Webinar «Overvoltage limiters for the data transfer systems protection», page 2

The sixth webinar of "Surge protection" series

Webinar text. Page 2

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RST limiters production stages

RST limiters production stages

Производство ограничителей перенапряжений RST Production of RST overvoltage limiters

1. Исходные положения

  • назначение проектируемого УЗИП
  • количество защищаемых линий
  • необходимые параметры
  • корпус и способ крепления

1. Initial provisions

  • purpose of the designed SPD
  • number of the protected lines
  • necessary parameters
  • enclosure and mounting method

2. Проект

  • разработка схемы УЗИП
  • выбор элементов
  • проект РСВ и модель 3D
  • подготовка проектной документации

2. Design

  • develop SPD diagrams
  • selection of elements
  • design of PCB and 3D model
  • preparation of design documentation

3. Подготовка прототипов для тестирования

3. Preparation of prototypes for testing

схема

diagram

Проект РСВ

PCB design

Модель 3D

3D model

 

— At first we shall determine for each limiter, which original terms shall be, that is to say, if that product was developed by the client, we shall determine its purpose, for which system protection and how many lines for relevant signal shall be protected. Final parameters of the limiter are determined based on the data, which is the maximum voltage and current supplied in that signal, which is the maximum operational frequency range. So to avoid interferences and any limitations in functioning of the system to be protected after connection of the limiter in to the protected circuit. The next stage is development of the protection system, for which we select compatible elements, such as arresters, inductance coils or diodes. Based on the circuits and design of that elements we develop the design of a panel, on to which you will install the elements. It is in our scope. When the design, as well as the technical documentation are ready, we prepare the prototypes for tests.

 

Surge limiters testing

Surge limiters testing

4. Испытания в Лаборатории RST

  • механические испытания
  • измерения номинальных электрических параметров
  • импульсные испытания, определение уровня ограничения по напряжению
  • климатические испытания

4. Tests by RST Laboratory

  • mechanical tests
  • measurement of nominal electric parameters
  • pulse tests, determination of the voltage limitation level
  • climatic tests

5. Испытания внешние

  • испытания устойчивости к импульсам большой энергии
  • уничтожающие испытания (импульсная перегрузка)

5. External tests

  • high-energy pulse resistance tests
  • destructive tests (pulse overloading)

 

— Testing by our laboratory. At first, we carry out mechanical tests, measure nominal electric parameters of our circuit and carry out pulse tests by using generators seen on the right. On the low left corner one can see the tests carried out by us in Bialystok University of Technology, the tests of resistance against high-energy pulses and the tests of destruction of protective circuits, because we need such information to specify it in the technical data.

 

Execution of documentation

Execution of documentation

6. Оформление документации

  • проектная документация
  • отчёты из испытаний с результатами измерений
  • выдача декларации о соответствии и разрешение на производство

6. Execution of documentation

  •  design documentation
  • reports on tests with measurement results
  • issue of the declaration of conformity and permit to release for production

7. Продукция

  • собственная

7. Products

  • in-house

проект

design

прототип

prototype

производство

production

 

— Upon the end, we have got benefits from these three stages after positive results of tests. Here you can see the protection elements on Polish railways, resisting quite high impact currents, which are specific for the railways electromagnetic environment.

Tests as per IEC 61643-21

Tests as per IEC 61643-21

Испытания типа по IEC/EN 61643-21 Tests as per IEC / EN 61643-21
Испытания типа на примере ограничителей производства RST Type testing of RST limiter samples

Согласно указаниям стандарта:

IEC/EN 61643-21:
Устройства защиты от импульсных перенапряжений низковольтные.

Часть 21: устройства защиты от импульсных перенапряжений в системах телекоммуникации и сигнализации (информационных системах).

Требования к работоспособности и методы испытаний

According to the standard instructions:

IEC/EN 61643-21:
Low-voltage surge protection devices.

Part 21: Surge protection devices for telecommunication and alarm systems (data systems).

Requirements for functional capability and test methods.

 

— We always carry out the tests for low-current lines. According to IEC standard 61643-21 – low-voltage circuit surge protection devices, telecommunication and alarm surge protection devices (in data systems). This standard is also used in Russia, therefore results of our tests are also applicable to your country.

