Component Protection

Addressing Protection

Tech Topics:

Note 3, Issue 2
Issues for Surge
Protective Devices
Michael J. Lang Introduction
Field Engineering Manager
Concerns about Surge Protective Device (SPD) failures in the field and device
performance have led to some major changes in the industry in recent years.
Overview Most of the safety issues have centered on the various failure modes of the MOV
inside the SPDs. Safety standards and products have undergone some very
•• SPDs and MOV Failure radical changes in the past 3 years. Review of these changes is important to
Modes ensure that you are taking advantage of these significant safety improvements.

•• Abnormal Voltages As of September 29, 2009, suppliers of UL Listed SPD (formerly transient
voltage surge suppressors (TVSSs) must comply with the latest revisions of
•• Repetitive Pulses UL 1449 - Standard for Surge Protective Device, 3rd Edition to maintain their
UL Listing. Failure of a SPD to comply with the new revisions of UL 1449 will
•• Transient Energies Above void its UL listing and possibly that of the systems where it is used. Since
the Maximum Rating Article 285 of NEC® 2011 requires that SPD devices be listed and labeled with
a short circuit current rating (SCCR), loss of their UL listing will preclude their
•• North American Standards
use. Likewise, UL508A uses the SCCR of the TVSS to develop a SCCR for
and NEC Requirements
industrial control panels. The loss of the TVSS’s UL listing could preclude its
•• Protection Options use in industrial control panels. See [1] for more information on the changes
in UL 1449.

This note will provide:

•• An overview of MOV-based SPD failure modes.

•• A review of key tests required by the UL 1449 standard.

•• An overview of protection options.

Failure Mode Concerns

Under normal voltage conditions,
the MOV shown in Figure 1 is
in a very high resistance (non-
conductive) state. When a high
voltage transient is imposed on the
power line, the MOV changes to a
low resistance, highly conductive
state when the transient voltage
exceeds the MCOV of the MOV. The Figure 1: Typical Connection of TVSS

1 — CPN3-2: Addressing Protection Issues for Surge Protective Devices

USA T 978 462 6662 F 978 462 0181 [email protected]

CANADA T 416 252 9371 F 416 252 6572 [email protected]

ep-us.mersen.com ep-ca.mersen.com
Tech Topics: Component Protection Note 3, Issue 2

majority of the energy of the transient is then shunted through rupture (see Figure 3 & 4 for an example). When the MOV is
the MOV and the voltage imposed on the protected equipment connected across the line terminals of electrical equipment and
is limited to a safe level. After the transient voltage decreases not adequately protected, its failure can lead to serious arcing
below the MCOV, the MOV returns to its high resistance state. faults in the equipment. Consequently, protection against a
The duration of this conduction can be less than 100μS. broad range of currents is necessary to safeguard against this
mode of failure.
The MOV must then dissipate the heat generated during the
conductive state. If subsequent conduction states occur
too soon after the first transient, the heat energy cannot be
dissipated adequately and the MOV temperature can rise to
damaging levels.
There are three causes of MOV failures:

•• Continuous overvoltage above the MCOV.

