eps magazine, january 2012

0112EPSpC1:Layout 1 1/16/12 9:28 AM Page C1

FOR FREE INFO, CIRCLE 1 ON READER SERVICE CARD

0112EPSpFullPages.qxd:Company Spotlight 1/13/12 2:18 PM Page C2


0112EPSpFullPages.qxd:Company Spotlight 1/13/12 2:18 PM Page 1

PUBLISHERDanny J. Salchert

OFFICE MANAGERAnita Salchert

ASSOCIATE PUBLISHERJerry DiChiara

[email protected]

CREATIVE DIRECTOR Derek Gaylard

CONTRIBUTING WRITERSGreg Bennorth

Jeff Jowett

CIRCULATION DIRECTORPam Fulmer

PRESIDENT Danny J. Salchert

Executive and Advertising Offices3591 Cahaba Beach Road

Birmingham, AL 35242toll free: 800.981.4541 phone: 205.981.4541

fax: 205.981.4544www.epsmag.net • [email protected]

Electrical Products & Solutions™ is publishedtwelve times a year on a monthly basis by ABDCommunications, Inc., 3591 Cahaba Beach Road,Birmingham, Alabama, 35242, USA. ElectricalProducts & Solutions™ is distributed free to qualifiedsubscribers. Non-qualified subscription rates are$57.00 per year in the U.S. and Canada and $84.00per year for foreign subscribers (surface mail). U.S.Postage paid at Birmingham, Alabama and addi-tional mailing offices.

Electrical Products & Solutions™ is distributed toqualified readers in the electrical contracting industry.Publisher is not liable for all content (including edito-rial and illustrations provided by advertisers) of adver-tisements published and does not accept responsibilityfor any claims made against the publisher. It is the ad-vertiser’s or agency’s responsibility to obtain appro-priate releases on any item or individuals pictured in anadvertisement. Reproduction of this magazine inwhole or in part is prohibited without prior written per-mission from the publisher.

POSTMASTER: Send address changes toABD Communications, Inc., P.O. Box 382885

Birmingham, Alabama 35238-2885

P R I N T E D I N T H E U S A

FEATURES6 Safety Aspects for

Photovoltaic Applications

22 A New Technology Augments Low-Resistance TestingBy Jeff Jowett

28 A Smart StartThe State of Programmed Start Technology & Opportunities in the 2012 MarketplaceBy Greg Bennorth

16 Old Walmart + Electrical Upgrade = New 9-1-1 Center Sumter County, Florida improves public safety when it gives a former department store a thorough makeover

DEPARTMENTS

2 Electrical Products & Solutions • January 2012

CONTENTS

6

32 Industry News

34 Product Focus

40 Ad Index

ON THE COVERPhoto courtesy of Megger

CASE STUDY 16

0112EPSp02.qxd:Layout 1 1/16/12 10:00 AM Page 2

complicated and expensive, if not impos-sible without disassembling the electric-ity generating facility.

The planning of the PV system musttake into account local conditions, i.e.wind intensity, snowfall, the nature of thesurrounding countryside and shape, con-dition and design of the building. A pho-tovoltaic system not only constitutes astatic load on an existing construction, be-cause of its actual weight, but also a dy-namic load - through changing the impactof wind on the structure. In the case of in-stallations on flat roofs, where photo-voltaic modules are usually mounted onauxiliary structures allowing orientationof the modules towards the sun to opti-mize output, it is important to take intoaccount the likelihood of snowdrift for-mation which causes an additional load


FEATURE • Conergy

on the building structures.The components should be carefully se-

lected during system planning based onload-bearing capacity, technical designand the quality and durability of the com-ponents. Many PV modules, for example,are rated for only relatively low staticloads which could easily be exceeded bythe combination of wind and snow loadscommonly experienced on industrialroofs. Certain mounting structures may re-quire more ballast than the building is ca-pable of bearing. It is important that thecomponents be compatible with eachother and the building, while allowing forefficient, economical installation.

The mounting system is the least ex-pensive part of a rooftop installation, butalso the least accessible and most difficultto check. A high-quality

THE SAFETY OF photovoltaic ap-plications is increasingly attracting atten-tion as the PV industry matures. There arevarious aspects impacting the safety of solarpower installations. This article will exam-ine fundamental issues regarding photo-voltaic modules installed on buildings.

Mechanical ResistancePhotovoltaic systems integrated into

buildings need to be analyzed within thecontext of the building as a whole.

