How to Test Surge Protector

How to Test Surge Protector

Created by: Glen Zhu | Updated Date: December 13th, 2024

How to Test Surge Protector

Test Equipment

1. Impulse Current Generator (8/20µs & 10/350µs)

Impulse current generator (8/20µs)

The impact current of 8/20µs can be simulated by a double exponential function. In engineering, the main circuit is often constructed using RLC to generate the impact current.

The Circuit of impulse current generators

Table shows the design of different circuit parameters to generate a 20kA 8/20µs impulse current.

C/uF L/uH R/Ω U0/kV Source impedance Rp/Ω
4 18.9 2.043 77.940 3.882
8 9.45 1.022 38.820 1.941
12 6.30 0.681 25.880 1.294
16 4.73 0.511 19.410 0.971
20 3.78 0.409 15.528 0.777
24 3.15 0.341 12.940 0.647
28 2.70 0.292 11.091 0.555
32 2.36 0.255 9.705 0.485
36 2.10 0.227 8.627 0.431

Therelationship between capacitors and source impedance

Once the charging capacitance C is determined, L and R are determined. U0 only affects the peak discharge current; the larger the capacitance, the smaller the tuning inductance and tuning resistance. When outputting the same impulse current, a lower voltage is required.

The B32K385 residual voltage curve under different impulse currents

The B32K385,s dynamic impedance with impulse current and source impedances

Relationship between degradation level of the same chip U1mA and number of tests under different source impedances
(a)The change rule of U1mA under the 0.799Ω source impedance system
(b)Variation law of U1mA under 0.52Ω source impedance system

Impulse current generator (10/350µs)

A.Crowbar efficient circuit

At the peak, frequent oscillations occur after wave clipping, which is also a serious impact on MOV-type SPDs. In other words, its ability to withstand test loads is very low and lags behind the current development of SPD technology.
B. Overdamped C-RL discharge circuit

When it comes to the zero-crossing point of 0 and nearly 2ms for the tail wave, it exceeds other principle generators by nearly twice. This continuous current will have a serious impact on samples with high dynamic resistance like MOVs. The ball gap arc blowing system needs improvement.

Manufacturers and testing agencies should pay attention to the following points when conducting Class I tests on high-energy MOV chips:

(1) When using Crowbar efficient circuit to test high-energy MOV Class I products, do not judge that the sample’s ability to transfer charge is insufficient based on tail wave losses. In fact, it is due to insufficient load capacity of the testing equipment, which requires either modifying the equipment circuit or replacing a suitable generator.

(2) When using traditional C-RL circuits to test high-energy MOV Class I products, chip breakdown issues often occur in most cases due to excessively long tail wave continuous current. However, this issue should not directly lead to an unsatisfactory test conclusion.

Current Wave Superposition Circuit

(3) As a third-party laboratory, it is recommended to judge the test samples with the most standard waveform. However, there is no regulation on the zeroing time of the waveform tails in the standards, which is also a controversial issue.

(4) Maintaining technical communication with the inspected unit and conducting reasonable witnessing experiments or comparative experiments are also important means.

Finally, it should be emphasized that while each device meets standards, differences in testing results can be greatly influenced by the operator’s operation, understanding, experience, and even attitude!

2. Impulse Voltage Generator (1.2/50µs)

Parallel charging, series discharge, output source impedance is related to the capacitance value of the capacitor, discharge tube and surge protective device test: generally 40Ω and 100Ω. High voltage discharge, lightning attachment point test generally approaches high impedance ideal voltage source.

Impulse voltage generator basic circuit

Common multiple pole parallel charging circuit

3. Complex Wave Generator (1.2/50µs & 8/20µs )

Examples for decoupling networks of single-phase and three-phase power supplies

Selection of coupling components

  • The selection of different coupling components will have a certain impact on the output waveform of the composite wave generator. Commonly used coupling components include capacitor coupling, resistance-capacitance (RC) coupling, varistor coupling, and spark gap/spark tube coupling.
  • In principle, these components can transmit surge signals to the test sample without significantly affecting the output waveform parameters, while ensuring that they do not breakdown when U is applied. Studying the effect of coupling components in composite wave generators on output waveforms leads to conclusions.
  • Capacitor coupling is suitable for situations where the power frequency voltage of the power supply is not too high and the combination wave test level is not too high (such as 6kV/3kV combined waves). However, it is not the best way to couple when power frequency voltage is higher (e.g., AC600V) or combination wave test levels are higher (30kV/15kA or 20kV/10kA).
  • Varistor couplings are more suitable for situations with higher combination wave test levels, moderate power frequency voltages, and relatively loose requirements for combination wave waveform parameters.
  • Spark gap/spark tube couplings have a small dynamic resistance when passing through surge currents. They do not affect short-circuit current waveforms in combined waves and have a wide range of voltage protection levels, making them a good choice.

