Surge Protection

For Business-Critical Continuity™

Integrating SPDs in Switchgear & Switchboards

Causes More Problems than it Solves

White Paper – July 2010

Integrating surge protective devices (SPD) into distribution equipment (i.e. switchgear, switchboards, and
panelboards) started in the late 1990’s as a new method to market and as a way to reduce the overall
installation costs associated with SPDs. However, during the initial roll out of this application, incomplete
engineering analyses were performed to address the safety and performance attributes of integrating SPDs
into the distribution equipment.
TABLE I
There are many characteristics that affect LET-THROUGH VOLTAGE OF SPDS
the performance of an SPD (e.g. BASED ON CONDUCTOR SIZE [1]
technology, components, topology,
quality, etc.). While the individual SPD is an Peak Amplitude of Voltage Drop Voltage Drop
integral part of overall protection, the 8/20 µs Surge of Conductor of Conductor
connection of the SPD to the electrical Current (Amperes) (12 inches) (36 inches)
system can have the most dramatic effect. 500 22 66
Choosing conductors that are too long, 1,000 44 132
have sharp bends, or utilize small 3,000 132 395
conductors can significantly increase the 10,000 439 1316
let-through voltage of the installed SPD, 15,000 658 1974
which reduces the ability of the SPD to 25,000 1097 3290
protect the electrical system and the
installed electronic equipment (Table I). As
a system, integrated SPDs have consistently demonstrated that their ability to limit the amplitude of
overvoltage transients is inferior to SPDs installed external to distribution equipment.

The safety of SPDs has been rocky at best. Some manufacturers have an excellent record of producing SPDs
with minimal catastrophic failures, while others do not. SPDs integrated into distribution equipment pose a
dual problem: SPD safety and safety of the distribution equipment. There are documented cases of SPDs
failing violently in distribution equipment (Figure 1).
Catastrophic failures have been known to create great volumes of ionized gases that contribute to
distribution equipment failure. To increase SPD safety Underwriters Laboratories (UL) Standard for Safety,
Surge Protective Devices, 1449 third edition, has much higher safety requirements than the first edition.

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 FIGURE 1
INTEGRATED SPDS FAILURES

In addition to product safety standards, there are standards guiding SPDs installation. The Institute of
Electrical and Electronic Engineers (IEEE) states in IEEE Guide for the Application for Surge-Protective Devices
(SPDs) for Low-Voltage (1000 V or less) AC Power Circuits, that SPDs integrated into distribution equipment can
damage the distribution equipment during failure conditions.

APPLICATION EXAMPLE
Integrating SPDs into distribution equipment can have numerous perils. To reduce the risk of collateral
damage to the distribution equipment, those integrating SPDs need to locate the SPDs in separate and
isolated compartments within the distribution equipment. Figure 2 shows an illustration of how an SPD is
typically installed internal to a switchgear assembly. The design and construction of switchgear and
switchboard have many similarities, differing only in the some components and the application.

In Figure 2, the switchgear assembly has a main disconnect (item 1) that feeds the internal bus bars. Item 2
consists of mechanical, rack-type, circuit breakers with adjustable trip mechanisms, and they are located in
the remainder of the switchgear compartments. Additionally, there is a separate cable compartment.
Separate cable compartments are not always available. In those configurations, conductors are routed in the
same area as the internal bus bars.
FIGURE 2
LEFT & FRONTAL ILLUSTRATION OF TYPICAL SPD SWITCHGEAR INSTALLATION
Rear Cable Internal SPD
Compartment Bus Bar
TOP
3
3

SPD
Disconnect Bus
2 2
Compartment

BOTTOM
REAR FRONT

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The SPD is located in a separate bucket within the switchgear (item 3). Utilizing the separate compartment
limits any collateral damage to the distribution equipment during a catastrophic failure. A limited number of
SPDs utilize internal overcurrent protective devices (i.e. fuses), while others rely on external overcurrent
protective devices (i.e. fuses, circuit breakers) to provide short circuit current protection. Regardless of the
location of the overcurrent protective device, SPDs are typically installed with a disconnect located upstream
of the SPD. The external circuit breaker provides short circuit current protection to the SPD and any
conductors upstream of the SPD, and as a means to disconnect the SPD.