When designing a PV system, it is es-sential to evaluate the structural conditionof the building, not just in terms of suffi-cient static load-bearing capacity of thevarious components, but also in terms ofits physical condition. For example, afterPV system installation, roof replacementor even repair becomes significantly more Continued on page 8

Safety Aspects forPhotovoltaic Applications

0112EPSp06,08,12,14:Company Spotlight 1/13/12 2:28 PM Page 6


recommended to use designs devised byleading manufacturers of photovoltaicmounting systems.For instance, ballast-only mounting

systems eliminate the penetrations that arethe primary cause of leaks. If a ballast-only system is not possible, then installersshould look for mounting systems thatprovide reliable, long-term sealing of anyroof penetrations that are required and thatthose penetrations do not void the roofer’swarranty. While many installers devisetheir own mounting structures from inex-

pensive, generic building materials, it ishighly recommended that mounting sys-tems should be supplied from a reputablemanufacturer and expressly designed formounting PV systems on roofs. It is alsohighly recommended that when possible,the original roofer or roofing contractorbe contacted to perform or approve anypenetrations made to the roof so that theroof warranty remains in effect.The most expensive components of a

solar power system are the photovoltaicmodules. There are many factors affect-ing the mechanical integrity of photo-voltaic modules on roofs under winterconditions. Modules must withstand heat,frost, water, snow, ice, wind and other in-cidental loads for a minimum of their 20-year service life. The glass, which coversthe photovoltaic cells, is usually encasedin an aluminium frame and is particularlysignificant in terms of the module’s ser-vice life.The load-bearing capacity is an impor-

tant property of the glass, both in terms ofpressure and uplift. The load-bearing ca-pacity of 2400 kPa offered by somecheaper modules is not suitable for all lo-cations. This particularly applies in roofinstallations, which not only have to with-stand the “standard” load, but also possi-ble snowdrifts or turbulent airflow leadingto uplift, especially near the edges or cor-ners of roofs.The task of the module’s frame is to se-

cure the actual composite structure ofglass, cells and covering foil in order toprotect it from mechanical damage. Theframe also prevents water from penetrat-ing between the individual layers of thecomposite structure. The stiffness of theframe is important for protection duringtransport and installation, especially forroof installation as they are transportedand stacked in large bundles. It is recom-mended to avoid frames with a plasticconnector or compressed profile cornerjoints. Hollow profile frames are also un-suitable for severe weather conditions, be-cause they are prone to be destroyed ordamaged within a few years by water in-filtrating and freezing.When selecting a module it is also rec-

ommended to review the certification andtests the module has passed. Reputablemanufacturers subject their products totests over and above the industry require-ments and standards.

mounting system should not only offerstructural strength adequate for thestresses on site, but must also be entirelymaintenance-free and made from corro-sion and UV-resistant materials. If mod-ules are anchored through the roofing tothe building structure, then the designshould prevent the possibility of waterleaking into the roof structure and thebuilding itself. Experimenting with dif-ferent designs in an attempt to save a neg-ligible percentage of the overallinvestment may backfire in the future. It is

FEATURE • Conergy Continued from page 6

Continued on page 12



photovoltaic installations as a risk factorfor building insurance, especially whenthe installation conforms to local and na-tional electrical codes and is performedusing best industry practices.According to statistics, most cases of

fires in photovoltaic installations causedby the equipment itself are due to faultywiring and voltage inverters.Inverters must be installed according to

the manufacturer’s recommendations,while taking into account the location andsurrounding space. Distances from anybarriers are usually stipulated for coolingreasons. It is a good idea to install this de-vice where it is protected from theweather (rain, sun), although high-quality

products have an IP65 cover designed, orthe equivalent NEMA (National Electri-cal Manufacturers Association) rating, toallow them to be installed in an outdoorenvironment. If the device is located in aprotected, cool location, out of the sun,this will definitely have a positive effecton the performance and service life of thedevice.Photovoltaic modules usually contain a

minimal amount of flammable material(connection boxes, connectors and cablinginsulation) and their potential for causinga quite large fire is negligible. However,low-quality, inexpensively manufacturedmodule junction boxes have the potentialto overheat and ignite material in or nearthe junction box. The destruction of poor-quality modules through connection boxesbeing burnt out as a result of poor-qualityconnections, leaks or material used withlow thermal resistance are more common.Contact between individual cells causedby imprecisions in manufacturing can alsolead to local overheating and subsequentdestruction of the module.DC cable runs should be in fireproof

sleeves, ideally split into plus and minus ifin a cable trough with a separation barrier.At least for the parts of the cabling exposedto the weather (humidity, temperaturechanges, UV radiation), it is important touse high-quality cables designed for suchpurposes. Damage to the cabling during in-stallation can lead to short circuits and elec-trical shocks or to increased resistance andsubsequent melting of the cable and elec-trical arcs and fire. It is therefore increas-ingly important to adhere to local codesand best practices and pay close attention tohow the cabling is planned and installed asregards to sharp edges, flammable materi-als, periodic inspections and maintenance,etc. The choice of connectors and their con-nection itself also has an impact on thesafety of cabling. An improperly installedconnector or a connector which loosensover time poses the same risk as damagedcabling. This risk can be eliminatedthrough selection of suitable connectors,properly installed. It is a good idea to con-sider installing a fire switch for each stringof modules, located near the modules.These switches are only turned on in theevent of AC production. If the building’selectricity supply is disconnected due tofire-fighting activity, all the strings are au-tomatically disconnected

For example there are modules on themarket that manufacturers test for resis-tance to ammonia or hail with an impactforce up to 23 times higher than what isrequired under the standard.

