Chris M. Finen, P.E.

Application Engineer
Eaton Electrical

Understanding TVSS
and its Application
Overview

Background
Test waveforms and standards
TVSS Features
Application and Mounting Considerations
NEC Code Compliance
Changes in 2005
TVSS Overcurrent Coordination Safety
Upcoming UL1449 Changes
Industry Myths
Specification Guidelines
You Cant Afford to Take Risks

Each year, there are over $1 billion worth of

lightning-related insurance industry losses

Nashville Area
averages 6 strikes/km2
per year
Lightning Activity stats for the US
How Does TVSS Work?

TVSS is a
passive, parallel L
connected device
Under normal Surge MOVs
Load

circumstances, Current, KA
TVSS has
extremely high G
impedance to
ground
During a surge event, the TVSS instantly
changes to a very low impedance
Surge is shunted to ground
Summary of Applicable Standards

Standard (current revision date) Purpose of Standard/Comments

UL 1449 (1987) - Transient Voltage 1. Safety Test (constructed of approved components in a safe manner).
Surge Suppressors 2. Suppressed Voltage Rating (let-through voltage rating using the IEEE
C62.41 C1 test wave). Other IEEE recommended wave forms such as the
C3 and B3 Ringwave are not tested by UL.
Note: UL 1449 does not require a maximum surge current test.
nd
UL 1449 (2 Edition 1996) 1. Additional Safety Tests. Test for other standards used to improve
safety of products.
2. Surge Test. Let through voltage tested at lower current than 1st Edition
10 kA (IEEE Cat C3) used for the first time, however, it was used only to
see if products fail safely.
UL 1283 (1996) - Electromagnetic This safety standard covers EMI filters connected to 600 V or lower circuits.
Interference Filters The UL 1283 is a safety standard and does include performance tests such
as MIL-STD-220A Insertion Loss or Cat B3 Ringwave Let-Through Voltage
tests.
UL 497, 497A, 497B Safety standard for primary telephone line protectors, isolated signal loops
and surge protection used on communication/data lines. No performance
tests conducted for data/communication lines.
IEEE C62.41 (1991) Recommended Practice on Surge Voltages in Low Voltage AC Power
Circuits (ANSI). This document defines the test waves for SPDs.
IEEE C62.45 (1992) Guide on Surge Testing for Low Voltage Equipment
(ANSI). This document describes the test methodology for testing SPDs.
IEEE Emerald Book Reference manual for the operation of electronic loads (includes grounding,
power requirements, etc.)
NEMA LS-1 NEMA Technical Committee guide for the specification of surge protection
devices including physical and operating parameters.
NEC National Electrical Code articles 245, 680 and 800
NFPA 780 Lightning Protection Code recommendations for the use of surge protection
devices at a facility service entrance.
TVSS IEEE and UL Tests

IEEE Categories (Emerald Book)

Ca te gory A Ca te gory B Ca te gory C
- Long Bra nc h Circ uits - Ma jor fe e de rs - Outdoor Ove rhe a d Line s
- Indoor Re c e pta c le - Short bra nc h c irc uits - Se rvic e Entra nc e
- Indoor se rvic e pa ne ls
TVSS IEEE and UL Tests

IEEE Test Waveforms

1.2 x 50 S (V)
8 x 20 S (A)
0.5 S x 100kHz Combination
Voltage Ring Wave Wave
Category Level (kV) Current (A) Current (kA)
A1 Low 2 70
A2 Medium 3 130
A3 High 6 200

B1 Low 2 170 1
B2 Medium 4 330 2
B3 High 6 500 3

C1 Low 6 3
C2 Medium 10 5
C3 High 20 10
TVSS IEEE and UL Tests

IEEE Test Waveforms

Category C3 (20kV, 10kA)
Represents the high level surge imposed on an electrical system
service entrance due to a direct lightning striking
Category C1 (6kV, 3kA)
Represents a lower order surge on a service entrance caused by
switching events, distance lightning strikes, etc.
Category B3 (6kV, 500A 100kHz Ringwave)
Represents a typical internally generated repetitive surge event
10000
due to motor starting, capacitor switching, breaker closing, etc.
8000

8000 6000

4000
6000

2000
4000
0
2000
-2000

0
-4000
0 10 20 30 40 -10 0 10 20 30 40

Combination Wave Ring Wave

TVSS IEEE and UL Tests

UL1449 2nd Edition Performance Test

Procedure
Let Through Voltage Test (Performed with 6
of wire connected to the unit)
Single 6kV, 500A pulse - measure Let Through Voltage
10 positive 6kV, 3kA pulses
10 negative 6kV, 3kA pulses
Another single 6kV, 500A pulse - measure Let Through
Voltage*
Assign Let Through Voltage classification