•• Repetitive pulses

•• Transient energies above the maximum rating of the device

Abnormal Overvoltages Figure 3: TVSS damage Figure 4: Case rupture of MOV during
due to abnormal abnormal overvoltage test.
Overvoltage operation of an MOV is the fastest way to MOV overvoltage test.
failure. Under sustained overvoltages an MOV can fail due to a
phenomena referred to as thermal runaway. Thermal runaway Abnormal overvoltages can be caused by loss of neutral or
can occur when the normal 60 Hz power system voltage becomes misapplication of the device (e.g. a SPD rated 120V installed
higher than the MCOV rating of the MOV and initiates flow of on 480V application).
continuous 60 Hz current through the MOV. Figure 3 shows the Repetitive Pulses
current that results when a 320V-rated MOV was connected to
480V. When the voltage is above the MCOV, the MOV enters MOVs also have multiple pulse ratings. Every time an MOV
its conductive state and current flows through the device until conducts transient energy, its life is slightly reduced. For a
the voltage GOES BELOW THIS VALUE. The magnitude of this given surge length, the expected number of pulses the MOV
current flow depends on the dynamic resistance of the MOV in can safely absorb during its lifetime is displayed. One surge
its conductive state and the impedance of the power system. near its capacity of 10kA may degrade the MOV’s life just
as much as 20 surges at .2kA. The pulse lifetime ratings
are based on the definition of rated life, which is the point
at which the nominal voltage of the MOV has decreased
by 10%.
Surges can breakdown some of the junctions between the zinc
oxide grains in the MOV. The greater the energy absorbed
during a transient, the greater the number of junctions damaged.
The result is a reduction of the MCOV and capability of the MOV
energy absorbing capability. This change in structure does not
affect the ability of the MOV to clamp surges. Conversely, the
voltage required for MOV conduction is reduced.
If the MCOV is reduced to the point that the MOV conducts
Figure 2: Currents resulting from abnormal overvoltage test. Notice that during part of the normal 60 Hz voltage wave, the MOV will go
current flow begins when the voltage goes above the MCOV in each into thermal runaway as described previously. Failure (case
half cycle.
rupture) will occur when the heat generated by the 60 Hz current
The continuous heating generated by this current will exceed the through the MOV exceeds the MOVs energy capacity.
energy capacity of the MOV and eventually cause the device to

2 — CPN3-2: Addressing Protection Issues for Surge Protective Devices

USA T 978 462 6662 F 978 462 0181 [email protected]

CANADA T 416 252 9371 F 416 252 6572 [email protected]

ep-us.mersen.com ep-ca.mersen.com
Tech Topics: Component Protection Note 3, Issue 2

Transient Energies Above the Maximum Rating After further investigations, UL issued a revision to UL 1449 in
February of 2005, adding new test current levels. To address
MOV’s have a maximum single pulse peak current rating.
concerns of intermediate short circuit current levels, the Full
Typically, this rating is determined with the 8/20 μS waveshape
Phase Voltage—Short Circuit Current Abnormal Overvoltage
defined in IEEE C62.45-2002. (See page 4 for a discussion
Test of Section 37.3 was changed to require tests to be performed
of the standard test waveform defined in IEEE C62.45-2002).
with fault currents of 100A, 500A, 1000A and the selected
This rating identifies the maximum transient energy that can
SCCR of the device. In addition, the Limited Current Abnormal
be absorbed by the MOV without damage to the device. This
Overvoltage test of Section 37.4 changed test currents to 10A,
type of failure is not likely but can occur when a SPD with a
5A, 2.5A and 0.5A. Compliance to the standard’s requirements
single pulse peak current rating is improperly selected for an
at all test current levels is required to maintain the UL Listing
application. Exposed to pulse energy beyond its rating, the
of existing TVSS designs. Manufacturers of TVSS’s were given
MOV can fail catastrophically on a subsequent pulse. When
until February 9, 2007 to comply with these requirements since
connected across the terminals of equipment connected to the
it was anticipated that products and/or protection schemes
power system, a resultant 60 Hz arc fault current can cause
needed to be re-designed.
catastrophic damage without adequate protection.
The third edition of UL 1449 went into effect on September
North American Standards and NEC Requirements
9th, 2009. This edition replaced the term TVSS with SPD,
Several changes have been made to North American codes combined secondary surge arrestors with SPD’s and created
and standards in recent years to address safety concerns about type designations based on point of use. The Voltage Protection
surge suppression products. Rating replaced the suppressed voltage rating (SVR) using a
National Electric Code higher surge test current and a different methodology. A Nominal
Discharge Current (In) was also added. See [1] for more details
Article 285, Surge Protective Devices (SPD), was added to the
on these changes.
2002 edition of the National Electric Code to cover the safe
application of surge suppression products permanently installed Overview of UL 1449 Test Requirements
on premise wiring systems. Current Testing. These tests verify that the SPDs can withstand
Section 285.5 requires that such products be listed devices. continuous overvoltages with a wide range of potential fault
Section 285.6 requires that the SPD be marked with short circuit currents without creating conditions that would increase the risk
current ratings (SCCR) to ensure that the SPD is not installed of fire or electric shock. Creation of holes in the enclosure or
in a location where the available fault current is greater than the emission of flame, molten metal, glowing or flaming particles is
capability of the surge suppressor’s protection system. SCCRs not allowed. Test voltages are based on the SPDs voltage rating.
are necessary to ensure compliance with NEC 110.10. Short circuit current rating test- For Type 1 and Type 2 SPDs.
UL 1449 Standard for Transient Voltage Surge Test voltages are identified for each allowable device rating.
Suppressors This test applies full-phase voltage across the device for up
to seven hours or until the SPD is safely disconnected from
SPD devices listed to the UL 1449 standard are acceptable
for application on wiring systems per NEC 285.5. They must the AC supply. For example, 480V is applied across devices
successfully pass the tests detailed on page 4 without creating rated 277V. This test is performed with an available fault
conditions that would increase the risk of fire or shock. Changes current value chosen from Table 39.2 by the manufacturer
to this standard in recent years have had major implications in (see Table 1). In this test, the device will likely go into thermal
the selection of protection schemes. runaway as described earlier and will need to be safely
The second edition of UL 1449, initially issued in 1996, added disconnected from the circuit to pass this test.
the Abnormal Overvoltage Tests to address field failures caused Available Fault Current Ratings from Table 61.2 of UL 1449
by temporary overvoltage (TOV) conditions with low follow
5kA 25kA 85kA
currents. To pass the Limited Current Abnormal Overvoltage
10kA 30kA 100kA
Test, a TVSS needed to meet the standard’s requirements for test
14kA 42kA 125kA
currents of 5A, 2.5A, 0.5A and 0.125A. Overcurrent protective
18kA 50kA 150kA
devices (OCPD) typically selected to protect MOV’s from case
22kA 65kA 200kA
rupture and sized to pass larger surge currents without opening,
were not able to open for small follow currents caused by Table 1: Test Currents.
thermal runaway.
3 — Critical Changes to the NFPA 70E Standard 2009 Edition
3 — CPN3-2: Addressing Protection Issues for Surge Protective Devices