Fire Safety (Danger)Even though it is a relatively small risk,

photovoltaic installations represent a po-tential danger for buildings as a possiblecause of fire. According to the statisticspublished by BDJ VersicherungsmaklerGmbH & Co. KG., a leading German in-surance company, photovoltaic installa-tions caused only 0.1% of fires in 2009.This small risk is also reflected by the factthat insurance companies do not regard





pliance with the recommendations set outabove, it is a good idea to add monitoringof the overall installation. There are sys-tems currently available on the market thatallow virtual real-time monitoring ofpower generating unit performance. Thisallows the owner or administrator of theunit to be informed about a possible out-age or anomalies affecting energy pro-duction, by text message, e-mail or fax.The owner or administrator can also im-mediately react by requesting mainte-nance and therefore minimizing outputlosses. A good monitoring system canusually archive data from when the facil-ity first came on-line, allowing compari-son and inspection of yields on a daily,weekly, monthly or annual basis. Somesystems even offer smart phone applica-tions, which allow users constant accessto their PV system data.Routine maintenance of the installation

also has an impact on reliability. It is notonly important to clear snow in winter, butalso to perform regular inspections of the

whole facility (at least once a year). Thisenables the detection of faults and preven-tion of outages and may also prevent moresignificant damage to the system and thelocation at which it is installed.

ConclusionThe above shows that the cheapest in-

stallation may not be the most effectivelong-term solution for the photovoltaic ap-plication planned. From experience, theo-retically identical electricity generatingfacilities with the same performance on pa-per, in the same locality and with the sameorientation, but with different components,have shown outputs over the first year ofoperation differing by 5-15%. How theselower-output systems will function in fu-ture years, if they do so at all, can only beguessed. Because PV systems, in particu-lar, are expected to perform for long peri-ods of time, it is especially true that thebitterness of poor performance is likely tolinger long after the sweetness of a lowprice has faded.

and the cabling is therefore no longer asource of danger.

Operational Safety - ReliabilityThe reliability of a PV system is influ-

enced by the set of mechanical and firesafety factors above, to which should beadded the electricity generating unit’s ac-tual output. The output of solar power sys-tems over the course of a year is directlydependent on the parameters of each de-vice, the efficiency of the modules, thecharacteristics of the modules as a func-tion of the level of solar irradiation, tem-perature and also the dimensions(diameter) of the cabling and the effi-ciency and operating range of the invert-ers. Since a PV system represents along-term investment, it is important toconsider the long term durability and reli-ability of the system components, themanufacturer’s reputation and the war-ranty terms and duration.To minimize losses caused by possible

photovoltaic system outages, despite com-





CASE STUDY • Copper Development Association

Old Walmart + Electrical Upgrade = New 9-1-1 CenterSumter County, Florida improves public safety when it gives

a former department store a thorough makeover

of an iceberg of trouble: The two electricalsystems were independently grounded, eachwith its own ground rod. That’s not gooddesign, so the systems were combined andgrounded to one of the existing galvanizedsteel electrodes.A 121-ft. communications tower was

erected in 2007, and the 9-1-1 center wasoccupied the following year, including fire,police, weather-alert and other public-safetycommunications facilities.Fortunately, Chief Deputy Sheriff Jordan

had the technical talent on board to seewhere improvements were needed. Hedirected his communications chief, Admin-istrative Lieutenant Russell G. Merritt andMarie Keenum (ENP), Sumter County’s9-1-1 Coordinator, to evaluate the electri-cal and grounding systems thoroughly.Keenum, who experienced the previouslightning damage event, and Merritt, a re-tired Army Sergeant Major with a career’sworth of experience in communications,saw serious problems. They recommendedthat the county seek professional help.Marie Keenum had previous experience

working with, and therefore selected, JohnWest, president and founder of Power &Systems Innovations, Inc., an Orlando-based company that specializes in powerquality improvement, grounding and light-ning-protection system design. Mr. Westand his company are well known in light-ning alley, having upgraded several regionalemergency facilities similar to those inBushnell. West acted as consultant and pro-ject manager and hired Rick Thompson,president of Power Quality Solutions, Inc.,to plan and install an upgraded system.Good things were starting to happen.

Real Problem: Poor GroundingThompson confirmed Lieutenant Mer-

ritt’s report that the existing system wasflawed, and that the major problem waspoor grounding. Among the most glaringissues were that:• The new transmission tower also had itsown independent grounding system con-sisting of an electrode and a ring groundthat was not directly connected to thebuilding’s service

A FEW YEARS AGO, the SumterCounty, Florida government took over whathad been a 55,000-sq ft. Walmart store inthe city of Bushnell. Walmart wanted tobuild a larger outlet nearby and the countybadly needed office space, so the deal was awin-win situation. The building is now thespacious new home for several county of-fices, including those of the Sheriff’s De-partment.