 

Test scope as per IEC 61643-21

Test scope as per IEC 61643-21

Объём испытаний по EN 61643-21

Test scope as per EN 61643-21

1. Общие требования:

  • идентификация и документация
  • обозначение

1. General requirements:

  • identification and documentation
  • designation

2. Механические требования:

  • зажимы
  • монтаж
  • стойкость к прониканию твёрдых тел и воды
  • защита от прямого прикосновения
  • устойчивость к воспламенению

2. Mechanical requirements:

  • clamps
  • mounting
  • resistance against ingress of solid particles and water
  • protection against direct touching
  • non-inflammability

3. Климатические требования:

  • устойчивость к высокой температуре и влажности (T=80°, RH > 90 %)
  • циклическое влияние климата и импульсов тока

3. Climatic requirements:

  • Resistance to high temperature (T=80°, RH > 90 %)
  • Cyclic climate impact and current pulses

4. Электрические требования – параметры передачи:

  • ёмкость
  • вносимое затухание
  • отражение
  • продольный баланс
  • коэффициент погрешности бит (КПБ)
  • перекрестная наводка на передающем конце (ПНПК)

4. Electrical requirements – transmission parameters:

  • capacitance
  • insertion loss
  • return loss
  • longitudinal balance
  • bit error ratio
  • near – end crosstalk (NEXT)

 

— The test scope in short. General requirements, namely identification and documentation, designation of the element. Mechanical requirements include clamps, mounting, resistance to solid particles and water proofing, direct access prevention and non-inflammability. Climatic requirements include high temperature and humidity resistance, cyclic impact of climate and current pulse at the same time.

 

 

Requirements for the voltage limitation

Requirements for the voltage limitation

5. Требования к ограничению напряжения:

  • максимальное длительное рабочее напряжение Uc
  • сопротивление изоляции (ток утечки) при Uc
  • защитный уровень напряжения Up
  • устойчивость к воздействию импульсного тока
  • вид повреждения при перегрузке
  • вид повреждения в результате перенапряжения
  • мертвая зона

5. Requirements for voltage limitation:

  •  maximum continuous operational voltage Uc
  • insulation resistance (leakage current) at Uc
  • protective level of voltage Up
  • resistance to pulse current
  • damage type in case of overload
  • damage type due to overvoltage
  • dead space

6. Требования к токоограничению:

  • номинальный ток IN
  • последовательное сопротивление RDC
  • время-токовая характеристика срабатывания
  • время возврата в исходное состояние
  • максимальное напряжение отключения
  • испытание в рабочем режиме
  • устойчивость к воздействию переменного тока
  • устойчивость к воздействию импульсов тока

6. Requirements for current limitation:

  • nominal current IN
  • serial resistance RDC
  • time-current parameter of actuation
  • resetting time
  • maximum turn-off voltage
  • operational test
  • resistance to alternating current effect
  • resistance to current pulses
Только УЗИП (SPD) содержащие элементы ограничивающие ток Only SPD containing element limiting current

 

— Requirements for the voltage limitation include the maximum continuous operational voltage, insulation resistance (leakage current) at such maximum voltage, safety voltage level, i.e. the limitation voltage, resistance to pulse current impact, damage type in case of overload, voltage type resulted from overvoltage and dead space. Dead space refers to the location where the element is not sensitive yet. After actuation we shall identify in which locations the dead space is presented, and if it will affect the safety of the protected system or not. Next is the current limitation requirement, that is to say, a nominal current, resistance sequence, that is allowed to be connected to the line without changing its parameters, time-current actuation parameter, resetting time, the maximum cutoff voltage, operational test, resistance to alternating current and resistance to current pulses. This concerns SPD that include current limiting elements. As you can see, there are many parameters.