*Must not vary from original Let Through Voltage by more than
10%
TVSS IEEE and UL Tests

UL1449 2nd Edition Safety Test Procedure

Overvoltage Test
110% of rated voltage applied for 7 hours
Unit may not fail unless it automatically resets
Abnormal Overvoltage Test
L-L voltage is applied to the L-N mode (i.e. 208vac on a
120vac mode)
Unit may fail but must do so safely
High Current Test
Applies fault current of 25kAIC
Low Current Test (Slow Cook Test)
.125, .5, 2.5, and 5 amps are applied for 7 hours.
TVSS IEEE and UL Tests

High Energy Impulse Let-Through Test

Let Through Voltage Test (Measured at the terminals
of the unit)
Single Shot of IEEE Category C3 (20kV, 10kA)

NEMA LS-1
Recognize the UL1449 tests for let through and
safety
Additional Maximum Surge Current Rating test
Single Shot test at rated surge current rating*

*Maximum surge capable of being generated at an

independent lab is 250kA.
TVSS IEEE and UL Tests

REQUIRE INDEPENDENT TEST REPORTS

ON ALL TVSS PRODUCTS
Units must be tested as a complete unit
Some manufacturers will only test a single
component and will calculate the affect of
paralleling multiple components
All reputable TVSS manufacturers have their
TVSS units independently tested to verify ratings
Surge Current (kA) Ratings

Higher surge current (kA) ratings are achieved

by paralleling more MOVs
Gives more paths for the surge to go to ground
Each individual MOV has to handle less of the
total surge
Increases the life of the TVSS (# of Repetitive
Surges)
Higher kA ratings do NOT increase
performance, only the life of the unit
Surge Current Ratings

Let Through Voltage

Higher kA ratings increase the number of repetitive
surges a device can take
Let though voltage is the same
regardless of kA rating
208/120v Modes:
L-N; L-G N-G Repetitive C3 Surges
100kA 400v 330v 8,000
120kA 400v 330v 9,000
160kA 400v 330v 10,000
200kA 400v 330v 11,000
250kA 400v 330v 12,000
300kA 400v 330v 13,000
400kA 400v 330v 14,000
500kA 400v 330v 15,000
Surge Current Ratings

Why do are Manufacturers and specifiers

pushing higher kA ratings?
Has lightning gotten stronger?
Have lightning storms become more frequent?
Manufacturer XX Recommendations
1993 .250 kA/phase
1995..350 kA/phase
1997 .400
1998.. 500
2006.. To infinity and beyond
Recommend ratings for service entrance of
250kA/phase (125kA/Mode) with
minimum Repetitive Surge Rating of 12,000.
(~25year life expectancy)
Modes of Protection

Each connection is considered a Mode

L-N, L-G, N-G (Wye systems)
L-L, L-G (Delta systems)
L-L MOVs are not effective on Wye systems
L-L MOVs have higher voltage ratings
L-N, L-G MOVs will react much quicker
Not impedance matched
Dont reduce Let Through Voltage or Life
Couple surges to all phases
Surge Current Ratings

Two Stage
Coordinated
Protection Plan
Surge Current Ratings

Recommendations (maximums)
Service Entrance (Switchboards, Switchgear,
MCC Main Entrance)
250kA/phase (12,000 Repetitive surges)
Distribution Panels, High Exposure Roof Top
Equipment
160kA/phase (10,000 Repetitive surges)
Branch Locations (Panels, MCC, Busway, etc.)
120kA/phase (9,000 Repetitive surges)
Series Connected Critical Loads (PLC power
supplies, cash registers, etc.
apply as needed
Performance

What affects TVSS performance (let through

voltage)?
Filtering (Hybrid TVSS design)
Circuit Board Design
Circuit Impedance
Mounting / Installation
Filtering (aka: Hybrid TVSS, Sinewave
tracking)
The benefits realized when combining MOVs and
capacitor filtering are:
Current Sharing: Reduces MOV stress and increases life
expectancy (better withstand capability)
Lower Let-Through Voltage: Capacitive filters provide an
additional low impedance shunt path for both impulse and
ringwaves.
Noise Attenuation: Removes low voltage high frequency
disturbances at any phase angle (often referred to as
sinewave tracking).
Reliability: Better performance, longer life and noise
attenuation provide more value than a MOV only device.
L MOVs
Filter
Surge
Capacitor
current LOAD