Important Management SupportBut there was a catch: the key compo-

nent of any sheriff’s department is its com-munication center, including the all-important 9-1-1 hub and dispatch room.Sumter County’s problem was that its new9-1-1 center is located smack in the heartof the most lightning-prone region in theentire country, Florida’s notorious “light-ning alley”, yet the building’s electrical andgrounding systems were built for a 1970s-vintage department store!Chief Deputy Sheriff Jack Jordan knew

the problem personally. He was on duty in2004 when a lightning strike to the county’sprevious communications center took outall 9-1-1 communications, as he puts it,“right when we needed a 9-1-1 center!” Theseriousness of the situation wasn’t lost onthe Chief Deputy Sheriff, and good thingsgenerally happen when top managementrecognizes a problem.The first priority was to get the building

remodeled and move in. The old electricalsystem, built for a department store, wasupgraded at the same time. The structurehad dual 480-V services plus two emer-gency generators, but right there was the tip Continued on page 18

0112EPSp16,18,20:Company Spotlight 1/16/12 9:26 AM Page 16


mon old grounding electrode, as it shouldhave been.

• In the transmitter rooms, contractorsbuilding’s two distribution transformerswere had “daisy-chained” ground leadsfrom several pieces of equipment to com-mon grounding points. That’s a shortcut,but it adds resistance and potential groundloops to the ground path.

Total System UpgradeMr. Thompson designed the new

grounding system. Chief Deputy SheriffJordan authorized work to begin immedi-ately. The cost, between $38,000 and$40,000, was tiny compared with the im-proved public safety it bought for SumterCounty’s 98,000 inhabitants.

Less than One Ohm!Transmission Tower & Ring Ground.Thompson began the upgrade at the

tower. He installed three new copper-cladelectrodes, one at the base of each towerleg, at depths of 40 ft., 8 ft. and 58 ft., re-spectively. The deep electrodes would en-sure low resistance. He exothermicallywelded an AWG 4/0 bare copper ringground to the electrodes then ran AWG4/0 pigtails to the tower and external sys-tem elements and surrounded the conduc-tors with bentonite. Bentonite is a claymineral that expands when moistened,making good contact to earth. It also pro-tects copper against corrosion over a widerange of soil conditions.To bond grounding conductors to the

tower legs, Thompson first welded 1/4-insteel tabs to the tower legs, then exother-mally welded the 4/0 to them. (The weldswere sprayed with protective paint.) Thebonds are robust and are easy to inspect andservice if needed.Coax Shields. Coaxial cables originat-

ing at antennas on the tower weren’tgrounded, so Thompson installed a cop-per ground bar on the tower above the

point where the cables make a 90º turn tothe ice bridge and toward the buildingbulkhead. He bonded short copper leadsto shields on the waveguides, then dou-ble-lugged them to the ground bar. Theleads slope downward to keep the path to-ward earth as direct as practical. Similarly,a length of 4/0 (encased in PVC conduit)extends straight down from the ground barto the buried ring.

Horizontal Electrode. Thompson laid100 ft. of AWG 4/0 bare copper groundingconductors in a two-foot-deep trench run-ning parallel to, and approximately 20 ft.behind, the main building. The copper,which is bonded to the ring ground, servesas a horizontal grounding electrode to di-rect lightning energy from away from thetower and building. The buried copper mayalso have helped reduce the system’sground resistance.Emergency Generators. The facility

has two propane-fueled emergency genera-tors, rated at 150 kVA and 40 kVA.Thompson ran AWG 4/0 copper from thering ground to the generators, overlappingflimsy existing grounds. He also groundedthe generators’ propane fuel line, securingall conductors to the concrete slabs withHilti nails, which are stronger and moretamper-resistant than screws.

Copper Ground BusGrounding electrodes are normally dri-

ven at or near a facility’s electrical serviceentrance. That was the case for the originalgrounding system at the former Walmartstore. Thompson bonded to the old rod, butused the deep, low-resistance electrodes andring at the nearby tower as the primary earthconnection.Connections from the ring and from all

other grounding conductors, including theground-neutral bonds in the service en-trance, were routed to a 1/4-in. thickgrounding plate mounted on standoffs onthe building wall below

entrance ground. Again, independentgrounds should not be used, since, in com-munications systems, they are a fertilesource of noisy ground-loop currents.Thompson also found that coaxial cableleads connecting antennas on the towerwith the comm center were not grounded.Had lightning struck the tower, it wouldhave had a direct, high-conductivity pathinto communications equipment.

