protect the Surge Suppressorand associated wiring if a fault develops. Theovercurrent protection should be installed insuch a manner to also provide a means ofisolating the TDS-DINLINE module from themains supply. This is an important safetyconsideration and is required in the event thatany future maintenance or testing is needed.

For Surge Suppressors installed in the“preferred” connection method (page 12),upstream overcurrent protection should beinstalled based on the maximum currentcarrying capacity of the conductors.Australian regulations AS3000-1991, Table B2specifies the following upstream protection forthe protection of single phase circuits.

Ph Ph Ph

A mm2

Conductor Size Required Fuse

A mm2 CB or Fuse Rewirable Fuse

1.5 mm2 16A 12A

2.5 mm2 20A 16A

4.0 mm2 25A 20A

6.0 mm2 32A 25A

Fuse selection based on maximum current carrying capacity ofconductor. Smaller rated fuse may be selected if required.CB = Circuit Breaker.

A mm2


For Surge Suppressors installed in the “non-preferred” connection method (page 13),depending upon the size and fusing in themain circuit, the “T” connection may requireindependent fusing to be installed.

Circuits with upstream protection rated atgreater than 100A must have a 100A HRCfuse or circuit breaker installed in the Tconnection as detailed by the followingdiagram.

Warning:

Isolation/fusing installed in the “T” connectionmay disconnect the Surge Suppressor from thecircuit/equipment to be protected. The remotealarm contacts of the ALARM RELAY (TDS-AR) should be used to detect this occurrence.Operation of the isolation/fuse will remove theprotection from the circuit.

Ph

A mm2 B mm2

Supply Upstream* T-Connection RequiredConductor Protection Size T-Connection Size FuseA mm2 A fuse rating B mm2 B fuse rating1.5 mm2 16A 1.5 - 6 mm2 Nil2.5 mm2 20A 2.5 - 6 mm2 Nil4.0 mm2 25A 4 - 6 mm2 Nil6.0 mm2 32A 6 mm2 Nil>6.0 mm2 <100A 6 mm2 Nil**>6 mm2 >100A 6 mm2 100 A*** Fuse rating A selection based on maximum current carrying capacity of

conductor. Smaller rating fuse may be selected ir required.** Short circuit protection selection based on I2t rating of cable and fuse.

A B

Supply

The selection of the 100A HRC fuse is notbased on the load carrying capacity of themain circuit but the “T” connection I2t rating.The “T” connection under normal conditionsdoes not carry the load current. Only undersurge or fault conditions does this connectioncarry large currents. Under AustralianStandard AS3008.1-1989 it is permissible torate the protection for these types of circuitsby the I2t ratings of the cable. For installationof Surge Suppressor in countries not coveredby these regulations it is recommended thatthis practice be followed, unless it conflictswith the compliance of the local regulations.

12. STATUS INDICATION

A characteristic of all transient and surgeprotection devices is that they degrade inproportion to the magnitude and number of

incident surges to which they have beensubjected. Status indication should beperiodically monitored to determine ifreplacement is required.

2S units

These units are identified by the single StatusIndicator provided on the front panel. Whenpower is applied and full surge capacity isavailable the Status Indicator will beilluminated. Should the indicator fail toilluminate the Surge Suppressor should bereplaced, as optimum protection is no longerprovided. Note: The Status Indicator will notoperate (regardless of surge capacity) if poweris not available.

4S units

These units are identified by two StatusIndicators which are provided on the frontpanel. These Status Indicators monitor


separate protection segments. Each StatusIndicator is illuminated when power isavailable and when full surge capacity isavailable by that segment. The SurgeSuppressor should be replaced if eitherStatus Indicator fails to illuminate. Note: TheStatus Indicators will not operate (regardlessof surge capacity) if power is not available.

8S units

These units are identified by four StatusIndicators which operate similar to above. TheSurge Suppressor should be replaced if anytwo or more Status Indicators fail toilluminate.

13. MAINTENANCE & TESTING

Before removing any unit from serviceensure that power to the device isisolated. Replacement of any SurgeSuppressor should only be undertaken inaccordance with all relevant Electricityand Safety Standards by suitablyqualified personnel.

TDS-DINLINE units should be inspectedperiodically, and also following any periods oflightning or transient activity. Check thestatus indicators and replace if recommendedin Section 12 -STATUS INDICATION.

For high transient exposure sites or those of acritical operational nature, it is recommendedthat the alarm outputs be monitored toprovide an additional warning of reducedcapacity (refer Section 14 - ALARM RELAY-TDS-AR).

TDS-DINLINE Surge Suppressor units aredesigned for optimum performance undersevere transient activity. To provide thisperformance, electronic components in theunit are encased in a patented proprietary,shock and thermal absorbent compound.Units cannot be serviced, they must bereplaced.

Do not attempt to open or tamper with theunits in any way as this may compromiseperformance and will void warranty.

Do not “Megger” or perform other types ofelectrical tests that apply voltages greaterthan the nominal operating voltage of theSurge Suppressor. The Suppressor willattempt to limit these voltages therebyaffecting the test result. Where these testsmust be performed, remove the SurgeSuppressor from circuit first.