USA T 978 462 6662 F 978 462 0181 [email protected]

CANADA T 416 252 9371 F 416 252 6572 [email protected]

ep-us.mersen.com ep-ca.mersen.com
Tech Topics: Component Protection Note 3, Issue 2

Intermediate current test. Test voltages are the same as the Oscillatory. The ringing 0.5 µS —100k Hz waveform shown
Short Circuit Current Rating tests. For example, 480V is in Figure 6 is used to simulate the oscillations created
applied across devices rated 277V. This test is performed with when a surge, impinging on a low-voltage indoor conductor
available fault currents of 100A, 500A, 1000A. In this test, the system, excites the natural resonant frequencies. Because
device will also likely go into thermal runaway and will need to of the expected impedance between the source and the
be safely disconnected from the circuit to pass this test. indoor locations such as an outlet, source impedances of
test generators are selected to limit current and energies to
Limited current abnormal overvoltage test. This test is similar
lower levels than the unidirectional waveforms.
to the full phase voltage test above, except that a variable
resistor in the test set-up is adjusted to limit the short circuit Unidirectional. The 1.2/50 µS voltage waveform shown in
test current. For permanently connected devices, four SPDs Figure 7 is used to simulate the voltage delivered by surges
are tested with short circuit currents of 10A, 5A, 2.5A and at outdoor and service entrance locations. A test voltage
0.5A respectively. The devices are energized for up to seven of 6kV is typically selected for indoor locations whereas
hours, until the temperature of the TVSS attains equilibrium 10kV and higher are used for outdoor locations. Source
or until the TVSS is safely disconnected from the AC supply. impedances are selected to deliver larger currents (and
energy) - see the 8/20 µS waveform also shown in Figure
Surge Testing. These tests verify that the TVSS will properly
7. These test circuits are also used for TVSS’s intended for
operate in the presence of impulse surges of 6kV without any
such indoor locations as feeders and short branch circuits.
evidence of fire, operation of protective devices or creation of
openings that expose energized parts. In both these test configurations, the voltage waveform is the open-
VPR - Voltage Protection Rating. Unidirectional test circuit voltage of the test generator and the current waveform is the
waveforms (see next section) are used to determine this current obtained by shorting the output of the test generator.
rating. Devices are subjected to three 6 kV/ 3 kA impulse
surges. The Voltage Protection Rating is a value chosen
from Table 63.1 in UL 1449 and must be higher than any of
the three measured limiting voltages.
In - Nominal Discharge Current Protection Rating - For Type
1 and Type 2 SPDs. After the VPR is determined, 15 surge
tests are performed at 6kV and the In current selected by the
manufacturer. Type 1 SPDs must be either 10kA or 20kA.
Type 2 SPDs can be 3kA, 5 kA, 10 kA or 20 kA. Test surges
are applied in 3 groups of 5 surges. There is 30 minutes rest
between each group. Following these tests, the SPDs are
Figure 6: 0.5μs-100k Hz. Oscillatory Test Waveform. The voltage has a rise time
subjected to the VPR tests. Results must be within 10% of the for its first peak of 0.5μS (from .1 to 0.9 times the first peak value). It then decays
original tests. while “ringing” at 100k Hz. Each Peak is approximately 60% of the previous peak.