How to Test Surge Protector

TOV Test Caused by Low Voltage System Failure

Test purpose:

When the low-voltage distribution system experiences switch operation or faults (such as sudden unloading or single-phase faults) or iron-magnetic resonance effects, harmonics will generate a long-lasting power frequency overvoltage on the SPD, which is called temporary overvoltage. The purpose of this test is to assess whether the SPD can withstand or fail in a non-harmful manner under temporary overvoltage caused by low-voltage system failures.

Test method

(1) Install the SPD according to the manufacturer’s instructions for normal use conditions. Cover all five sides of the test box (except for the mounting surface) with thin paper (thin, soft and with a certain strength paper generally used for wrapping fragile items, weighing between 12g/m2~25g/m2). The size of the test box is usually a cube with each side length of 200~300mm, ensuring that the thin paper is at least 100±20mm away from all directions of the specimen based on actual dimensions of SPD.

Common TOV Test box

The duration of UT is 5020.8ms, the voltage of UT is 336.6V, and the time interval between UT and UREF is 90.4ms.
TN Network TT Network IT Network
SPD between L-N 1.32UREF 1.32UREF 1.32UREF
SPD between L-PE 1.32UREF UREF

General situation:

Uref=255V
UT=1.32×255V=336V
For SPD with Uc higher than or equal to UT, this test is not necessary.

How to Test Surge Arrester

TOV Test Caused by High (medium) Voltage System Failure

  • Due to a short circuit fault between the phase line and ground line of the high-voltage power supply line, a stress voltage will be generated between the ground line and phase line during low-voltage measurement of the transformer, which is called transient overvoltage (TOV) fault.
  • The stress voltage acting between the ground wire (PE) and phase wire (L) is 1200V+U0, while that acting between the ground wire (PE) and neutral wire (N) is 1200V.
Allowable AC voltage stress in low-voltage electrical equipment (V) Cut-off time (S)
U0+250V
U0+1200V
>5
≤5

GB/T 1689510-2021 Low-voltage electrical apparatus Part 4-44: Safety protection Voltage disturbance and electromagnetic disturbance protection

Schematic diagram of TOV fault

1. Short circuit between phase line and ground on high voltage side transmission line

2. The phase wire of armored cable short-circuited with the metal armor due to external force.

How to Test Surge Protection Device

Short-circuit Current Characteristic Test

Test purpose

In order to check the performance of the internal connections of SPD, to ensure that the internal connections of SPD have the ability to withstand short-circuit currents in fault conditions. If the manufacturer specifies external disconnectors and overcurrent protectors, they should be tested together with SPD to ensure that there is no burning, melting carbonization or spitting out of materials when short-circuit current flows through, causing fires, explosions or flashovers.

Sample preparation

The voltage limiting elements and voltage switch elements (MOV, GDT, gaps etc.) inside the SPD should be replaced with appropriate copper blocks (analogous substitutes) to ensure that the internal connections remain unchanged in terms of cross-sections and surrounding materials (such as resin) and packaging. When non-linear elements are connected in parallel within an SPD, each non-linear element in each current path should be replaced.

This test should be conducted on two different test configurations for each configuration a) and b), using a set of separately prepared samples:

a) Declared short-circuit withstand capability test
b) Low short-circuit current test

Short circuit module production

Metal screen grid

The metal screen grid should be fixed near the installation on all sides of the SPD, and the minimum distance is specified according to the manufacturer’s claim.

  • Structure: Woven metal wire mesh, perforated metal or metal plate mesh.
  • Ratio of open area/total area: 0.45~0.65
  • Hole size not exceeding 30mm2
  • Surface treatment: Bare or conductive electroplating.
  • Resistance: The resistance from the farthest point of the metal screen grid to the connection point of the metal screen grid should be small enough not to limit the short-circuit current of the screen circuit.

The metal screen grid is a quadrilateral frame, not a box. It should be connected to one tested terminal of SPD through a 6AgL/gG fuse after each short-circuit test. The connection of the grid should be moved to another terminal of SPD.