14. ALARM RELAY (TDS-AR)

The Surge Suppressor status monitoringcircuit which provides the visual statusdisplay also provides a low voltage opto-coupler alarm output circuit. This should onlybe connected to the TDS ALARM RELAY. TheTDS-AR voltage free alarm contacts may thenprovide output to external alarm systems orremote monitoring circuits.

The TDS ALARM RELAY provides fullyisolated potential free change-over alarmoutput contacts. One TDS-AR can be used perSuppressor opto-coupler alarm or MultipleSuppressor opto-coupler alarms can beconnected in series to the one TDS-AR toprovide a common output.


1 x TDS-AR supports:20 x TDS140-2S

or 10 x TDS 180-4Sor 5 x TDS 1160-8Sor relative combinations.

It is recommended that the TDS-AR unit bepowered from the same power circuit thatfeeds to the Surge Suppressor beingmonitored, however it can be powered fromother circuits. This allows for example, oneTDS-AR unit to be connected to separateSurge Suppressors that are protecting a threephase circuit.

To satisfy Australian wiring regulations thephase supply to the TDS-AR needs to beprotected by an overcurrent fuse/circuitbreaker. The overcurrent protection should beselected according to the wiring size

connecting to the TDS-AR Phase and Neutralterminals. For reference a table of values isgiven on page 24.

Note. Depending upon the usage of the TDS-AR output contacts, failure of power to theTDS-AR may be interpreted as a failure of oneor more Surge Suppressors. Visual inspectionof all units Status displays would determinethis.

Normal (green) indicator OFF Red indicator ON Relay is de-energisedPower is supplied

Normal (green) indicator OFFRed indicator OFFRelay is de-energisedPower is OFF

Normal

12Fault16

14

Normal

12Fault16

14

Surge Suppressor in alarm modeor power to Suppressor has been removed

Power to TDS-AR removedProtection status unknown

DISPLAY

EXPLANATION

Normal

Fault

16

12

14

Normal (green) indicator ONRed indicator OFFRelay is energisedPower is supplied

Normal operation

Protection OperationalSTATUS Protection Alarm Fault Mode


To transientprotectedequipment

To remotealarmcircuit

SINGLE ALARM CONNECTION EXAMPLE

TDS140-2S

WARNING - Connections are polarity sensitive. Do not reverse.

TDS-AR

NPh

E

Voltage free contactsOpto-coupler output

T2T1 X NL

MULTIPLE ALARM CONNECTION EXAMPLE

TDS180-4S TDS140-2S

WARNING - Connections are polarity sensitive. Do not reverse.

To remotealarmcircuit

TDS-AR

Voltage free contacts

NLT1T1 T2T2 X T2T1 X


the wiring size used to connect to the TDS-ARPh & N terminals.

Australian regulations AS3000-1991, Table B2specifies the following upstream protection forsingle phase circuits, unenclosed in air.

Cable Size HRC Fuse or CB Rewirable Fuse

1.5mm2 16A 12A

2.5mm2 20A 16A

4mm2 25A 20A

6mm2 32A 25A

Where overcurrent protection of theappropriate rating or smaller is already fittedin the upstream circuit, overcurrent protectionat the TDS-AR will not be required.

TDS-AR SPECIFICATIONS:

Output Contact Ratings

Nominal switching capacity 2A 30VDC

Maximum switching power 60W 125VA

Maximum switching voltage 220VDC, 250VAC

Maximum switching current 2A

Input to output isolation 4kV

Note: TDS-AR operates on supply voltagesof 100-480V Vrms.

TDS-AR OVERCURRENT PROTECTION

The power supply to the TDS-AR circuit mustbe provided with upstream overcurrentprotection. The fuse rating should be based on

ALARM TESTING

Testing of the Alarm Relay which is connectedto a fully functional Surge Suppressor unitcan be accomplished by removing power to theSurge Suppressor only. The Alarm RelayStatus indication and output contacts shouldalter from the Normal to Fault condition.

Testing of the Alarm Relay unit alone may beaccomplished by disconnecting the + / -connections to the unit. When power is appliedthe “Fault” Status Indicator should beilluminated. By connecting the + / - terminalstogether, the “Normal” Status Indicator shouldbe illuminated. The output contacts shouldalter to the appropriate state.

USE OF OTHER INTERFACESOnly ERICO TDS-AR units are recommendedfor the interfacing of equipment to the TDS-DINLINE opto-coupler alarm output circuit.

The direct connection of other equipment to theopto-coupler alarm output circuit may notprovide sufficient isolation or exceed the opto-coupler specifications. This may damage theSurge Suppressor and/or the connectedequipment. Warranty may be voided under suchcircumstances.

Opto-coupler

Protectiondiode

SURGE SUPPRESSOR OPTO-COUPLER ALARM

Opto-coupler

Vce = 30V DC

Ic = 150 mA

Note: TDS XXX-4S andTDS XXX-8S have respectively 2 and 4 opto-couples connectedinternally in series.