 

Category of stability

Category of stability

Категории устойчивости

Resistance category

Категория

Category

Тип испытания

Test type

Напряжение холостого хода

Idle run voltage

Ток короткого замыкания

Short circuit current

Минимальное число импульсов

Minimum number of pulses

Очень низкая скорость возрастания

Very lot increase rate

A/мкс
0.1 до 2 A/мкс
Длительность
мкс

A/µs
0.1 to 2 A/µs
Duration
µs

Переменный ток (АС)

Alternating current AC

Низкая скорость возрастания

low increase rate

высокая скорость возрастания

high increase rate

импульсы большой энергии

высоковольтной

High-energy pulse

High-frequency

один цикл

One cycle

УЗИП должны ограничивать импульсное напряжение при испытании в условиях, определяемых таблицей. Измеренное ограниченное напряжение не должно превышать заданного уровня напряжения защиты Uc

SPD shall limit specified pulse voltage under test in conditions determined by table. Measured limited voltage shall not exceed the specified protection voltage level Uc

 

— Without relevant testing launching a surge protection device into the market will be prohibited. Prohibited because we shall test for compliance with the minimum requirements for parameters specification, in terms of quality, for us to be sure, that the element will function properly at the required moment and not to waste a lot of money when accepting other elements. Look at this table with pulse test data In practice the parameters that I've mentioned above, correspond to category B2, category of elements C2 and category D1, which are the most of our concern and critical for our elements. We see, that category D1 is the category of testing impact currents having the lightning pulse form of 10/350 µs, the value is from 500 А to 2.5 kA and the pulses of 8/20 µs induced for the category С2 from 1 kA to 5 kA. And for the tested telecommunication signal, it is the pulse of 1 kB to 4 kV with the form of 10/700 µs.

Pulse tests in the laboratory RST

Pulse tests in the laboratory RST

Импульсные испытания в Лаборатории RST:

  • устойчивость категории С1 с импульсам 0,5 кА 8/20 мкс
  • устойчивость категории С2 с импульсам 5 кА 8/20 мкс
  • устойчивость категории В1 с импульсам do 10 кВ  10/700 мкс (телекоммуникационный)
  • измерение защитного уровня напряжения Up
  • измерение времени возврата в исходное состояние
  • мертвая зона

Pulse tests in the RST laboratory:

  • resistance of category C1 to pulses of 0.5 kA 8/20 µs
  • resistance of category C2 to pulses of 5 kA 8/20 µs
  • resistance of category B1 to pulses up to 10 kV 10/700 µs – telecommunication
  • measurement of protective voltage level Up
  • measurement of resetting time
  • dead space

Импульсный генератор EMTEST

EMTEST pulse generator

 

— We generally need the following parameters that are tested in our laboratory. Actually, we purchased the instrumentation by taking into account the railway systems, however, their pulse parameters excess the others, so it is suitable for other systems as well. If we look at the tested pulse parameters, these provide stability as per category C1 at the pulse of 500 А 8/20 µs, and С2 at 5 kA 8/20 µs. In case of the category B1 telecommunication pulse, we are able to test up to 10 kV, which is very high. Measurement of the safety voltage level Up. Measurement of the resetting time and dead space. The instrumentation allows memorizing oscillograms and transmit them to a PC, therefore, generally the test documentation is stored in electronic form, in which case everyone who desire to check the fact of test, is free to do it. In practice, these documents are always verified, including by specialized institution of that country.

 

 

 

High-energy impact tests

High-energy impact tests

Испытания ударами большой энергии (внешняя лаборатория):

  • устойчивость категории C2 для Imax = 20 kA 8/20 мкс
  • устойчивость категории D1 для Iimp = 3,5 kA 10/350 мкс
  • испытания перегрузки импульсным током 8/20 мкс

High-energy impact tests (outsourcing laboratory):

  • resistance of category C2 for Imax = 20 kA 8/20 µs
  • resistance of category D1 for Iimp = 3.5 kA 10/350 µs
  • pulse current overloading test 8/20 µs

 

— High-energy impact tests. We are not able to carry out such tests, because we have not required instrumentation, this is why we need to pay for them to Bialystok University of Technology. It is the symbol of the University of Technlogy. In this case we test our elements with the pulses of 20 kA 8/20 µs and with the lightning pulses of 3.5 kA, it is very high, 10/350 µs, as well as the surge tests with the pulse current of 8/20 µs. After such tests we are sure of 100%, that when installing signal hardware under the lightning protection, that is to say, within zone 0В, in the first and second zone, those hardware will always work properly at the lightning current pulses not exceeding 200 kA. Higher is always possible as well, however, we do not test at higher values, since the standards not requiring so.