The screen grid is not covered with thin paper, observe whether the SPD flies to the metal screen grid, causing the 6AgL/gG fuse to blow.

a) Judgment logic for declared short-circuit withstand capability test

Criteria for judgment

(1) There should be no visible damage during the test process. After the test, minor dents or cracks found upon inspection can be ignored if they do not affect direct contact, unless the protection level (IP code) of the SPD is compromised. After the test, there should be no traces of burning on the specimen;

(2) Disconnection should be achieved through one or more internal and/or external disconnectors, and it should be checked whether they provide correct status indication;

(3) For SPDs with a protection level greater than or equal to IP20, a standard test probe applying a force of 5N should not touch live parts, except for live parts that were touched by the SPD before normal installation prior to testing;

(4) If disconnection occurs during testing (internal or external), clear indication of effective disconnection of corresponding protective components should be present. In case of internal disconnection, the specimen shall maintain 1min at maximum continuous operating voltage Uc rated frequency connected as per normal use; short-circuit current capacity of test power supply shall be greater than or equal to 20mA; current passing through relevant protective components shall not exceed 1mA. Current passing through elements parallel to related protective components or other circuits (such as indicator circuits) may be ignored as long as they do not cause current flow through relevant protective components. Additionally, if applicable, current passing through PE terminals including parallel circuits and other circuits (such as indicator circuits) shall not exceed 1mA. If there are multiple wiring methods in normal use, each possible wiring method shall be checked.

(5) If current flows out short-circuit current shall within 5S cut off by one or more internal and/or external disconnectors;

(6) There should be no explosions or other hazards caused to personnel or equipment;

(7) There should be no flashovers on metal screens; gG fuses connecting screens during testing also must not actuate.

b)Low Short-Circuit Current Test

Criteria

(1) There should be no visible damage during the test process. After the test, minor dents or cracks found upon inspection can be ignored if they do not affect direct contact protection, unless the protection level (IP code) of the SPD is compromised. After the test, there should be no traces of burning on the specimen.

(2) For SPDs with a protection level greater than or equal to IP20, a standard test finger should apply a force of 5N without touching live parts, except for live parts that can be touched by normal installation before testing;

(3) There should be no explosions or other hazards to personnel or equipment;

(4) There should be no flashover on metal screens, and the 6AgL/gG fuse connected during testing should not operate.

If there is disconnection during testing, it must also comply with:

(1) Disconnection must be achieved through one or more internal and/or external disconnectors; their correct status indication should be checked;

(2) If disconnection occurs during testing (internal or external), there should be clear indication of effective disconnection for corresponding protective components. In case of internal disconnection, the specimen shall remain connected to rated frequency maximum continuous operating voltage Uc for 1min under normal use conditions; short-circuit current capacity of test power supply shall be greater than or equal to 200mA; current flowing through relevant protective components shall not exceed 1mA. Current flowing through elements parallel to related protective components or other circuits (such as indicator circuits) may be ignored as long as they do not cause current flow through relevant protective components. Additionally, if applicable, current flowing through PE terminals including parallel circuits and other circuits (such as indicator circuits), shall not exceed 1mA. If there are multiple wiring methods in normal use conditions, each possible wiring method shall be checked.

(3) In case of short-circuit current flowing out from power supply source, it shall cut off within 5S via one or more internal and/or external disconnectors.

The short-circuit current is set to 300A, 45°, and the product disconnects after 1763.1ms.

How to Test a Surge Protection Device

Additional Test for Simulating SPD Failure Mode

Test purpose

During normal operation, SPD may fail due to short circuit or open circuit faults. The short-circuit current test is conducted to assess the performance of the internal connections of the SPD by directly replacing the protective components with copper blocks and applying the expected short-circuit current. This test simulates an overvoltage fault added to a normal system operation that causes the SPD to fail. The objective is to determine if the SPD can withstand the expected short-circuit current without causing fires, explosions, arcing, or other accidents.

Sample preparation

For this test, any electronic indicator circuits can be disconnected.

  • Select appropriate pre-treatment voltage based on Uc value of SPD, apply for 50+5% duration. Expected short-circuit current from power supply should be within 1A~20A (r.m.s); each group of samples should be tested under short-circuit currents of 100A, 500A and 1000A UREF unless these values exceed rated short-circuit current declared by SPD manufacturer.
  • After pre-treatment voltage application, apply voltage UREF 0-5% on sample for 5min or at least 0.5s after current is cut off internally or externally. There should be no interruption between applying pre-treatment voltage and UREF conversion.

Criteria for judgment

(1) There should be no visible damage during the test process. After the test, minor dents or cracks found upon inspection can be ignored if they do not affect direct contact, unless the protection level (IP code) of the SPD is compromised. There should be no traces of burning on the specimen after testing;

(2) For SPDs with a protection level greater than or equal to IP20, a standard test value should be applied with a force of 5N without touching live parts, except for live parts that were touched by the SPD before normal installation prior to testing;

(3) There should be no explosions or other hazards caused to personnel or equipment;

(4) There should be no flashover on metal screens, and during testing, the 6AgL/gG fuse connected to the screen should not operate.