PERFORMANCE & SAFETY REVIEW OF SPD INSTALLATION

UL standards require that the circuit breaker used in a switchgear or switchboard application be a Listed
device [2, 3]. The choices are between an AC Power Circuit Breaker, Listed to UL 1066; and a Molded Case
Circuit Breaker (MCCB), Listed to UL 489. In switchgear and switchboards utilizing AC Power Circuit Breakers
that are energized and de-energized through a rack mechanism, the rack type of circuit breaker to protect an
SPD is impractical. With only a specific number of compartments available, front mounted and accessible
circuit breakers are reserved to other primary or branch circuits. Therefore, when SPDs are integrated into
this type of equipment, a MCCB is used.

PERFORMANCE
Locating the circuit breaker internal to the switchgear raises both performance and safety concerns. To
connect the SPD to the electrical distribution, the conductor starts at the internal bus bars, connects to the
internal MCCB, and ends at the SPD. Connection of the SPD to the phase bus bars is determined by the
placement of the circuit breaker and the SPD, resulting in the shortest lead length possible. However, in a
typical integrated installation (see Figure 2), the length of the conductor for each phase can exceed forty-
eight (48) inches.

While connection to the phase bus bars seems long, the connection to a neutral or ground bus can be longer.
Connection of the SPD to neutral and ground is accomplished at the main neutral or ground bus bar within
the switchgear or switchboard. While there is no circuit breaker to interface with, these conductors can
exceed forty-eight (48) inches.

As described earlier, conductor length can affect the performance of an SPD; the longer the lead length
connecting the SPD to the electrical distribution, the higher the let-through voltage. This results in less
protection of the electrical distribution system and all connected loads. Table II shows the let-through voltage
at the internal bus connection of an SPD with a voltage protection rating (VPR) of 400 V, and a conducted lead
length of forty-eight (48)
inches. TABLE II
LET-THROUGH VOLTAGE OF CONNECTED SPD
As the amplitude of the
transient current increases Let-through
from 500 A to 10,000 A, the Peak Voltage Voltage Drop of Voltage of SPD
let-through voltage of the Amplitude of Protection Conductor Connected to
connected SPD increases from 8/20 µs Surge Rating of SPD (48 inches) Internal Bus
488 V to 2,156 V even when Current (VPR) (Volts) (Volts peak)
the voltage protection rating of (Amperes)
the SPD remains at 400 V. If 500 400 88 488
the transient current increases 1,000 400 176 576
to 25,000 A, then the let- 3,000 400 528 928
through voltage of the 10,000 400 1756 2156
connected SPD increases to 15,000 400 2632 3032
4,788 V. 25,000 400 4388 4788

But, what amplitude will cause damage to the electrical distribution system of the facility and its connected
equipment? Many components have parameters associated with transient conditions (e.g. BIL, PIV, dielectric
withstand, surge immunity, etc). Design parameters such as basic impulse level (BIL), peak inverse voltage
(PIV) and surge immunity are good parameters to determine the maximum transient voltage capability, but
they are relevant to only specific components and are not or cannot be used universally.

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The most widely known parameter for overvoltage immunity of equipment is dielectric withstand. The
dielectric withstand of equipment is detail in UL Standards, regardless of the products listing status (i.e. Listed
or Recognized) is 1000 vac plus two-times the rated voltage from any phase (line or neutral) to ground. For
equipment designed for a 120, single-phase, two-wire plus ground system, the dielectric withstand is 1240
vac or 1750 volts peak. An SPD with a VPR of 400 V, connected to the electrical distribution with forty-eight
(48) inch conductors, and exposed to a 10,000 A 8/20 ì s current results in a peak voltage as seen by the
equipment and connected loads of 2,156 volts, which will not provide adequate protection to the connected
equipment. Inadequate transient protection will lead to damage of the connected loads.