N
Filtering

Let Through Voltage

(Input: Cat B3, 100 kHz, 6000V, 500A)

1000

no filter

500

Surge quality
-500 Event filter

poor filter
Filtering

Filter Specifications
Attenuation 50 kHz 100 kHz 500 kHz 1 MHz 5 MHz 10 MHz 50 MHz 100 MHz
Frequency

47 dB 50 dB 37 dB 37 dB 37 dB 38 dB 47 dB 53 dB

Harmonics Surges and Noise Radio Frequency

Disturbance
Frequency
50 / 60Hz 1 kHz 1 MHz 100 MHz

EMI/RFI Attenuation: 50dB @ 100kHz

Filter Bandwidth: 50kHz to 100MHz
Ringwave Let-Through Voltage < 160v (IEEE
Category B3, 208v System L-N)
Circuit Impedance

Some TVSS manufacturers use a parallel array of

MOVs
This configuration does not equal share surge
current. (More impedance to outside MOVs)
Closer MOVs take more of the surge energy, can fail
sooner

Surge
current

MOVs MOVs
Circuit Board Design

Surge Plane Technology

Cutler-Hammer is the first to utilize the ground
plane concept in the design of a low
impedance suppression platform
The ground plane provides the lowest possible impedance at high
frequencies
The plane ensures equal low impedance paths (both resistive and
inductive components)
Any two points (i.e. A,B,C or D) will be at the same potential
Circuit Impedance

All MOVs should be matched for impedance

in order to equal share surge events
Most all manufacturers use impedance
matched MOVs
TVSS units with replaceable modules
introduce more impedance into the system.
(banana clips, etc are not low impedance
connections)
Mounting / Installation
Installation Lead Length Can Increase Let-Through Voltage by
15- 25 volts Per Inch

Additional
Let-Through
Voltage Using
IEEE C1
(6000V,
3000A)
Waveform
(UL1449 Test
Wave)

Installation Criteria Order of Importance:

1) Lead Length - 75% reduction
2) Twisting Wires - 23% reduction
3) Larger Wire - minimal reduction
Mounting / Installation

Three main types of TVSS mounting /

installation
1. Side Mounted
2. Integrated with cable connection to a breaker
3. Integrated with direct bus bar mounting
Eaton Electrical submitted a CPS200
(200kA/phase) unit with each mounting
configuration to and independent test lab for
Let Through Voltage Testing.
This independently tests the actual as
installed performance of the TVSS.
Side Mounted
Integrated Cabled to breaker
Integrated Direct Bus Bar Mounting
Results

Integrated TVSS with direct bus bar

connection is the Best Approach for
maximum performance (Lowest Let
Through Voltages - LTV)

Integrated TVSS cabled to breaker allowed

13% - 29% higher LTV than direct bus bar
integrated.
Side mounted TVSS allowed 28% - 46%
higher LTV than direct bus bar integrated.

Conclusion: The identical device can have

up to 46% reduction in performance simply
by the way it is applied.
New construction should always utilize integrated
Side mounted should be used for retrofit
applications
Mounting / Installation - Significant Performance
Advantages Using Integrated Surge

Less lead length = lower let through voltage

Less components to install in the field
Consistency of installation
No lost wall space
UL listed as a complete assembly
Advantages to integrated SPDs -Rough In
Construction Phase

Conduit stubbed
up in concrete
before panels are
installed
Side Mounted SPDs Can Not Be Mounted
Next To Panel
Lead length
= 6 - 10 feet
Increased
let-through
voltage can
No space be 100s of
between No space volts!
panels above or
below due to
conduit
Integrated Surge Guarantees Correct
Installation

Lowest possible let-

through voltage
Proper installation is
assured
Cleaner installation
Advantages to integrated SPDs - Code
Compliance
2005 NEC Code changes: (TVSS Article 285)
2002 NEC TVSS must be mounted downstream of
the service disconnecting means.
2005 NEC (230.82(8)) TVSS equipment may is
permitted on to be connected to the line side of the
service disconnecting means if:
the TVSS is provided in listed equipment which
includes a disconnecting means and overcurrent
protection.