(5) Disconnection should be achieved through one or more internal and/or external disconnectors; their correct status indication must be checked;

(6) If disconnection occurs during testing (internal or external), there must be clear indication of effective disconnection of corresponding protective components. In case of internal disconnection, the specimen shall remain connected at rated frequency maximum continuous operating voltage Uc for 1min under normal use conditions; short-circuit current capacity of test power supply shall be greater than or equal to 20mA; current flowing through relevant protective components shall not exceed 1mA. Current flowing through components parallel to and circuits associated with protective elements (such as indicator circuits) may be ignored as long as they do not cause current flow through relevant protective elements. Additionally, if applicable, current flowing through PE terminals including parallel circuits and other circuits (such as indicator circuits), shall not exceed 1mA. If there are multiple wiring configurations in normal use, each possible wiring configuration must be checked.

Single chip pressure sensitive tolerance qualified demonstration

Three pieces of non-conforming pressure-sensitive demonstrations

(1) When the declared value of the pre-treatment short-circuit current is large, for example 20A, for varistor products in the pre-treatment stage, short-circuit failure will occur within 5s. If it is a qualified product, timely disconnection through external/internal disconnectors within 5s without any danger such as fire or explosion will occur.

(2) When the declared value of the pre-treatment short-circuit current is small, for example 1~2A, during the pre-treatment stage, products may not be fully activated and with a small short-circuit circuit, even inferior varistor products will not experience phenomena such as fire. Therefore, it is recommended that manufacturers increase the declared value of the pre-treatment short-circuit current and use more stringent test levels to ensure product quality.

(3) The expected short-circuit current value claimed by the manufacturer in the SPD short-circuit test should be carefully considered. If the claimed value is too high, for example, above 300A, the probability of passing the short-circuit current characteristic test will be higher. This is because internal connecting components are more likely to disconnect within 5 seconds due to excessive current. However, for simulated SPD failure tests, if the SPD does not completely trip during the pre-processing stage and is subjected to subsequent reference voltage effects, a high expected short-circuit current will increase the probability of SPD ignition and combustion. Therefore, the expected short-circuit current value should be a compromise in order to ensure that both tests can be passed.

(4) When conducting this test on switch-type products, it is generally unlikely to see a phenomenon similar to the ignition and combustion of MOV valve pieces. The product may not turn on or may frequently short circuit or open circuit with the periodic variation of AC voltage.

How to Test Surge Protection Devices

Limit Voltage Test

Equipment name

Parameter requirements

Impact current generator

 

10/350µs: Iimp tolerance ±10%, charge quantity Q tolerance -10%/+20%, specific energy tolerance -10%/+45%;

8/20µs: Peak value tolerance ±10%, front time tolerance ±10%, half peak time tolerance ±10%, overshoot or oscillation amplitude not greater than 5% of peak value, reverse peak current value not greater than 30% of peak value.

Surge voltage generator

1.2/50µs: Peak deviation ±5%, front time deviation ±30%, half peak time deviation ±20%, amplitude of the rising part from 0% to 80% of the peak value of the impulse voltage not greater than 3% of the peak value, generator short-circuit current less than 20%In

Compound wave generator (with even-odd network)

1. 2/50µs: Peak deviation 20kV±5%, front time deviation ±30%, half peak time deviation ±20%, amplitude of the rising part of the impulse voltage peak from 0% to 80% not greater than 3% of the peak value, short-circuit current of generator less than 20% In;

8/20µs: Peak deviation 10kA±10%, front time deviation ±10%, half peak time deviation ±10%, overshoot or oscillation amplitude not greater than 5% of the peak value, reverse peak current value not greater than 30% of the peak value, virtual impedance is 2Ω

Measurement system (oscilloscope, Rogowski coil, voltage divider, etc.)

Current: accuracy within ±3%;

Voltage: accuracy within ±3%;

Bandwidth at least 25MHz, overshoot less than 3%;

Standard trial production, electrical indicator, push-pull force gauge

 

Articulated probe: diameter 12mm, length 80mm; spherical probe: diameter 12.5mm

Voltage: AC 40~50V

Thrust: range 50N, graduation value 0.25N

Test connection method:

A) The divider connection wire is tightly attached to the product surface after being twisted in pairs
B) The low-voltage end of SPD should use short terminal blocks instead of wires as much as possible

Line length

terminal block

9cm lead wire

100cm lead wire

current/kA

19.64

19.79

18.56

Residual pressure/kV

1.57

1.63

1.69

The use of longer low-voltage end leads to a measured residual voltage value that is 120V higher.