SAFETY
The effect of an SPD failure on electrical distribution equipment will be minimized through the placement of
the SPD in a separate compartment within the switchgear or switchboard. However, all equipment requires
periodic maintenance and testing. Circuit breakers need to be serviced at least every two (2) years. Electrical
connections should be tightened yearly. SPDs also need to be serviced as surge components will need to be
replaced as a result of attenuating transients, or resulting from random component failure.
TABLE III
When working on electrical
PERSONAL PROTECTIVE EQUIPMENT (PPE) LEVELS [4]
equipment, the National Fire
Protection Association’s (NFPA)
Category Requirements
Standard for Electrical Safety in
Long sleeve shirt and long pants (natural
the Workplace, NFPA 70E, has 0
fibers), safety glasses
imposed specific personal
Flame retardant (FR) long sleeve shirt and
protection equipment (PPE) on
1 long pants, hard hat, safety glasses,
personnel working on electrical leather shoes
and mechanical equipment. The FR long sleeve shirt and long pants, hard hat,
amount or type of PPE required 2
safety glasses, leather shoes, arc flash shield
is dependent on the arc flash Cotton underwear, FR long sleeve shirt and
hazard and voltage at the service long pants, FR coveralls, hard hat, safety
location. 3
glasses, leather shoes, arc flash suit hood,
hearing protection
When an integrated SPD Cotton Underwear, FR long sleeve shirt and
requires servicing or long pants, hard hat, safety glasses, leather
maintenance, the technician has 4
shoes, hearing protection, multi-layer
two methods in which to arc flash suit
perform this work: energized or
de-energized. Most work on an SPD will be conducted when the SPD is de-energized. However, to de-
energize the SPD requires that the circuit breaker installed in the switchgear or switchboard be de-energized.

When working on energized equipment which includes opening circuit breakers located internal to
switchgear or switchboard assemblies (Figure 2), NFPA 70E requires a justification and analysis be completed.
Specifically, NFPA 70E Article 130.1 states “Energized electrical conductors and circuit parts to which an
employee might be exposed shall be put into an electrically safe work condition before an employee works
within the Limited Approach Boundary of those conductors or parts.”

Because heat, ventilating, air conditioning (HVAC) equipment, lighting, legally required loads (e.g. pollution
abatement equipment) and critical process equipment are commonly interconnected on the electrical
distribution system within the facility, most facility or process managers are not able to de-energize a
complete switchgear or switchboard assembly to perform maintenance or servicing of an SPD. After a system
analysis is conducted detailing the hazards associated with removing electrical power from the switchgear or
switchboard assembly, it is possible to open the circuit breaker associated with the SPD as long as proper
personal protective equipment (PPE) is used. While many systems can be worked on live, proper processes
must be followed (e.g. obtaining a “hot work” permit, wearing rated PPE) to ensure employee and equipment
safety.

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Switchgear and switchboard assemblies are located at the service FIGURE 3
entrance where high amplitudes of short circuit current exist. Short ARC FLASH & PPE
circuit current is one of the components incorporated into the arc
flash hazard analysis. If switchgear and switchboard assemblies can
be accessed when energized, it typically requires Category 3 or higher
PPE (Table III and Figure 3). In addition to PPE, performing
maintenance or servicing energized equipment requires a “hot work”
permit, which requires investigation into the arc flash hazards,
voltage hazards, mechanical hazards, and management sign-off.
Some organizations also require that a potential problem analysis be
conducted to ensure that any potential adverse actions are identified
and preventative measures are accounted for to ensure the safety of
personnel and minimization of process downtime.

