Effective January 2016
Application Paper AP01001003E Supersedes April 2009
Application considerations for surge
protective devices when used with
generators and automatic transfer switches
Introduction
The purpose of this paper is to address the subject
of how to properly apply surge protective devices
(SPDs) to systems using transfer switch equip-
ment and generators, and to avoid common pitfalls
associated with the application of surge protection
to these systems. SPDs are widely used in
virtually all modern electrical systems. The use of
electronic and computer controls in almost every
aspect of industrial, commercial, institutional, and
residential applications makes surge protection a
necessity. However, improper application of surge
suppression can result in suboptimal performance
and reduced SPD life.
What is the purpose of a surge
protective device?
The purpose of an SPD is to protect electrical
and electronic equipment from damage and
degradation due to short duration, high-energy
transients. Typical voltage transients have a
duration of microseconds to a few milliseconds.
IEEET C62.41.2 describes a number of transient
waveforms that might be found on an electrical
system. They range in magnitude up to 10 kV,
10 kA with a typical duration of 20 microseconds.
Sustained overvoltage, also called temporary
overvoltage (TOV), is another power quality event.
A TOV is an overvoltage that lasts at one or more
cycles, which is about 17 milliseconds on a 60 Hz
system. Typically, TOVs have a much lower
magnitude, 1.7 to 3.0 times the nominal system
voltage, but a much longer duration, from a few
seconds to many minutes.
While SPDs do an excellent job of mitigating
voltage transients, they are not designed to
provide continuous sinusoidal voltage regulation.
When an SPD is subjected to a sustained
overvoltage, there is a very real danger of the
SPD going into a thermal runaway and being
permanently damaged. Modern surge suppressors
that have passed ULT 1449 4th Edition testing
should pose no external threat of damage even
when exposed to a sustained overvoltage. When
exposed to a sustained overvoltage, the SPD
should safely disconnect itself from the circuit.
What is thermal runaway?
Thermal runaway describes a condition where an
increase in temperature causes a condition that
further increases the temperature and can quickly
lead to the destruction of the device. The main
building block of an SPD is a metal-oxide varistor
(MOV). An MOV is a nonlinear device that has a
very high impedance when the applied voltage is
below the threshold voltage, and a low impedance
when the applied voltage is above the threshold
voltage. An increase in voltage past its threshold
causes an increase in current flow that, in turn,
causes an increase in the temperature of the MOV.
An MOV that sees an increase in temperature will
decrease in impedance, causing a further increase
in current flow that leads to rapid thermal runaway
condition. An MOV can quickly and safely recover
from a short-duration voltage transient; however,
when an MOV is subjected to a sustained over-
voltage, the MOV goes into thermal runaway and
can not recover. Figure 1 shows a graph that indi-
cates typical threshold levels of time and voltage
above which an MOV will go into thermal runaway.
Voltage (per Unit MCOV)
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0.01 0.1 1 10 100 1000 10,000
Time (sec)
Figure 1. Typical sustained overvoltage damage
curve for an MOV
Application Paper AP01001003E
Effective January 2016
Overvoltages in generators
Overvoltages in generators can occur for a number
of reasons:
• Initial startup overshoot
• Poor voltage regulation
• Step change in load
• Single-phase ground fault
• Excitation control failure
• Overspeed
Thermal runaway, as described above, can have a devastating effect
on MOVs in a matter of a few cycles. Power obtained from the
electrical utility typically has very good voltage regulation due to
the large size of the generators, or most often multiple generators,
versus the relative size of the individual loads. Utility generators also
have very precise regulators and sophisticated protection schemes
to ensure that the voltage stays within a very tight band, even down
to a few cycles duration.
Standby or emergency generators, however, typically have poorer
voltage regulation. Voltage overshoot at startup and during a step
change in load is very common. Also, for cost considerations,
many voltage regulators do not regulate well in the short term,
for example, cycles-to-seconds time frame. Most standby power
or emergency power generation systems are designed with the
purpose of keeping critical loads, such as emergency lighting, sump
pumps, and critical loads, operating “no matter what” with power
quality as a secondary consideration.