Connection method

Not twisted pair

Twisted pair

current/kA

19.54

19.64

Residual pressure/kV

1.64

1.57

The double twisting caused the measured residual voltage to be 70V higher.

Reasons for different residual voltage curves:

  • Curve 1 corresponds to discharge current waveform 8/20µs;
  • Curves 2 and 3 are normal residual voltage curves, with the discharge current of curve 2 smaller than that of curve 3;
  • Curve 5 is the induced voltage (interference voltage) generated in a circuit with magnetic coupling to discharge current 1;
  • Curve 4 is interference voltage 5 superimposed on the normal limiting voltages of MOVs, represented by curves 2 and 3.

In general, the interference of discharge current can be eliminated by adjusting the spatial position and direction of the voltage divider.

Method for determining limiting voltage:

  • Record the peak values (absolute values) of impulse voltage and impulse current in sequence, and draw a linear quadratic fitting relationship graph of current and residual pressure through software.
  • When the calculated value is significantly different from the actual value, you can also add point (0,0) to the fitting data.
  • According to the fitting formula, determine the voltage values at currents up to Iimp (Class I) and In (Class II).
Comparison of residual pressure curves with and without a switching element

Criteria for data results:

  • The laboratory should assess the measurement uncertainty suitable for this project in the laboratory. When the measured value approaches Up, according to “Application of Measurement Uncertainty in Conformity Assessment” (CNAS-TRL-010:2019) and “Guidelines for Reporting Detection and Calibration Results and Compliance with Specifications” (RB/T 197-2015), determine whether the sample meets requirements.
  • If after adding an expanded uncertainty with a probability of 95%, the measurement result does not exceed the specified limit value (Up), then it can be determined as “compliant” or “qualified”.
  • If after subtracting an expanded uncertainty with a probability of 95%, the measurement result exceeds the specified limit value (Up), then it can be determined as “compliant” or “non-compliant”.
  • If within specification limits (Up), but after adding an expanded uncertainty with a probability of 95%, it exceeds these limits, then it can be determined as “compliant” or “qualified”.
  • If outside specification limits (Up), but after subtracting an expanded uncertainty with a probability of 95%, it does not exceed these limits, then it can be determined as “non-compliant” or “non-conforming”.

For example, if a laboratory’s extended uncertainty for limiting voltage projects is 70.0V (with a probability of 95% and k=2), and if a sample’s Up value is 1.8kV, when measuring result shows up as 1.75kV – even though exceeding Up when including extended uncertainties – since actual measurement doesn’t surpass Up directly; therefore deemed qualified.

Surge Protection Device Testing

Action Load Test

Equipment name

Parameter requirements

Impact current generator

10/350µs: Iimp tolerance ±10%, charge quantity Q tolerance -10%/+20%, specific energy tolerance -10%/+45%;

8/20µs: Peak value tolerance ±10%, front time tolerance ±10%, half peak time tolerance ±10%, overshoot or oscillation amplitude not greater than 5% of peak value, reverse peak current value not greater than 30% of peak value.

Impedance current tester/power meter/clamp ammeter

Current: Range 0-20mA, resolution not exceeding 0.1mA;

Voltage: AC 0-1000V, error within ±3%

Compound wave generator (with even-odd network)

 

1. 2/50µs: Peak deviation 20kV±5%, front time deviation ±30%, half peak time deviation ±20%, amplitude of the rising part from 0% to 80% of the peak value not greater than 3% of the peak value, short-circuit current of generator less than 20% In;

8/20µs: Peak deviation 10kA±10%, front time deviation ±10%, half peak time deviation ±10%, overshoot or oscillation amplitude not greater than 5% of the peak value, reverse peak current value not greater than 30% of the peak value, virtual impedance is 2Ω

Measurement system (oscilloscope, Rogowski coil, voltage divider, etc.)

Current: Accuracy within ±3%;

Voltage: Accuracy within ±3%;

Bandwidth at least 25MHz, overshoot less than 3%;

Standard trial production, electrical indicator, push-pull force gauge

Articulated probe: diameter 12mm, length 80mm; spherical probe: diameter 12.5mm

Voltage: AC 40~50V

Thrust: range 50N, graduation value 0.25N

The experiment should use another test sample, connected to the test sample cabinet of the 8/20μs impulse current generator, select the impulse resistance-capacitance divider, and the coil testing the continuous flow peak value should be connected in series with the circuit on both sides of the test sample and power supply.

