Why does the AC SPD fuse frequently?

An AC surge protector (also known as a surge protection device or SPD) may frequently blow for several reasons, which can be related to design, installation, maintenance, and external environmental factors. Below are some common causes and explanations:

1. Poor Quality of the Surge Protector

• Insufficient Voltage Rating: If the surge protector's rated voltage or maximum continuous operating voltage (UC) is lower than the actual system voltage or the highest possible fault voltage, it may be subjected to excessive voltage during normal operation, leading to frequent damage or blowing.

• Manufacturing Defects: Low-quality surge protectors may have internal component defects, such as poor-quality varistors or faulty soldering, which can affect their performance and cause them to fail under surge conditions.

2. Lack of or Improper Front-End Protection

• No Backup Protection: According to standards, a fuse or circuit breaker should be installed upstream of the surge protector to prevent the flow of sustained fault currents (i.e., power frequency follow current) if the surge protector fails. Without this protection, when the surge protector breaks down due to a surge, the sustained fault current can pass through it, causing overheating or even a fire.

• Incorrect Fuse Selection: Even if a fuse is installed, if its rated current or type is not appropriate, it may not cut off the fault current in time, leading to overloading and damage to the surge protector.

3. Poor Grounding

• High Ground Resistance: The grounding wire of the surge protector must be connected to a reliable grounding system, with a ground resistance that meets the standard (typically less than 10 ohms). If the grounding is poor, lightning currents cannot be effectively discharged, and the surge protector will bear excessive voltage and current, leading to frequent blowing.

• Inadequate Ground Wire Specifications: The cross-sectional area of the grounding wire should be sufficient (usually at least 4 square millimeters) to handle lightning currents. If the grounding wire is too thin, it may overheat and fail during a lightning strike, affecting the surge protector's performance.

4. Frequent Lightning Activity

• Lightning-Prone Areas: In regions with frequent lightning activity, especially where equipment is installed in open fields or on mountaintops (e.g., photovoltaic systems or substations), the surge protector may be frequently exposed to lightning strikes. If the surge protector's protection level is insufficient to handle such frequent strikes, it may blow out frequently.

• Induced Lightning: Besides direct lightning strikes, induced lightning can also introduce overvoltage through power lines or communication lines. If multi-level protection measures are inadequate, induced lightning can cause the surge protector to act frequently and eventually blow.

5. Switching Surges and Transient Voltages

• Switching Equipment-Induced Surges: Large power circuits' switching operations, the connection or disconnection of inductive or capacitive loads, and the switching of large electrical systems or transformers can generate significant switching surges and transient voltages. These transient voltages can exceed the surge protector's capacity, leading to frequent blowing.

• Grid Fluctuations: In areas with unstable grid voltage, especially where the voltage fluctuates significantly, the surge protector may act frequently, particularly if its maximum continuous operating voltage is close to the range of voltage fluctuations.

6. Improper Selection of the Surge Protector

• Incorrect Maximum Continuous Operating Voltage (UC): As mentioned earlier, the surge protector's UC should be higher than the highest possible sustained fault voltage in the system. If the UC value is too low, the surge protector may be subjected to excessive voltage during normal operation, leading to frequent damage.

• Incorrect Residual Voltage (Ures): The residual voltage is the voltage across the surge protector when it absorbs a surge current. If the residual voltage is too high, it may damage downstream equipment; if it is too low, it means the surge protector's maximum continuous operating voltage is lower, making it prone to frequent damage.

7. Uncoordinated Multi-Level Protection Design

• Lack of Multi-Level Protection: To effectively protect against lightning and transient voltages, multiple levels of surge protectors should be installed at different stages of the power system. If only one level of protection is installed, or if the coordination between levels is poor, a single surge protector may bear too much surge energy, leading to frequent blowing.

• Coordination Issues: Multi-level surge protectors should work together, with the front-stage protector responding first to absorb most of the surge energy, while the rear-stage protector handles the remaining energy. If the response times or energy absorption capabilities of the protectors are mismatched, one level may become overloaded.

8. Aging or Damaged Surge Protectors

• End of Service Life: Surge protectors have a limited service life, and over time, their internal components (such as varistors) may degrade, reducing their performance. An aged surge protector may no longer effectively absorb surge energy, leading to frequent blowing.

• Poor Maintenance: Regular inspection and maintenance are necessary to ensure the surge protector remains in good condition. If maintenance is neglected, the surge protector may fail due to internal component damage or poor contact.

9. External Environmental Factors

• High Temperature: High ambient temperatures can affect the performance of the surge protector, causing it to overheat and eventually blow. This is especially true for outdoor-installed surge protectors where heat dissipation is poor.

• Humidity and Corrosion: Humid environments or corrosive gases can erode the surge protector's housing and internal components, reducing its insulation performance and increasing the risk of short circuits or blowing.

Solutions

• Select the Right Surge Protector: Choose a surge protector with appropriate technical parameters (such as maximum continuous operating voltage, residual voltage, and rated discharge current) based on the system's voltage level, lightning activity frequency, and grid stability.

• Ensure Proper Installation and Grounding: Install the surge protector in the correct location and ensure that it has a fuse or circuit breaker upstream. Additionally, ensure that the grounding system meets the standard requirements, with low ground resistance.

• Implement Multi-Level Protection: Install multiple levels of surge protectors at different stages of the power system to ensure proper coordination and effective distribution of surge energy.

• Regular Maintenance and Inspection: Regularly inspect the surge protector's condition and replace it if it shows signs of aging or damage to ensure it remains in optimal working condition.