• The grounding electrode system for thebuilding itself consisted of a single galva-nized steel electrode installed in the 1970s.Thompson measured resistance to groundat the electrode and found that it registered230 Ω, which is way above the five-ohmmaximum cited in IEEE recommendedpractices and nearly ten times higher thanthe 25-Ω limit noted in the National Elec-trical Code® for a single electrode.

• The two emergency generators werealso independently grounded. Thegrounding conductor bond at one gen-erator was in questionable condition andthe other one used an automotive hoseclamp (a fairly common but definitelyvery poor practice).

• Rainwater had penetrated the 480-V ser-vice entrance panels, corroding fuse con-nections. The panels themselves were notbonded to ground, another issue left overfrom the days when the building was a re-tail facility. It had to be corrected.

• Panels and sub-panels in the main electri-cal closet were protected by a combina-tion of lightning arrestors and surgeprotection devices (SPDs). It isn’t knownif lightning ever did enter the building, butat least one of the lightning arrestors at theservice entrance was damaged and one ofthem had been replaced. SPDs are sup-posed to shunt voltage spikes to ground.They can’t do that when they’re not wellgrounded.

• The building’s two distribution trans-formers were supposedly grounded tobuild several pieces of equipment to com-

CASE STUDY • Copper Development Association Continued from page 16




the main (outdoor) grounding bus. Itserves as the collection point for ground-ing conductors from panels, sub-panelsand additional ground bars in equipmentrooms.

• The site’s two distribution transformershad been “grounded” to building steel, butthe steel was not bonded to the groundingelectrode. Thompson grounded themproperly with AWG 4/0 copper, which heran directly to the main facility groundingbus outside using one of the four bulkheadpenetrations.

• Technical Electric Systems fitted panelsand sub-panels with new SPDs. The in-tent here was to provide multi-layeredSPD protection, i.e., at the service en-trance, at the main distribution panel in-doors, at sub-panels and, finally, at loadpoints such as computer terminals down-stream. Surge protection was installed byMike Henry of Technical Electric Sys-tems, Inc.

• Lastly, Thompson attacked the hodge-podge of grounding that he, John West

and Lieutenant Merritt had found in com-munications equipment rooms, on trans-mitters, routers, and other gear. Hereplaced the daisy-chained grounds withhomeruns to grounding plates and in-stalled a separate grounding plate for coaxshields at the point where they enter theradio room. That provided redundant pro-tection since the coax cables were alsogrounded at the tower, thus providing twopoints at which lightning energy could beshunted away from communicationsequipment.

9-1-1: Ready When NeededWith the lives of 98,000 Sumter

County residents at potential risk, thereis no question that the 9-1-1 system up-grades were worth the cost. There havebeen no disruptions since the upgrades.Chief Deputy Sheriff Jordan and the cit-izens his department serves can now restassured that they’ll have reliable com-munications “right when a 9-1-1 centeris needed”.

the dual service entrance cabinets, which,in turn, was connected to the facility’smain grounding bus – another copper plate– on the exterior wall below the waveguideentrance bulkhead. Also bonded to thelower ground bar was the building’s orig-inal grounding electrode and two newTransguard TG100 SPD units, one foreach service entrance cabinet. The TG100sare rated to 100 kA line-to-neutral andline-to-ground, and 200 kA per phase.It is absolutely imperative that SPD de-

vices be reliably grounded and that the re-sistance to ground (earth) be as low aspossible. SPD devices cannot function ifthey are not well grounded.

More and Better BondingIndoorsIndoors, Thompson concentrated on dis-

tribution transformers, sub-panels, and com-munications and computer racks inequipment rooms.• He first installed a ground bar indoors,aligned approximately back-to-back with

CASE STUDY • Copper Development Association Continued from page 18




FEATURE • Megger

A New Technology AugmentsLow-Resistance Testing

By Jeff Jowett

W. The resistance change amounts to only99 micro-ohms, well below the sensitiv-ity of a relatively “good” two-wire ohm-meter with 1 milli-ohm resolution.

The requirement for sensitivity un-precedented in many types of electricaltester means that factors not normallytaken into consideration become criticalto success with a low resistance ohmme-ter. Lead and contact resistance, parallelleakage paths, and

LOW RESISTANCE measurementcan mean different things in different ap-plications and to different people. But inthe textbook sense, low resistance mea-surement is measurement below 1 ohm.Electrical equipment depends on the con-trolled flow of current within operatingparameters in order to provide maximumperformance. Increased resistance, causedby corrosion, wear, temperature effects,vibration, loosening of contacts, joints andwelds, or a litany of other possiblesources, can reduce the equipment’s op-erating capabilities, waste energy, losepower, and lead to breakdown, damage,and fire. Low resistance ohmmeter testsare, therefore, an integral part of an elec-trical maintenance program.