Diagram of continuation flow test connection
Continuous current for half a cycle
Continuous current for one cycle
90 degree impact angle
Type I test action load

Due to the long tail truncation time of the 10/350µs waveform, the duration of the follow current cutoff in the figure is 18.70ms, much higher than the duration of triggering follow current at 8/20µs.

Key points for testing:

  • Usually, in order to conveniently collect current in laboratories, a clamp ammeter is used to manually determine whether power consumption decreases based on the product of voltage and current. However, due to the very small residual current at reference test voltage for products, usually at microampere level, with weak induced voltage signals, a high-precision clamp ammeter needs to be selected for accurate collection;
  • When using an oscilloscope to simultaneously capture voltage and current waveforms, in order to display the triggering phase of power frequency voltage waveform, an oscilloscope with millisecond-level time base is chosen. Under millisecond-level time base setting where sampling rate decreases on oscilloscope resulting in lower resolution display capability; hence under this setting only one sharp peak pulse can be displayed from 8/20μs current waveform. Therefore it’s recommended that two oscilloscopes are used simultaneously for measuring both voltage and current waveforms ensuring accurate and complete waveform display; if necessary monitoring follow-up flow waveforms concurrently allows more intuitive observation of its duration and size;
  • As resistive component or power consumption monitoring changes continuously over time should maintain steady state after keeping power frequency AC supply connected for 15 minutes before testing its stable value as final measurement result;
  • During actual operation of SPD surge currents randomly superimpose on system voltages. When system voltages are AC mains frequencies there arises issue regarding phase relationship between surge currents & system voltages. Generally when SPD has clamping characteristics most severe condition occurs when surge currents superimpose exactly at same phase peaks as system voltages; whereas switch type SPD have different superposition phases depending upon presence or absence of freewheeling diodes hence experiment designed here involves gradual change in superposition phases.
  • During the test, the capacity of the power frequency AC power supply, that is, the output capability, determines the current flowing into the SPD when it conducts, which has an important impact on the test results. The standard stipulates that for SPDs with a continuous current of less than or equal to 500A, the impedance of the power frequency power supply connected to the sample should meet that when the continuous current flows through it, at both ends of the power frequency power supply (the description in GB/T 18802.11-2020 standard is incorrect and should not be measured from SPD’s terminal), and cannot exceed U. A decrease in peak value of 10% of voltage peak value.
  • If SPD is classified as both Class I and Class II, the test may be conducted only once, but the most severe test parameters under both categories should be used in consultation with the manufacturer.
  • The test to determine the size of the continuous flow is only used as a basis for selecting the action load test power supply, and does not make any qualification judgments.
  • After the dynamic load test, check the stability and additional dynamic load test for industrial tests. The short-circuit current capacity of the power frequency power supply used in the dynamic load test is 5A, but the characteristics of the power frequency power supply used in Class I and Class II dynamic load tests should meet the following requirements:
  1. For SPDs with a continuous current rating less than or equal to 500A: The impedance of the power supply should ensure that when the continuous current flows, the drop in peak voltage at power frequency cannot exceed 10% of the Uc peak value.
  1. For SPDs with a continuous current rating greater than 500A: The expected short-circuit current of the power supply should be either the rated breaking and continuing current value I specified by the manufacturer, or 500A, whichever is greater. For SPDs only connected between neutral and protective earth in TT and/or TN systems, the expected short-circuit current of the power supply should be at least 100A.

Surge Protector Test

Electric Trace Test

Equipment name

Parameter requirements

Electric traceability test equipment

Electrode: Platinum metal with a minimum purity of 99% should be used for the electrodes. The two electrodes should have a rectangular cross-section of (5.0±0.1) mm x (12.0±0.1) mm, with a -30±2 slope. The two electrode faces should be perpendicular to each other, with an angle between the electrodes of 60±5 degrees. The distance between the electrodes should be 4.0±0.1mm, and the force applied to the surface of the specimen for each electrode should be 1.00±0.05 N.

Dielectric withstand test equipment test circuit: The sinusoidal voltage should vary from 100 to 600V, with a frequency of 48-62Hz. The maximum error of the voltage device is 1.5%, and the power supply power should not be less than 0..6kVA.The short-circuit current between the two electrodes should be able to reach 1..0 ± .01A, and at this current level, voltage drop shouldn’t exceed10%.The maximum error in short-circuit current is ±3%.