15. TDS-SC SURGE COUNTER

The Surge Counter is designed to interface tothe TDS DINLINE units via the supplied CT,to record the number of surges and impulsesdiverted. This is achieved by measuring thetransient current diverted by the TDSprotection device. It is important that the CTbe installed into the circuit where it ismeasuring the surge current only, and notwhere mains load current is passed throughthe core. Method 1 and Method 2 (page 28)detail the correct connection. Page 27 showsan incorrect connection as the equipment loadcurrent is passed through the CT core. Themagnetic field from the load carryingconductor may cause the CT core to saturate.The surge Counter may fail to record anytransients and additionally dangerously highvoltages may be present on the TDS-SC & CTterminals.

WARNINGS

• Do not install CT into load current carryingcircuits.

• CT must be installed into surge currentpath only.

• Only install the CT and Surge Counter afterall power and transient sources areremoved and isolated from the equipmentthe Surge Counter is to monitor.

• Do not open circuit or disconnectconnections on the secondary of the CTwhen monitored circuit is powered orconnected to possible transient source.Hazardous voltages may exist in thesecondary circuit and in the CT/TDS-SC ifthese instructions are not followed.

• Only this CT should be used with the TDS-SC Surge Counter, other suppliers devicesmay not operate correctly or pose a safetyhazard.

• These instructions should only be carriedout by qualified personnel in accordancewith relevant national electrical and safetycodes. Hazardous voltage may exist in themonitored system. LOAD

Incorrect Method

CT

TDS-SC

SURGE COUNTER CONNECTION METHODS*

* Typical connections only

C1C2

0586


LOAD

TDS Surge Suppressor

Surge Current

Correct Method 1 Correct Method 2

CT

TDS-SC

SURGE COUNTER CONNECTION METHODS*

LOADSurge Current

CT

TDS-SCC1C2

0586

C1C2

0586

* Typical connections only

14. TYPICAL DOMESTIC INSTALLATION (from 80A fused supply)

LIGHTS

LIGHTS

GPO

GPO

GPO

GPO

RCDELCB

A

N

Neutral Neutral Earth

MEN Link

RCD Protected

TDS140-2S-277

T2T1 X


17. EXTENDED WARRANTY

This product has a limited warranty to be freefrom defects in materials and workmanship for aperiod of five (5) years from the date of dispatchfrom the Manufacturer. The Purchaseracknowledges that lightning is a natural eventwith statistical variation in behaviour and energylevels which may exceed product ratings, and 100 %protection is not offered and cannot be providedfor. Therefore the Manufacturer’s liability islimited to the repair or replacement of the product(at the Manufacturer’s sole option) which in itsjudgement has not been abused, misused,interfered with by any person not authorised bythe Manufacturer, or exposed to energy ortransient levels exceeding the Manufacturer’sspecifications for the product. The product mustbe installed and earthed (where applicable) instrict accordance with the Manufacturer’sspecifications and all relevant national Electricityand Safety Standards. The Manufacturer and the

Purchaser mutually acknowledge that theproduct, by its nature, may be subject todegradation as a consequence of the number andseverity of surges and transients that itexperiences in normal use, and that this warrantyexcludes such gradual or sudden degradation.This warranty does not indemnify the Purchaserof the product for any consequential claim fordamages or loss of operations or service or profits.Customers should contact their nearestmanufacturer’s agent to obtain a Product RepairAuthorisation Number prior to making any claimunder this warranty. This is only a summary ofthe warranty given by the Manufacturer. The fulltext of the warranty is set out in theManufacturer’s Conditions of Quotation and Sale.The above limited warranty is additional to rightswhich arise in respect of the sale of industrial andtechnical products and services to knowledgablebuyers under the Australian Trade Practices Act1974 as amended.

18. SIX POINT PLAN

TDS-DINLINE SURGE SUPPRESSORs forman important part of the much larger ERICOlightning, surge and transient protectionphilosophy (ERICO Lightning Technologies“Six Point Plan”). The level of protection andthe degree of attention dedicated to each ofthe six points will require carefulconsideration for each site. The degree ofprotection required is determined by theindividual site location/exposure with the aidof risk management principals.

For further advice on your protection needsplease contact your local representative.

Capture thelightning strike

Eliminate earth loops and differentials

Conduct the strike to ground safely

Protect equipment from transients on telecommunication and signal lines

Protect equipment from surges on power lines

Dissipate the energythrough a low impedance earth system

Ph-E ProtectionPh-N Protection N-E Protection Ph-Ph Protection

Terminals Ph-N Ph-E N-E Phx - Phy T1 Ph E E PhxT2 N Ph N PhyX Ph N Ph Phx

TDS-DINLINE CONNECTION OPTIONS

T1 T2 XT1 T2 X

E N PhE Ph NPh N Ph

T1 T2 X T1 T2 X

PROTECTION MODE

Phx Phy Phx

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SURGE SUPPRESSOR © Copyright · Standard AS3008.1-1989 it is permissible to rate the protection...

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