It is not uncommon that the voltage fluctuations of a typical standby
generator exceed the limits of the voltage damage curve of a
typically rated SPD (see “Specifying a surge unit for generators”).
The failure of SPDs due to a sustained overvoltage is typically not
covered under manufacturers’ warranties, as this is clearly outside
of the designed operating parameters of an SPD.
Recommendations for SPDs when used in
emergency power systems equipment
The 2014 National Electrical CodeT, Article 700.8, defines emergency
power systems as systems legally required to automatically supply
power to designated loads upon loss of normal power. The code
requires a listed SPD to be installed in or on all emergency systems
switchboards and panelboards.
1. Make sure that the generator is sufficiently sized. Take into
account any motor loads or other loads that have a high inrush
current. Electric motors typically draw 6 to 10 times their full load
current when started. Make sure your generator is sufficiently
sized to handle the startup of these motors. An undersized
generator is prone to severe undervoltages as connected motors
are started followed by a severe overvoltage when the motors
reach their operating speed. Most generator manufacturers offer
software that will assist in sizing the generator properly.
2. Invest in a high-quality voltage regulator for the generator.
Mechanical governors and low-cost electronic regulators may
be a tempting option in cost-sensitive applications; however,
the long-term effects of damage to SPDs and other equipment
due to sustained overvoltages often quickly outweigh the cost
savings of a low-cost regulator.
Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com
© 2016 Eaton
All Rights Reserved
Printed in USA
Publication No. AP01001003E / Z17598
January 2016
Application considerations for surge
protective devices when used with
generators and automatic transfer switches
Specifying a surge unit for generators
1. Eaton recommends installing the following voltage coded SPD
units in or on all three-phase emergency electrical equipment to
improve the reliability of emergency power systems.
System applied voltage Eaton SPD voltage code
600 volts wye (4W+G) 600D
600 volts delta (3W+G) 600D
600 volts resistance grounded 600D
480 volts delta (3W+G) 480D
277/480 volts wye (4W+G) 480D
480 volts resistance grounded 480D
120/208 volts wye (4W+G) 240D
Units with the voltage codes in the table above are capable of
continuously withstanding the nominal system line-to-line voltage
in the line-to-ground mode. As such, the line-to-ground mode
can ride through typical emergency system voltage events that
would cause thermal runaway in units with other voltage codes.
2. Eaton recommends specifying the kA rating of the SPD unit per
the location categories as outlined in the latest IEEE C62.41.1
standard. Most typical emergency power systems equipment
falls under the location category B. These SPD units should have
a minimum kA rating of 80 kA to 160 kA per phase. Actual kA
rating can be adjusted depending upon site conditions.
3. A UL nominal discharge current is defined as the peak value
of 8/20 microsecond surge current conducted through the SPD.
The let-through voltage cannot change by more than 10% after
15 surges are applied to the SPD. Eaton recommends a minimum
nominal discharge current rating of 20 kA. This is the most durably
recognized SPD unit per the latest UL 1449 standards.
4. The 2014 National Electrical Code, Article 700.8, requires a
listed SPD to be installed in or on all emergency power systems
switchboards and panelboards to protect the downstream loads.
For generator or transfer switch surge protection applications,
please consult with Eaton’s TRC at 1-800-809-2772 option 4,
option 3.
Conclusion
SPDs offer many positive benefits and can successfully prevent
damage and disruption to electrical and electronic equipment.
Per the 2014 National Electrical Code, Article 700.8, a listed SPD
shall be installed in or on all emergency systems switchboards and
panelboards. Eaton’s recommendations for specifying a surge unit
for generators is designed to improve the reliability of emergency
power systems. For new construction applications, integrating
surge products into panelboards and switchboards provides the
most reliable solution with superior performance. For existing
installations, Eaton makes a complete line of products to meet
your risk exposure needs.
For technical support and application engineering
assistance, please consult with Eaton’s TRC at
1-800-809-2772, option 4, option 2
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