SurgCalc™
APT's SPD Sizing Tool
In today‘s electronic world, electrical systems for the home or business just aren’t complete unless they incorporate surge protection. The most effective way to defend and safeguard this environment against damaging surges is by hardwiring surge protective devices (SPDs) throughout the electrical distribution system.
Government studies suggest that the most efficient way to surge protect an electrical system is by applying hardwired surge protective devices at the main incoming electrical and communications services. Additional hardwired suppressors were recommended to prevent backfed surges that could bypass the primary electrical service SPD. Also, localized equipment SPDs are recommended to protect against residual and internally generated surges.
Following these practices, 5 common SPD electrical systems installation points can be identified. Applying surge protection at these points will maximize a facility’s surge immunity. These locations can easily be remembered by using the following acronym, “The best surge protection installation is a
S.O.L.I.D. one.” Where
S.O.L.I.D. stands for the following:
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Service Entrance
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Outside Loads
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Lower Voltage Panels
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Individual Loads
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Data Lines
With SOLID installation points identified, we can use SurgCalc™ to select appropriate SPD surge current and modes of protection redundancy.
SurgCalc™ is a facility surge susceptibility profiling tool that uses the answers to the following survey questions to generate the facilities surge index. This index is then used to select either Super, Standard, or minimal redundancies for each SOLID location of your facility.
SELECTION STEPS
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Answer each question by selection the appropriate answer from the corresponding pull down menu that best represents your facilities characteristics.
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At the end of the questionnaire is an SPD Redundancy selection pull down menu. It is defaulted to Super Redundancy, which is recommended for mission critical or high profile locations. Click on submit to see the APT SPD recommendations.
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For Standard and Minimal redundancies, click on category pull down menu, and select the appropriate category. Once the new category is selected, click on submit, and the corresponding SPD part numbers will appear corresponding to these redundancies.
Most consultants will print out the results and include them with their project file.
With the help of SurgCalc™’s susceptibility profiling, consultants can quickly find a calculated recommendation instead of just guessing or relying on a manufacturer’s representative’s recommendation.
If you need further assistance, please contact the APT Technical support group at
800.237.4567
1. Geographic location of the facility.
This can be determined by consulting an Isokeuronic map and finding the location of the facility. Colored regions show increased number of lightning days experienced within the region. Each region corresponds to an IEEE exposure classification category.
2. Facility location relative to other buildings.
If the facility is in a rural location isolated from other structures, or on a hilltop the probability of a lightning induced surges is much higher than in an urban environment.
3. Adjacent Structures.
If the facility has a large antenna, water tower, or is the tallest building in the area it has a higher probability than a facility nestled among other structures.
4. Location of the facility on the utility service.
If the facility is at the end of the utility line surges will travel down the transmission line, or if there are other large industrial facilities on the same line surges could be introduced on the line by these nearby endusers.
5. Utility history for an existing facility or for facilities being served by the same utility of a planned facility.
If there has been equipment disruption or equipment damage in an existing facility this is an indication of a high probability of surge activity. If this is a new facility, an inquiry to other facilities served by the same utility will give an indication of surge activity.
6. Consideration of the equipment being protected and the function this equipment performs as it applies to the facility mission.
If the equipment is supporting mission critical functions such as an on-line database, a continuous process control application, life support equipment, or other equipment that is essential for the operation of the facility it should have a high level of protection.
7. Expense to repair equipment.
If there is equipment within the facility that is very expensive to repair if damaged, such as MRI equipment, network controllers, CNC machinery etc. the level of protection should be high to avoid expensive repair bills.
IEEE C62.41 Category:
Recommended Products and Critical Specifications
IEEE C62.41
Facility Exposure (Application Level)
Calculated Exposure Index
| IEEE C62.41.1 |
Low Exposure
Exposure Index <35 |
Medium Exposure
Exposure Index 35 to 65 |
High Exposure
Exposure Index > 65 |
| Category C (Service Entrance) |
150kA to 200kA |
200kA to 300kA |
400kA to 500kA |
| Category B (Distribution Panel) |
50kA to 100kA |
100kA to 150kA |
150kA to 200kA |
| Category A (Individual Circuits) |
50kA to 100kA |
50kA to 100kA |
50kA to 100kA |
Maximum Redundant Applications
| IEEE C62.41.1 |
Low Exposure
Exposure Index <35 |
Medium Exposure
Exposure Index 35 to 65 |
High Exposure
Exposure Index > 65 |
| Category C (Service Entrance) |
150kA to 250kA |
300kA to 400kA |
600kA to 1000kA |
| Category B (Distribution Panel) |
100kA to 150kA |
150kA to 300kA |
400kA to 600kA |
| Category A (Individual Circuits) |
50kA to 100kA |
150kA to 300kA |
400kA to 600kA |
Surge Protection Terms and Features
| Redundancy |
Redundancy is the real meaning of surge current capability. As cited in our presentation and technical papers, the IEEE limits the maximum service entrance surge exposure to roughly around 10kA. This means that today's SPDs with their large kA ratings reaching 1,000,000 Amps will never be exposed to surge currents near their nameplate rating. Thus, the nameplate kA rating is a redundant rating above the IEEE 10kA maximum. For example, a 150kA per phase surge protector is a 15 times redundant system.
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| Maximum Redundancy |
This is the largest kA ratings APT recommends to be applied to systems in North America. The maximum surge current rating at this level is 400kA per phase, which is 40 times the IEEE's service entrance maximum surge.
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| Super Redundancy |
There are some clients who desire the highest amount of redundancy. APT provides suppressors which are double of our maximum redundancy levels. These devices max out at 1000kA/phase.
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| Modular Suppressors |
Modular suppressors are suppressors that can be replaced in the field without replacing the entire suppressor being replaced. These units are configured with either a single replaceable module or with multiple modules.
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| Non-Modular Suppressors |
These are throw-away suppressors. Once these suppressors give up their lives protecting load equipment, they can't be repaired. They need to be replaced and the bad unit is tossed away.
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| Budgetary Suppressors |
Budgetary suppressors provide similar protection as our standard units, but they may have lower surge current ratings and/or reduced monitoring capabilities.
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| IEEE Surge Exposure Categories - C, B, and A |
IEEE C62.41.1 and IEEE C62.41.2 describe a facilities surge voltage and current exposure levels based upon electrical distribution locations. Just like fault currents, surge current magnitudes are reduced as it travels further within a facility. This is due to the increasing impedance opposing the flow of surge currents. To better describe this concept, the IEEE developed the following "location categories:"
Category C - Parts of the distribution system that is located outside the facility and including interior sections that include revenue metering up to the line side of the main overcurrent protection device.
Category B - Parts of the distribution system that starts at the load side of the main overcurrent device and includes major feeders, and short branch circuits.
Category A - Parts of the distribution system that includes long branch circuits and receptacles.
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