Drip device: Test solution droplets should occur at intervals of30 ± .05s, with a drip height of35 ± .05mm,and target time between drops being30s.

Specimen support platform: One or more appropriately sized glass plates with a total thickness not less than4mm.

Electronic balance

Weight: 0~500g, accuracy 0.01g  

conductivity meter

Conductivity: 0.00~100.0mS/cm, error ±1%;

Temperature: 0~99.9℃, error ±0.4℃

Experimental Purpose:

The electrical erosion test is an important method to evaluate the corrosion resistance of insulation materials, and it is an important basis for determining whether materials can be used in harsh environments. It is particularly important to correctly measure the Comparative Tracking Index (CTI) and Proof Tracking Index (PTI) of insulation materials.

Preparation of Test Samples:

Size and shape of test samples: The sample surface should be flat, smooth, and scratch-free. The surface area should prevent liquid from flowing out from the edges during testing. The size should not be less than 20mm x 20mm, with a thickness of 3mm or more. Multiple material samples can overlap to achieve a minimum thickness of at least 3 mm.

Preparation of Test Solution:

Use deionized water, ammonium chloride powder, conductivity tester and electronic balance to prepare the test solution A: Analytical pure anhydrous ammonium chloride (NH4Cl) reagent with a mass fraction of about 0.1% and a purity not less than 99.8% is dissolved in deionized water. The resistivity of the solution at 23±1℃ is 3.95±0.05 Ω.m, at 25℃ it is 3.75±0.05 Ω*m, and at 20℃ it is 4.25±0.05 Ωm.

Preparation for Equipment Calibration:

(1) Electrode and droplet device adjustment: Adjust the X-axis moving table and Y-axis moving table, place the glass on the lifting platform, then place the sample on the glass, adjust the lifting platform to make two electrode arms form a horizontal line, so that each electrode arm exerts a force of 1.00±0.05N on the sample, with a distance between two electrodes of 4.0±0.1mm; adjust the two knobs behind the droplet mechanism to move it up and down, so that the needle tip of the syringe is 35±5 mm away from the upper surface of the sample.

(2) Leakage mark drop liquid adjustment: Pour a suitable amount of deionized water into the dropper cup, press the “drain” button on the panel to remove air from the needle. Pour the prepared solution into the dropper cup, press the “drop” button, observe if there are any drops that have not fallen or if more than one drop falls at once. Start the experiment after normal dripping of drops.

(3) Short circuit debugging: Adjust the required test voltage value, then rotate the current adjustment knob, press the “electrode short circuit” button to make the short-circuit current 1.0±0.1A. At this current, the voltage drop indicated on the voltmeter should not exceed 10%. The maximum error of the measurement device for short-circuit current value is ±3%.

Test method:

The withstand voltage value depends on the measured creepage distance value and the corresponding material group category. If the corresponding material group category is not qualified, reduce one category for further testing until the lowest category of materials. For example, if a product’s U is 385V and the minimum measured creepage distance is 3.0 mm, according to Table 5.19 SPD creepage distance, meeting material group categories II or above, then select a withstand voltage value of 400V with 50 drops of liquid. If this test level cannot pass, then the corresponding creepage distance is also deemed unqualified and continue to do the next test level at 175V with 50 drops.

Key points of testing:

(1) The surface of the sample should be clean without dust, dirt, fingerprints, grease, oil release agents or other contaminants that may affect test results. When cleaning samples, care should be taken to avoid causing swelling, softening or substantial abrasions that could damage materials. Among common contaminants on sample surfaces are dust and fingerprints. Dust can be removed directly with distilled water while fingerprints mainly consist of water, inorganic salts and fatty oils which are difficult to detect but easily affect test results; they can be cleaned using an alcohol solution around 20% concentration followed by rinsing with distilled or deionized water to effectively remove contaminants from sample surfaces without affecting test results.

(2) The thickness of samples must not be less than 3mm because typically under samples there are glass or steel plates as pads; during tests chloride ammonium ion solutions generate a lot of heat so if samples need to endure heat but are too thin it will quickly dissipate heat preventing them from enduring chloride ammonium ion solutions’ effects thus ensuring sample thickness no less than 3mm during tests or stacking same-material samples together so their combined thickness exceeds at least over three millimeters while stacked sample sizes should ideally match each other.

(3) Analytical grade (denoted by letter AR) anhydrous ammonium chloride purity must not fall below 99.5%; generally only reagent grade (denoted by letter GR) achieves purity levels exceeding at least over ninety-nine point eight percent; solvents when unopened have shelf lives around five years but once opened require sealing storage shortening shelf life down two years; if solvent used in tests has solidified it needs drying in oven before use preventing moisture within solvent affecting final solution preparation process.