It is important to be familiar with thebasic test parameters. To be truly effec-tive, low resistance measurement needs tobe carried out with currents commensu-rate with operating conditions. This rulesout the common two-wire multimeter.Handheld two-wire instruments typicallyoperate from battery power and provideonly a few milli-amps of test current. Thiswill do for making a general assessmentof a circuit element or conductor, or therouting of a conductor in a circuit. But it isnot sufficient for a fullevaluation of equipmentcondition. Low levels oftest current can easilypass around imperfec-tions in the conductor solong as basic continuity isin place, leaving a falsesense of security. To getan idea of the magnitudesinvolved, consider the ba-sic power equation W =I2R, where W = watts, I =current in amperes, and R= resistance in ohms. Forexample, 6000 A across a1 µΩ bus = 36 W whileincreasing the bus resis-tance to 100 µΩ = 3600 Continued on page 24

Fig. 1

0112EPSp22,24,26:Company Spotlight 1/13/12 2:30 PM Page 22


probes. In this manner, resistances only afraction of a micro-ohm can be accuratelymeasured, and as shown by the exampleabove, even such small amounts can havea profound effect on the operation of crit-ical equipment.So far, so good, but the requirements

don’t end there. As has been stated, a hightest current is necessary for a rigorous testthat will prove the test item fully capableof its application’s demands. Voltage isnot an issue, as only a millivolt output isrequired for the tester to drive currentthrough such low resistances. But a heftycurrent source is a must and one of themost critical design demands placed on alow resistance ohmmeter. Industry stan-dard for most common applications is 10amps. But for heavy equipment, many in-dustries insist on maximum test currentsthat typically range into hundreds ofamps. This is particularly relevant to cir-cuit breaker testing by the utilities, andcarries over to many other heavy-duty in-dustrial applications. The requirement cre-

ates difficulties with size, weight, cost andman-hours for setup and operation of testinstruments. Stated directly, the challengeis how to get high current out of small,lightweight instrumentation. The solutionis…the ultra capacitor.Examination of the capacitance formula

shows how:

C = ∑r(A/d)

Where C is capacitance in Farads, is thedielectric constant (F/m)

outside influences like thermal emfs andlow levels of noise can all loom large bycomparison to what is being measured.The solution is the four-wire (Kelvinbridge) configuration characteristic of lowresistance ohmmeters (Fig. 1). The testerhas two current terminals and two poten-tial terminals. Via the former, a test cur-rent is established through the test item.Since the measured value of this currentis used in the resistance calculation, con-tact and lead resistance are canceled outand do not have an effect on the result.The potential terminals are connected toan internal voltmeter with a high imped-ance and sense the voltage generated bythe test current across the test item be-tween the two points of contact by thevoltage probes. Contact resistance of thepotential probes produces no additionalvoltage and has no effect on the potentialdifference detected by the probes. Thetester measures current and potential, andby Ohm’s Law calculates the resistanceof the test item between the potential

FEATURE • Megger Continued from page 22



Fig. 2



The averaging process used to calculatethe result affords typically 1-2% accuracyand resolution of 1 µΩ. This compares fa-vorably but not equally to bench-typeR&D models that may offer a fraction of apercent accuracy and 0.1 µΩ resolution.However, for the recommended field ap-plications, the measurements are fully re-liable and accord with industry standardsas listed above. At the same time, the ad-vantages for field (as opposed to lab) test-ing are obvious. The small size enablesthe tester to be used effectively in tightspaces and areas of difficult access, suchas raised bucket trucks, where a conven-tionally-sized model would be a challengeto operate and a drain on man hours.Heavy, bench-type testers can get banged

up easily in field envi-ronments, while ahandheld model can beeffectively ruggedized.With no dependenceon line power, a hand-held instrument can betaken anywhere. Andwith test intervals asshort as 0.1 second,depending on load andrequired current maxi-mum, the ultra capaci-tor can readily operatefor a full shift or

longer. Working close to the test objectreduces or eliminates the need for bulkyheavy-gauge current cables, and even thereduction in transportation costs can provesignificant.As Lt. Columbo might add, “One more

thing.” And usually, it was the clincher.With electrical testing, the most importantelement is personnel safety. The low in-ternal impedance that implements high

test current in a handheld model also per-mits testing of circuit breakers with bothsides grounded for maximum safety. Withconventional testing, having both sides ofthe breaker grounded establishes a parallelpath to the measurement circuit throughthe test item, thereby introducing a poten-tially significant error. The conventionalprocedure of lifting one ground in orderto run the test and then reconnecting it istime-consuming, risky, and invites humanerror. Ultra-capacitor technology allowsboth sides to remain grounded without in-troducing error into the measurementwhile at the same time affording maxi-mum protection to the operator (Fig. 3).While the application focuses most di-

rectly on circuit breaker contacts, the ad-vantages of the technology are obvious forthe testing of many other heavy-dutyitems such as bus bars, switchgear, dis-connects, safety grounds, fuses and cables,among others. The revolutionary ultra ca-pacitor when utilized as the core of a lowresistance tester overcomes significantpractical limitations of conventional ohm-meters with respect to bulk and opera-tional demands. This new technologyaffords the operator critical advantages incost saving, speed and ease of operation,and personal safety.