Climatic tests

Climatic tests

Климатические испытания:

Испытания согласно IEC / EN 61643-21:

  • Стойкость к высоким температурам T=80°C и влажности RH = 93% (240 ч)
  • Циклическое испытание окружающей средой с импульсными перенапряжениями (цикл B по per IEC / EN 61643-21, 120 ч).

Дополнительные испытания IEC/EN 60068:

  • сухое тепло T=80°C, RH < 40 % (24 ч)
  • холод T = 40°C, (24 ч)

Climatic tests:

Tests according to IEC / EN 61643-21:

  • High temperature resistance T=80°C and relative humidity RH = 93% (240 h)
  • Cyclic ambient test with pulse overvoltage (cycle B as per IEC / EN 61643-21, 120 h)

Additional tests IEC/EN 60068:

  • Dry warm T=80°C, RH < 40 % (24 h)
  • Cool T = 40°C, (24 h)

Климатическая камера

Memmert CTC256:

  • диапазон температур
  • диапазон
  • ёмкость 250 литров

Climatic chamber

Memmert CTC256:

  • temperature range:
  • relative humidity range:
  • capacity: 250 liters

 

— Climatic tests appeared to be very serious. Since we are going to sale the devices to various countries of the world, we are now negotiating with African ones, such tests have major significance. I can say, that not all hardware enclosures withstand special temperatures. There are many climatic zones in Russia, I suppose, you're very concerned of this issue. Well, what do we test? Again, we refer to the same standards, where additional requirements are contained as to other standards, here you can see them. High temperature (80˚ С) and 93 %, moisture resistance tests for 10 days. Cyclic ambient tests at pulse overvoltage, it is the cycle B, that is to say, mixed cycle, temperature and overvoltage together. Look, these take about 6 days, maybe 5 days. And additional tests: dry warm, at the heat degrees of 80˚ С, humidity percent and cool. I mean, our instrumentation shall test within the range of 40 to +180˚С at the humidity of 20 to 90 %. Capacitance is high, which is relevant for us, because the rooms can be large.

 

Test oscillograms

Test oscillograms

 

Климатические испытания:

Циклическое воздействие среды и импульсов тока: цикл B по EN 61643-21

Climatic tests:

cyclic ambient impact and current pulses: cycle B as per EN 61643-21

  влажность RH % Humidity RH %
  температура T °C Temperature T °C

Pomiar
Wilgotność względna
Temperatura otoczenia
Godz.
h
min

Измерение
Относительная влажность
Температура окружающей среды
Час
ч
мин.

Measurement
Relative humidity
Ambient temperature
Hour
h
min.

 

— If looking at these tests, even shortly, we can see quite sophisticated test algorithms. Fortunately, these are set automatically in our chamber. We get the oscillograms, if we can say so, like these only, and attach them to our documentation.

Determination of limiter nominal parameters

Determination of limiter nominal parameters

Определение номинальных параметров ограничителей:

  • Максимально длительное рабочее напряжение Uc
  • Сопротивление изоляции / ток утечки при Uc
  • Номинальный ток IN
  • Последовательное сопротивление RDC
  • Граничная частота fg

Determination of nominal parameters of limiters:

  • maximum continuous operational voltage Uc
  • insulation resistance / leakage current at Uc
  • nominal current IN
  • serial resistance RDC
  • limit frequency fg

— There are more of other parameters, which are relevant for the designer, in order to be sure, that all these data, which are given in the catalogue, or the data of elements have been proven. The maximum continuous operational voltage, insulation resistance, leakage current, nominal current allowed to be conducted through our protective hardware without damage shall always be tested. Resistance sequence and limit frequency. All these technical data are to be added to our catalogues.

 

Reasonableness of tests

Reasonableness of tests

Обоснованность проведения испытаний Reasonableness of tests

 

— Why these tests are mandatory? Which is the reason thereof? I'll show you examples of how it can be in practice, if we look at advertisements or technical data of any manufacturers.