An integrated SPD applied as shown in Figure 2, the facility manager

is required to sign a “hot work” permit, and the technician is required
to wear the appropriate PPE to remove the panels of the switchgear
or switchboard to disconnect the SPD from the electrical distribution.
Additional safety personnel are also required on-site while the
technician performs the required servicing or maintenance on the
integrated SPD.

CHANGING DISTRIBUTION EQUIPMENT FOR SPDs

Electrical distribution manufacturers have adapted how they apply SPDs. However, there is still more work to
be done to ensure that integrated SPDs provide protection to the electrical distribution equipment and the
connected loads. In addition, further design changes are required to ensure personnel safety during the
maintenance or servicing of the SPD.

To enhance the performance of the SPD and provide adequate protection, the impedance of the conductors
connecting the SPD and its overcurrent protective device to the internal bus bars must be significantly
reduced. Simply rerouting conductors may not remove enough conductor impedance to ensure that the SPD
can provide the transient protection needed. To achieve sufficiently lower conductor impedance, the
geometry of the conductors must change. The utilization of conductors arranged in a coaxial configuration
provides significantly lower conductor impedance during a transient conduction (Figure 4) [1].

To prevent people from working near live circuits, the overcurrent protective device for the SPD needs to be
moved to a location outside of the switchgear or switchboard deadfront. Having the SPD’s overcurrent
protective device outside of the deadfront will eliminate the need to wear PPE to de-energize the circuit.

FIGURE 4
ILLUSTRATION OF COAXIAL CONDUCTOR

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CONCLUSION
Surge protective devices (SPDs) are an important component to ensure quality electrical power is available to
critical processes. Product safety standards from UL and IEEE application guides have provided manufacturers
and end-users with requirements and guidelines to properly design and install SPDs. One of the significant
changes has been the realization that applying SPDs into switchgear and switchboards needs to be done with
care. If an integrated SPD is the preferred option, then the following items need to be accomplished to
ensure that an SPD failure will not damage the switchgear or switchboard assembly:

• The SPD needs to be placed in a separate compartment

• The conductor lengths connecting the SPD to the bus bars must be kept short – less than 24 inches
for each conductor or use coaxial conductors with a length of less than 100 inches
• The SPD’s overcurrent protective device or disconnect device must be accessible without requiring
the switchgear or switchboard assembly to be de-energized
• The SPD’s overcurrent protective device or disconnect device must be accessible without requiring
the technicians to obtain “hot work” permits or wear PPE to disconnect the SPD for service or
maintenance

Integrating an SPD into switchgear or switchboard assemblies can be accomplished if design engineers are
aware of the performance and safety needs of the SPD and the distribution equipment. If the guidelines listed
above are not followed, an SPD integrated into switchgear or switchboard assemblies can damage equipment
and endanger personnel.

The best method of applying an SPD is to place the SPD external to all distribution equipment. Externally
connected SPDs have the following advantages:

• Flexible mounting locations of the SPD overcurrent protective device

• Optional overcurrent protective device (i.e. fuse, circuit breaker) type and manufacturer
• Flexible mounting locations of the SPD
• Optional SPD type and manufacturer
• Shorter conductor length to the SPD
• SPDs can be serviced without wearing PPE

REFERENCES

1. Cole, B.R. (1999). Voltage Drop Calculations of Various Geometrical Configurations in the
Application of Surge Protection Devices (SPDs). Electrical Contracting & Engineering News,
1999 December
2. Underwriters Laboratories, Standard for Safety for Metal-Enclosed Low-Voltage Power Circuit
Breaker Switchgear, Fourth Edition, UL 1558, 1999 February, Northbrook, IL USA.
3. Underwriters Laboratories, Standard for Safety for Molded-Case Circuit Breakers, Molded-Case
Switches and Circuit-Breaker Enclosures, Tenth Edition, 2002 April, Northbrook, IL USA.
4. National Fire Protection Association, Standard for Electrical Safety in the Workplace, 2009
Edition, NFPA 70E-2009, Quincy, IL USA

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Surge Protection
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P (607) 721 8840
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