of the insulating material, A is surfacearea of the plates (m2), and d is distancebetween plates (m). The formula showsthat an increase in the surface area of thecapacitor plates with a corresponding de-crease in distance between them will raisecapacitance. But how to implement theidea? The answer is modern laser tech-nology, which can etch surface areaequivalent to two football fields into anultra capacitor the size of a D cell! As aresult, the ultra capacitor can be incorpo-rated into a handheld instrument that candeliver up to 200 Amps! This is enoughto satisfy the standardized testing require-ment for circuit breakers in the utility in-dustry, as well as numerous additionalhigh-current applications.The ultra capacitor can be charged from

AA rechargeable batteries in a handheldtester that is typically on the order of onetenth to one twentieth the weight of com-mon line-powered or battery-powered lowresistance ohmmeters. An ultra capacitorcan store on the order of 350 Farads…anenormous capacitance that can produceenough energy to lift 240 pounds threefeet! Once charged, a low internal resis-tance in the instrument enables the capac-itor to discharge 200 Amps through thetest item…across circuit breaker contacts,for instance. The instrument continuouslyand synchronously monitors voltage dropacross and currentthrough the test cir-cuit during discharge,and an average resis-tance value is calcu-lated and displayed(Fig. 2). Dischargetime is typically aboutthree seconds, longenough for an accu-rate measurement,and can be a fractionof a second depend-ing on load and cur-rent requirement. Restassured, the technology does not producemerely a “short-cut” measurement butrather conforms to recognized industrytest standards, including IEEE C37.09-1999 and C37.100-1992 and also IEC62271-100.No gain comes without some accom-

modation, and of course the technology isnot amenable to those applications that re-quire the use of continuous test current.

FEATURE • Megger Continued from page 24

“This newtechnology affords

the operator criticaladvantages in costsaving, speed andease of operation,

and personalsafety.”

Fig. 3



FEATURE • Universal Lighting Technologies

A Smart StartThe State of Programmed Start Technology

& Opportunities in the 2012 MarketplaceBy Greg Bennorth

come and go. That’s good for energy sav-ings, but harsh on the lamp.

Switching to a programmed start bal-last provides clear benefits for both thecontractor and the building owner/manager, especially when replacing a T12ballast. Electronic T8 lamp/ballast sys-tems, for example, reduce energy use asmuch as 40 percent compared to magneticT12 systems. A change in federal lawcoming in July 2012 will provide an addi-tional push towards programmed start T8and T5 ballasts by phasing out almost allT12 fluorescent lamps.

How It WorksThe starting process of a programmed

start ballast is gentler on the lamp thanprevious methods. With rapid and instantstart ballasts, an emissive material is re-leased from the cathode during the startingprocess and burned off. You can actuallysee the glow of this material before the

lamp ignites. The burning of this materialleads to end blackening and ultimatelylamp failure.

Programmed start ballasts are able tominimize the release and burning of emis-sive material by keeping voltage acrossthe lamp very low during a preheat inter-val. During this interval, the cathode isheated to at least 700°C. Since lamp volt-age is very low during this phase, theglow current is also low and the loss ofemissive material is minimal. The lengthof this step is pre-programmed into theballast circuitry (typically about 700 mil-liseconds). Once this step is complete, it’stime to apply voltage across the lamps, ig-niting them with minimal loss of the emis-sive material.

With rapid and instant start ballasts, theburning of emissive materials actuallydraws the emissions out of the cathodefaster, accelerating the process and essen-tially feeding itself.

WHEN IT COMES TO extendinglamp life, rapid start technology neverquite lived up to the hype. There has neverbeen a proven difference between rapidstart and instant start ballasts in terms ofhours of lamp operation. And when fix-tures are frequently cycled on and off,lamp life diminishes significantly with ei-ther technology.

Programmed start ballasts, on the otherhand, can triple the life of an electronicT8 or T5 lamp in frequently switched ap-plications. Extending lamp life not onlyreduces replacement costs and hassle, butsaves energy as well when used with oc-cupancy sensors.

In today’s marketplace, the strongestopportunity for sales of programmed startballasts is office space, both retrofit andnew construction, followed by educationalfacilities. Whether manually controlled orautomated, fixtures in these environmentsare regularly turned on and off as people Continued on page 30

0112EPSp28,30:Company Spotlight 1/13/12 2:33 PM Page 28


quick transition time with programmedstart ballasts further minimizes the loss ofemissive material during starting.