Side mounted units are only acceptable if they are

supplied with a disconnect internal to the TVSS.
(NOTE: This would require the utility to be
contacted to disconnect the service in order to
remove/replace the TVSS.)
Advantages to integrated SPDs - Code
Compliance
2005 NEC Code changes: (TVSS Article 285)
2002 NEC counts the TVSS disconnect as one of
the six allowed disconnects on a MLO Service
Entrance.
2005 NEC (230.71(A)) TVSS disconnect does
NOT count as one of the six allowed disconnects
if:
the TVSS and its disconnect are provided as part of
listed equipment

Side mounted units are only acceptable if they are

supplied with a disconnect internal to the TVSS.
(NOTE: This would require the utility to be
contacted to disconnect the service in order to
remove/replace the TVSS.)
SPD Overcurrent Protection

How do SPDs fail?

Most common misconception:
SPDs fail from surge events
This is not the case
The most common cause of SPD failure
(accounting for 90%) is due to temporary over
voltage (TOV)
This condition can be caused from:
Loss of neutral on 3ph 4w system
Improper installation
Elevated system voltage
Example of a Fuse Problem

Fuses did not work on this

over-voltage fault

MOVs went into thermal

run-away, and fuses did
not clear fault

Can result in operation of

upstream utility fuse to clear
fault,and result in facility
shut-down

Although rare events, these

can and do occur
SPD Overcurrent Coordination - Safety

SPDs should be viewed from a system

standpoint not stand alone devices
Coordinated with electrical system
Properly connected
The problem:
Need overcurrent protection that can:
1. Pass large surge currents without opening, but
2. Must open under low level (high impedance faults)
This cannot typically be accomplished by a
single overcurrent device.
Some manufacturers require minimum available
fault currents for their TVSS to operate safely.
SPD Overcurrent Coordination - Safety

TVSS Protection must:

Eliminate tripping of upstream breaker
Pass the full rated surge current
(100kA - 500kA)
Safely interrupt fault current ratings for
distribution equipment (up to 200kAIC)
Safely trips under all conditions
TOV
OV (improper connections)
Excessive surge (lifetime)
SPD Overcurrent Coordination - Safety

1 3

1-2 Thermal Fuse Spring & Metal Oxide Varistor Combination

3-4 Fuse - Trace as Overcurrent Disconnect
Thermo-Dynamic Fusing System
Thermo-Dynamic Fusing System
SPD Overcurrent Coordination

How are other SPDs designed?

Some SPDs attempt to provide high surge current
rated fusing (200-300kA)
And provide low fault current protection from TOV
conditions using the same fuse trace
Physical properties of a fuse means you cannot
have it both ways...

Drawbacks of this approach:

The SPD is not disconnected during low current faults
( i.e. mis-wiring, open neutral, over-voltage)
The upstream circuit breaker trips, resulting in a facility
shutdown
UL1449 does not test for these low fault current situations
(new UL 2.5 Edition safety revision test being added)
Changes to UL1449 Standard

Currently UL1449 2nd Edition is the recognized

industry standard
Tests for minimum levels of safety
Limited performance (Let Through Voltage) testing
February 2007 2.5th Edition safety revision
Adds a new Medium Fault Current test
10, 100, 500, and 1000 amps
Voltage is increased until conduction occurs
Current level is maintained until failure or protection
Must fail safely
2nd Edition only tests 5 amps and below, or 5000
amps and above
Changes to UL1449 Standard

3rd Edition (currently released in draft)

No major revisions to the 2.5th Edition
Rearranges into Surge Protective Device Types
Type 1
Surge arrestors
Devices can be mounted upstream of main
All will have to pass the safety requirements
Most surge arrestors as we know them today, will fail
Type 2
Permanently connected
Side mounted
Most side mounted TVSS devices as we know them
today, will be Type 1 and Type 2 listed
Changes to UL1449 Standard

3rd Edition (currently released in draft) (contd)

Type 3
Plug-in devices
Surge strips, etc.
Type 4
Assemblies / UL recognized products
Surge products that must be placed inside another
assembly
Integrated TVSS
Series connected filters (AEGIS)
Integrated TVSS as we know it today, will be Type 1 and
Type 4 listed
TVSS Industry Myths

Lightning Strokes can produce in upwards of

200,000 amps of surge current. (True or False)
TRUE
200,000 amps induced from a lightning strike
can flow into the electrical distribution system.
(True or False)
FALSE
Lightning energy takes various paths to ground
(building steel, plumbing, structural components,
etc.)
IEEE testing says a maximum of 20kV and 10kA
gets induced into the distribution system from a
lightning event.(Category C3 waveform)
TVSS Industry Myths