Operational Voltage Test. This test verifies that the SPD

will withstand an overvoltage of 115% of rated supply voltage
for 30 minutes. The SPD must pass this test without creating
conditions that would increase the risk of fire or electric shock.
Creation of holes in the enclosure or emission of flame, molten
metal, glowing or flaming particles is not allowed.
Dielectric Voltage-Withstand Test. This test verifies that the
SPD can withstand a 60 Hz voltage of 1000V plus two times
rating for one minute for various application points.
Waveforms for Testing TVSS Devices
IEEE C62.45-2002, IEEE Recommended Practice of Surge Figure 7: Unidirectional Test Waveforms. The rise time of 1.2 µS for the voltage
Testing for Equipment Connected to Low-Voltage AC Power wave is defined as 1.67 times the time it takes for the voltage to rise from 0.3 to
0.9 of its peak. The rise time of 8 µS for the current wave is defined as 1.25 times
Circuits identifies two waveforms that are commonly used for the time it takes for the current to rise from 0.1 to 0.9 of its peak. The decay time of
testing the performance of TVSS devices. 50 µS and 20 µS refer to the time it takes for the wave to decay to 50% of its peak.

4 — CPN3-2: Addressing Protection Issues for Surge Protective Devices

USA T 978 462 6662 F 978 462 0181 [email protected]

CANADA T 416 252 9371 F 416 252 6572 [email protected]

ep-us.mersen.com ep-ca.mersen.com
Tech Topics: Component Protection Note 3, Issue 2

Protection Options
MOV Thermal Protection
Current flow through an MOV due to 60 Hz overvoltages, as
discussed earlier, causes heating of the MOV. Thermal protectors
are designed to sense the temperature rise of the MOV and
disconnect it from the circuit before catastrophic failure occurs.
Complete electrical protection for SPD’s might include short
circuit protection and thermal sensing. The thermal protector
must have a thermal response that coordinates closely with the
response of the MOV.
Figure 9 compares the performance of an unprotected MOV with
Mersen’s TPMOVTM (Thermally Protected MOV). The varistor Figure 8: Fuse Protection of MOV.
rating (MCOV) of both MOVs was 320V. Both were tested at a Note: The requirements for the Measured Limited Voltage Test
150% overvoltage of 480V (see middle trace). The supply circuit changed in the UL 1449 3rd Edition. These changes became effective
had an available short-circuit current of 41.2 kA and X/R = 6.6. on September 29, 2009. For more information on the specific changes
contact our Technical Services Department.
The top trace in Figure 9 shows the current wave for the
unprotected MOV. The MOV starts conducting during the
part of the AC cycle where the supply voltage exceeds the
MCOV voltage of the MOV. The amplitude of the current
pulses depends on the dynamic resistance of the MOV. The
temperature of the MOV increases leading to failure of the
MOV after 0.176 seconds.
The bottom trace shows the response of the Mersen TPMOVTM.
In this case, the TPMOV operates after 0.045 seconds and
isolates the MOV without damage. Note that the current pulses
are higher than those of the device at the top. This is due to
slight differences in dynamic resistances between MOVs in the
conductive state.
For lower available short circuit current (i.e., higher system
impedances) the amplitude of the current pulses would be lower
and take longer to damage the MOV. The opening time of the
TPMOVTM would be greater, but would still disconnect from the
power system prior to MOV failure. Figure 9: Self-protected TPMOV® technology.