Example of parameters given by manufacturers

Example of parameters given by manufacturers

Ogranicznik przepięć video Ограничитель перенапряжения видео Video overvoltage limiter
DANE TECHNICZNE ТЕХНИЧЕСКИЕ ДАННЫЕ TECHNICAL DATA
napięcie ochrony защита по напряжению Voltage protection
maksymalny prąd wyładowczy максимальный ток разряда Maximum discharge current
poziom ochrony przy уровень защиты при Protection level at
tłumienie przelotowe переходное затухание Transient attenuation
pasmo przenoszenia частотная характеристика  Frequency characteristic   
uziemienie masy заземление на массу Earthing of mass
typ złącza wejścia тип входного разъема In connection type
typ złącza wyjścia тип выходного разъема Out connection type
Zbadana kategoria PN-EN 61643-21:2002 Протестированная категория PN-EN 61643-21:2002 Tested categoryPN-EN 61643-21:2002
Masa вес weight
Wymiary размеры dimensions
Pośrednie przez śrubę uziemiającą Промежуточный, винт заземления Interim, earthing screw
Gniazdo BNC гнездо  BNC BNC socket
Wtyk BNC вход  BNC BNC in
  Пример параметров указываемых производителями Example of parameters specified by manufacturers
  УЗИП системы видеонаблюдения CCTV system SPD

 

— These are in Polish, so I am to translate for you. I'll try to make it clear for you. For example, look at the parameters given by the CCTV manufacturer - these for the video surge protector. Which parameters arise, that we have not even mentioned earlier at all. For example, the level of protection at 1 kV per microsecond. Nothing is clear, who introduced this parameter, for what purpose? Maybe, it was translated from Chinese to Polish at that moment. Protection voltage over 2.4 V or higher, which can be 1,000 V and so on. Sorry, there is a lack of accuracy. A sort of tricks. Just read, they specified earthing, however, it is not clear, what is "mass" and "re-earthing bolt, indirectly". I'm sure, they are great sellers, but do not know actually what they sell. Look, there is a statement of testing according to the category standard, which category is C2. No any more details of tested samples and methods.

 

Parameters of SPD from other manufacturers

Parameters of SPD from other manufacturers

Instrukcja instalacji I obslugi urzqdzen ochronnych Инструкция инсталляции и обслуживания защитных устройств Installation and servicing guidelines for protective hardware
Parametry Параметры Parameters
Model Модель Model
Czas zadziałania Время работы Operation time
Napięcie pracy Рабочее напряжение Operational voltage
Żywotność жизнеспособность Survival ability
Rezystancja pracy Рабочее сопротивление Operational resistance
Rezystancja zwarciu toru przepięciowego сопротивление цепи перенапряжения Overvoltage circuit resistance
pasmo pracy рабочая группа Operating group
Tłumienność wtrąceniowa Затухание потерь Attenuation of losses
Tłumienność odbicia Затухание отражения Attenuation of reflection
Złączki Соединители Connectors
Wymiary (mm) Размеры (мм) Dimensions (mm)
Maks 1 ns Макс 1 цикл Max. 1 cycle
Maks. 100 ns Макс 100 циклов Max. 100 cycles
Maks. 4KV Макс 4 КBт Max. 4 kW
300 przepięc o wartości 100 А/s 300 скачков величиной 100 A/c 300 surges at the value of 100 A/s
Okolo 0 V Около 0 V About 0 V
szer ширина width
wys высота height
dl длина length
Masa масса weight

 

— The following example of parameters: operational voltage, actuation time is maximum of 1 ns or elements of as various type as much. What do they mean, how much? The voltage refers to operational voltage, so, if we would exercise a reverse engineering, this shall be the nominal voltage of not to exceed 4 kV. It is the CCTV parameter which is interesting one, it is just a couple of Volts. The durability of 300 overvoltages of 100 A/s - just a testing parameter. A man who made this table, is a quite incompetent in the subject he deals with. Operational resistance, sorry, of 10 GΩ, I suppose, It is originated from any soft sciences. So, what is the conclusion? Obviously, we need to select a vendor very carefully. I can say with respect to our Western partners, there are some problems occur from time to time, therefore we decided for such systems, as railways, power plants and so on, where we make designs by ourselves, we shall be responsible for the quality by providing own devices.

 

 

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