Intelligent Surge Protection Device EEL 4906 Engineering Design I and Professional Issues Team Members: Advisor: Cruz, Jaime e. Dr. Paris Wiley Dobbs, Michael Instructor: Guzman, Frank Selcuk Köse Ogundere, Adebowale corporate partner: Wallace, Richard JAIME Jaunary 26th 2015

Introduction SPD’s are electrical devices typically installed in power distribution panels, process control systems, communications systems, and other heavy-duty industrial systems, for the purpose of protecting against electrical surges and spikes, including those caused by lightning.  However, none of the SPD’s in the market allow for remote monitoring of the key components, and they are limited to certain electrical characteristics. RICHARD

Our Design Concept Intelligent Surge Protection Device Remote monitoring/reporting User friendly interface (PC software) Improve electrical characteristics of SPD Fuses Metal-Oxide Varistors (MOV’s) Conducting wires Avalanche diodes Sensing circuit to measure the degradation of the unit as a whole. Improve the external design (housing) Dozens of competing SPD’s available by a multitude of manufacturers. None are “intelligent” devices. According to PowerLogics, some manufacturers are working on “intelligent” type devices to do remote reporting, but none are currently patented or available to consumers. Distinguish between sustained overvoltage and a surge and notify the user via WiFi.

SPD FUNCTIONAL DIAGRAM WALE

Areas of Research Overvoltage sensing circuit Develop a circuit Use an existing patent available to the public Use existing proprietary sensing circuit and treat it as a black box High power indicator circuit: A high power transistor is used to detect high voltages. If the input voltage rises above the set threshold of the resistor on the base of the transistor, the transistor will conduct giving an high value which indicates the presence of an overvoltage.

MOV’s and Silicon Avalanche Diodes Areas of Research MOV’s and Silicon Avalanche Diodes Metal Oxide Varistor (MOV): Highest energy capability Excellent reliability Consistent performance Better mechanical connectivity for paralleling multiple components. Non-liner clamping curve gradually degrades over repeated use (only at high surge levels), moderate capacitance. Silicon Avalanche Diode(SAD): Flatter clamping curve Very low energy capability Expensive. Varistor IV Curve Avalanche Diode IV Curve FRANK Transient Voltage Suppressor Diodes

Silicon Avalanche Surge Suppressor Areas of Research Silicon Avalanche Surge Suppressor SASD uses a silicon based diode, similar to a Zener Diode. SASD response times are faster: 1 ps to 10 ps, compared to 1 ns to 10 ns for MOVs. They have a sharper bend in the curve around the breakdown voltage; As a result, they can clamp closer to the normal peak voltage FRANK

MODES OF PROTECTION - LINE CONNECTION Neutral Ground FRANK 7 Modes of Protection Avalanche Diodes will be added in a way to assist the reaction time of each Varistor (MOV)

Simplified Safe/Fail Circuit Diagram MOV MOV MOV Small Magnet Attached to MOV’s fail Indicator Hall Effect Sensor US1881 Output = High/Low Frank Micro Controller Info. via Wireless Comm. Info. Received at User PC

Implementation of the Hall Effect Circuit Senor Attached Here Magnet will be Attached Here Frank

Areas of Research Arduino UNO Microprocessor Process the information coming from the various sensors in the device. Conveys the information to the Wi-Fi module. Process incoming requests from remote users. Two-way user interface software Auto-reporting capabilities defined by the user User will be able to monitor the status of the SPD’s in real time. Tools available to create GUI: QT Project RICHARD

Areas of Research Wireless Transmission Existing Wi-Fi network is required. IEEE 802.11 a/b/g/n HF-A11 modules use UART interface which include 4 general signals: TXD/RXD/RTS/CTS Add RS-232 chipset to convert the signal to RS-232 voltage to communicate with the device (sensors). Sleep mode capability while maintaining association with the access point. RICHARD

Areas of Research: Housing Redesign Current Proposed WALE Tools Available: SolidWorks is solid modeling CAD (computer-aided design) software. 3D Printing

UPGRADES TO THE SPD FRANK

PRODUCT SPECIFICATIONS EXISTING PRODUCT SPECIFICATIONS Enhancements Nominal Discharge Current Rating 20kA > 30kA Maximum Surge Current Rating 100kA/mode; 200kA/ phase   Fault Current (SCCR) 200kAIC Product Design Modular per mode/phase Protective Components Thermal Protected MOV’s Thermally Protected MOV’s and TVS Diodes System Protection 30A Surge Fuses 50A Surge Fuses Connecting Leads 36 inches 10AWG 36” #8 AWG Recommended Breaker Size 30A 50A Response Time < 1 Nanosecond Frequency 50/60Hz Status Indicators Protection Status, Voltage Presence, Mechanical MOV failure Electronic MOV Failure Status, Surge Counter Enclosure Type Metal Thermo-Plastic Installation Location Indoor or Outdoor Weight 4.4lbs 3.8lbs Intelligent Features Static Device Remote reporting and monitoring via Wi-Fi, Sustained Overvoltage Notification, Surge Notification MIKE

Technical Risks Transient Sensing Circuitry Setting the threshold voltage for detection MOV and Avalanche Diodes Performance Not switching fast enough could damage Diodes Failed MOV/Diode Detection Circuitry False indication could leave the user unprotected Hall effect sensor performance in high current environment Wireless transmission Location may not have access to a Wi-Fi spot or weak signal FRANK

Tentative Timeline FRANK

QUESTIONS? Visit our website http://smartsurgeprotector.wordpress.com/ Contact any of us Cruz, Jaime jcruz15@mail.usf.edu Dobbs, Michael mdobbs@mail.usf.edu Guzman, Frank fguzman@mail.usf.edu Ogundere, Adebowale aoo@mail.usf.edu Wallace, Richard rbwallace@mail.usf.edu