follow current that will result from the low-resistance state of the
Fuse Protection
MOV failure. To protect against case rupture from the heating of
Fuses used in series with MOVs, as shown in Figure 8, are the follow current, the fuses used for these applications need to
not used to protect MOV’s from damage due to excessive I2t be very current limiting.
heating from surge currents. Instead they are used to clear high-
The VSP MOV fuse shown in Figure 8 has a surge current rating
level 60 Hz follow currents that could result from an MOV failure.
and not a 60 Hz ampere rating. For example, the VSP40 is rated
Fuses have been successfully used to protect equipment from to pass the energy of a 8/20 μS wave with a peak current value
the catastrophic failure of MOVs, when MOVs are connected of 40kA without opening, allowing the MOV to properly clamp
across the line terminals of equipment with large available fault the surge voltage as intended. If the MOV were to fail however,
currents and fail in a short circuit mode. To achieve optimum the VSP40 would offer excellent current-limiting performance
transient protection, the fuse must be selected to allow the against the 60 Hz follow current. Furthermore, the VSP’s
MOV’s rated surge current to pass without opening. In the case ampere interrupting rating (AIR) of 200,000A ensures that it
of MOV failure, the fuse must safely interrupt the potentially large could perform this function for all AC applications.

5 — Critical Changes to the NFPA 70E Standard 2009 Edition

5 — CPN3-2: Addressing Protection Issues for Surge Protective Devices

USA T 978 462 6662 F 978 462 0181 [email protected]

CANADA T 416 252 9371 F 416 252 6572 [email protected]

ep-us.mersen.com ep-ca.mersen.com
Tech Topics: Component Protection Note 3, Issue 2

Fuses selected to pass large surge currents and yet prevent

the catastrophic failures of MOV’s from large fault currents are
unlikely to clear the lower level currents specified in UL 1449’s
Limited Current Abnormal Overvoltage Tests and Intermediate
Current Tests before damage occurs to the MOV.

Recommended Products
Mersen’s complete family of surge protection devices includes
the TPMOV® (Thermally Protected MOV) technology, Surge-
Trap® surge protection devices, VSP surge-rated fuses and the
Surge Switch.

TPMOV® Technology Surge-Rated Fuses - VSP

Developed to address the failure Mersen surge suppression fuses are
characteristics of MOVs, Mersen’s specially designed to address the protection
TPMOV® (Thermally Protected MOV) of SPD systems. The VSP fuses are
technology, meets the new requirements designed to withstand 8x20μS surge pulses
of UL 1449. It is a completely fail-safe without opening, allowing the SPD system
device composed of a voltage clamping to react to the surge. All surge suppression
device and a disconnecting apparatus. It fuses have a 8x20 μS surge rating, not a
is UL 1449 Recognized, and features a continuous current rating. Under AC short
40kA 8/20μS max surge rating, a footprint circuit conditions these surge suppression
consistent with 25mm – 40mm MOVs, fuses are very current limiting.
visual and remote indication, and a small
package. Surge Switch
Mersen’s Surge Switch is an extremely
Surge-Trap® SPDs compact, high-performance, manually
Mersen, an industry pioneer in operated, non-fused switch with a unique
surge protection technology, has contact design that actually clamps
developed a world-class suite of contacts tighter during a surge. It is
surge protection devices for your specifically designed to withstand the high
entire facility. Surge-Trap SPDs surge current of 200kA with the 8x20µS
are designed to UL1449 3rd Edition waveform seen in transient-voltage surge
standards and feature Mersen’s protection device applications.
industry leading patented TPMOV®
technology inside. Providing
advanced overvoltage protection Additional Resources
to meet today’s toughest requirements, you can rely on
•• Component Protection Note 3: Addressing Overcurrent
Mersen’s Surge-Trap SPDs for proven and safe facility-
Issues for Transient Voltage Surge Suppressors
wide protection.
•• Component Protection Note 4: Important Changes to UL
1449 Safety Standards for Surge Suppression

“Complete electrical protection for SPDs typically includes

short circuit protection and thermal sensing.”

TT-CPN3-2-001 | 7500 | 8.11 | GROWLL — © 2011 Mersen

6 — CPN3-2: Addressing Protection Issues for Surge Protective Devices

USA T 978 462 6662 F 978 462 0181 [email protected]

CANADA T 416 252 9371 F 416 252 6572 [email protected]

ep-us.mersen.com ep-ca.mersen.com