(4) The conductivity of distilled water and deionized water is very low, indicating that they contain very few impurities. When the conductivity is low to a certain extent, the influence of impurities on the solution can be ignored. If the conductivity is too high, the relative content of impurities increases, significantly affecting the electrolysis of NH4Cl in the solution and thus affecting experimental results.

(5) The resistivity of a solution is an important factor influencing the results of electrical traceability tests. Solutions should be prepared according to the requirements for resistivity, with mass fraction only serving as a reference. It is best to prepare and use solutions immediately without storing them for too long. For example, if a solution is stored for an extended period in equipment prone to leakage currents, there may be a decrease in resistivity at the bottom of the solution. If storage is necessary, it should be sealed and kept in a cool place; when using it again, measure its resistivity to ensure it meets standard requirements.

(6) Temperature has a significant impact on the conductivity value of electrolytes. The conductivity value of electrolytes at specific concentrations changes with temperature variations. As temperature increases, electrolyte conductance enhances leading to lower resistance values and higher conductivity values. Standards specify that measurements for test solutions’ conductivity must be conducted at 23±1 ℃; before measuring electrolyte conductance, allow sufficient time for solutions to reach room temperature (23±1℃). Use either a thermometer or a conductance meter equipped with temperature sensors during measurement processes so that you can control your measured electrolyte’s temperature within 23±1℃ as per standards specified regulations.

(7) When the two electrodes are not perpendicular to the surface of the sample, that is, when the electrodes do not have good contact with the sample surface, it will seriously affect the test results. In addition, after multiple tests and combustion of the sample, there may be carbonization melting on the surface of platinum electrodes. If this electrode continues to be used for testing, carbides will form a barrier layer between the electrode and sample, affecting their contact. Therefore, in order to obtain more accurate test results, pay attention to observing the condition of the electrode after each test. If necessary, use fine sandpaper labeled 400 to polish the electrode carefully without changing its contour or turning its edge into a cylindrical shape; otherwise incomplete contact between electrode and sample may occur. After polishing is completed, rinse off with deionized water or distilled water.

(8) Each test voltage should have a separately set short-circuit current value. For different test voltages: if only one short-circuit current value is set (e.g., 1A for a 200V test voltage), then increasing it to 300V might result in exceeding 1A; conversely decreasing it to 150V might result in less than 1A. To ensure compliance with standards requirements during testing adjustments in voltage should always be accompanied by corresponding adjustments in short-circuit current.

(9) After each test – regardless of success or failure – solution splashes into equipment are likely as well as ash from burnt samples scattering onto armrests which could fall onto future samples affecting results negatively. Thus cleaning both electrodes and support devices post-test is essential using non-corrosive cleaners like alcohol followed by rinsing with deionized or distilled water while also cleaning droplet devices thoroughly afterwards.

(10) If the crawling distance is greater than or equal to twice the specified value in Table 5.19, or if the insulation material is made of ceramics, mica, or similar materials, no test is required.

(11) If multiple tests are performed on the same sample, there must be sufficient spacing between test points to prevent contamination of other surfaces being tested by splashing dirt from test points.

(12) During testing, it may be encountered that electrolyte or contaminants accumulate in pits or defects on the surface of the sample, causing the action of overcurrent relays rather than leakage current traces. In this case, the test must be redone.

Table Crawling distance of SPD     Unit: mm

Voltageb,c RMS/V Printed circuit board material pollution level Pollution level  
1 2 1 2 3
All materials group Material group excluding IIIb All materials group   Material group a Material group a
I II III I II IIId
10 0.025 0.4 0.08 0.4 0.4 0.4 1 1 1
12.5 0.025 0.4 0.09 0.42 0.42 0.42 1.0 1.05 1.05
16 0.025 0.4 0.1 0.45 0.45 0.45 1.1 1.1 1.1
20 0.025 0.4 0.11 0.48 0.48 0.48 1.2 1.2 1.2
25 0.025 0.4 0.125 0.5 0.5 0.5 1.2 1.25 1.25

Definition analysis:

(1) Comparative Tracking Index (CTI): The maximum voltage value at which 5 samples do not exhibit tracking failure or sustained burning during the application of 50 drops of liquid, such as PTI175.

(2) Comparative Tracking Index (CTI): The maximum voltage value at which 5 samples do not exhibit tracking failure or sustained burning during the application of 50 drops of liquid, also including a description of material performance during a test with 100 drops, indicated as CTI250 or CTI250 (200).

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