(Contd)
Cable insulation would fail and / or arcing would
occur at terminals.
TVSS would never see the surge.
Circuit breakers and Fuses will open due to surge
current:
8kA - 25kA Electronic Trip (Typical on SE)
20kA - 100kA Thermal Magnetic Trip
10kA Class CC Fuse
25kA Class R Fuse
NEMA LS-1 tests each TVSS to its published surge
current rating (up to 250kA)
TVSS Industry Myths

Magic Components
Selenium Cells
Metal Rectifiers
Used since 1920s. Discontinued due to high clamp voltage
and superior performance by MOVs, Zeners, etc.
Not proprietary - Not used by other manufacturers for a
reason
Do not increase surge suppression performance
Do not provide any appreciable protection from
Overvoltages (protection is system impedance
dependent)
Large and heavy

Expanded View of Selenium Cells

TVSS Industry Myths

Magic Components
Silicon Avalance Diodes (SADs)
SADs have faster response time than MOVs
Both MOVs & SADs respond 1000 times faster than a
surge event. Response time of components is not
recognized by IEEE, UL or NEMA.

Silicon Avalanche Diode (SAD):

141Amp (high surge rating)

Metal Oxide Varistor (MOV):

40,000 Amp; 40 mm

Note: SADs have a very low energy

content and not recommended
for high energy AC surge applications
TVSS Industry Myths

Magic Components
Epoxy encapsulated TVSS
Epoxy is used purely to keep the TVSS from being
dangerous when a failure occurs
Epoxy is rigid and cannot vent gases
TVSS Industry Myths

3rd Party Integration of TVSS

Typically is just a top hat on existing panel
TVSS is still wired to a breaker
reduced performance
Voids Panel / Switchboard UL rating
gets replaced with a UL508 panel shop rating
Voids manufacturers warranty
any field modifications void the standard manufacturers
warranty
Lack of AIC testing and final assembly testing
Potential problems with system coordination
Lack of field service support
TVSS Industry Myths

Integral disconnects
Disconnect is located inside the TVSS housing
Does not provide means for isolating the TVSS
Replacement of TVSS still requires a shutdown of
the service
Specifying SPDs

Spec should reflect functional and

performance characteristics
Avoid specifying how the product must be
constructed
Proprietary components, space-age polymers,
number of MOVs, size of MOVs, etc.
Good functional specifications will cover
these areas:
1. Performance
2. Life
3. Protection / System Coordination
4. Warranty
5. Monitoring
1. Performance

Specify actual Let Through Voltages from all

the test waveforms
UL 1449 2nd Edition tests
IEEE Category C3 High Energy Impulse
IEEE Category B3 Ringwave
Specify integrated TVSS where possible
direct bus bar connection (zero lead length)
Make sure entire assembly is tested. Beware of
third party manufacturers that modify
panelboards to integrate by cabling to a breaker.
Require independent testing from a
recognized test lab
2. Life

Specify life expectancy by number of repetitive

IEEE Category C3 (20kV, 10kA) surges
208/120v Modes:
L-N; L-G N-G Repetitive C3 Surges
100kA 400v 330v 8,000
120kA 400v 330v 9,000
160kA 400v 330v 10,000
200kA 400v 330v 11,000
250kA 400v 330v 12,000
300kA 400v 330v 13,000
400kA 400v 330v 14,000
500kA 400v 330v 15,000

Repetitive surge rating is more important than kA rating

Puts all manufacturers on an even playing field
3. Protection / System Coordination

SPDs = Reliability and Uptime

An SPD by design is a self sacrificing device
Over time and with repeated over-voltage
conditions an SPD can fail
As a result SPDs:
Must be designed to fail safely
Must not trip the upstream breaker and shut down
a facility
Must provide long term, maintenance free surge
protection
Current UL1449 2nd Edition does NOT test for
Medium fault currents
4. Warranty

Failure rates on quality TVSS units are very

low
Industry standard is a10 year full replacement
warranty (Regardless of kA rating)
Beware of limited, pro-rated, or replacement
component warranties
Interesting note: Some manufacturers that
have only been around for 5 years or less are
pushing 25 year warranties. Will these
companies be around in 25 years to honor
their warranties?
5. Monitoring

TVSS devices are NOT good power monitors!

(very low accuracy)
Use actual equipment designed
for power metering.

Typical TVSS monitoring

options:
Form C, Audible Alarm
Red/Green status LED
Audible Alarm w/ enable/disable
Surge counter
Questions?
Thank You!