Additional AdvantagesAnother advantage some programmed

start ballasts offer over rapid start ballastsis the ability to reduce power supplied tothe cathode after it has been sufficientlyheated. Additional power at this point pro-vides no advantage in lamp performancebut does consume electricity (about 2watts per lamp). By reducing power afterthe cathode is hot, the programmed startballast saves energy. Instant start ballastsoperate without heating filaments, so noenergy is used to heat the cathode beforeor after ignition.It should be noted that cathode heating

is required for T8 lamps when ballast fac-tors are less than .77. Programmed startballasts are able to provide power levelslower than instant start ballasts since theycan run the lamps at lower lamp currentwhile providing cathode heating.

Many programmed start ballasts fea-ture universal input voltage (120–277volts) for simplicity during installation.In addition, parallel lamp operation canbe incorporated with programmed starttechnology. When one lamp fails, theother lamp(s) will remain functional. Withseries lamp operation, when one lampfails, the other lamp(s) will not provideany significant amount of light. And,many programmed start ballasts are CEEand NEMA Premium compliant to helpcontractors identify the most energy-effi-cient choices of T8 fluorescent ballasts.Accelerated cycle testing of the instant,

rapid, and programmed start ballasts (with15 minute on/5 minute off cycles) providedclear evidence of improved lamp life withprogrammed start technology—exceeding40,000 starts compared to 16,000 with othermethods. The instant and rapid start ballastsperformed equally in the tests.From classrooms and copy rooms to re-

strooms and storage rooms, building own-ers and managers are getting smarter aboutturning the lights off (or at least down)when the room is not in use. The energysavings add up quickly and are a key sellingpoint for both retrofit and new construction.This leads to an important question: atwhich point does an application count as“frequently switched”? A good rule ofthumb is three hours per start. For ballaststhat remain on for at least three hours at astretch, an instant start ballast is generallypreferred. If the interval between starts isless than three hours, a programmed startballast is often a better choice.Since programmed start ballasts are

wired identically to rapid start ballasts andused in the same applications, some con-tractors and manufacturers use the term“programmed rapid start,” although thestarting processes are actually quite dis-tinct. No matter which terminology youprefer, the popularity of occupancy sen-sors and other automated lighting controlswill drive an increase in market share forthese types of ballasts in 2012 and be-yond, especially in commercial applica-tions. The opportunity to triple thelifespan of the lamp with zero change inthe installation process is simply too goodto pass up.

Greg Bennorth is the Director ofSystem Projects for Universal

Lighting Technologies.

This is one of the reasons the preheat in-terval is so effective at lengthening lamplife.Furthermore, the longer it takes for a

lamp to fully ignite when transitioningfrom glow current to full-on current, themore emissive material gets burned. Witha rapid start ballast, this time period isabout 80 to 100 milliseconds. But by pre-heating the cathode first, a programmedstart ballast is able to fully ignite extremelyfast—in as little as 30 milliseconds. This

FEATURE • Universal Lighting Technologies Continued from page 28


0112EPSp28,30:Company Spotlight 1/13/12 2:33 PM Page 30

Toshiba International Corporation an-nounced recently that its innovative newA19 LED lamp is now available on BestBuy’s website and in special sections ofselect Best Buy stores.The 40-watt equivalent LED light

bulbs are featured in three Best Buystores – one each in Houston, San Fran-cisco, and Chicago – that just launchedspecial home energy departments high-lighting the latest and greatest energy-saving technologies. The LED lamp isalso available on Best Buy’s website.Unlike many other LED lamps

launched to date, Toshiba’s A19 boastsa more traditional light bulb shape – afeature that research shows is importantto lighting designers, specifiers, and con-sumers. Toshiba’s new A19 lamp is man-ufactured using patented technology that

enables omnidirectional light distributionsimilar to that of an incandescent lamp.The A19 lamp is also dimmable andcomes in a 2700K color temperature.“Toshiba is extremely proud that its

LED lamps have been selected as fea-tured products in Best Buy’s Home En-ergy Departments,” said Ken Honeycutt,Senior Vice President at Toshiba Inter-national Corporation and the Chief Ven-ture Executive for Toshiba LEDLighting Systems Division.Manufactured to ENERGY STAR®

performance levels and undergoing EN-ERGY STAR® testing now, Toshiba’sA19 LED lamp reduces energy use bymore than 75 percent and lasts up to 40times longer than incandescent lamps.In fact, based on an average use of threehours a day, the A19 lamp is rated to last

22.8 years. The lamp also features a 450-lumen output, reaches full brightness in-stantly, and contains no mercury orlead.“Toshiba’s LED lighting is already

featured in art museums and businessesaround the world; now consumers canexperience this beautiful lighting in theirhomes,” said Peter DallePezze, VicePresident of Marketing and Product De-velopment, Toshiba International Cor-poration LED Lighting SystemsDivision.“We believe Best Buy’s decision to

carry LED lighting speaks to the excitingtransition that’s taking place in the light-ing industry,” DallePezze said. “Thanksto advances in technology, we are pro-ducing LED lamps that last for years andsignificantly reduce the energy usage inhomes and commercial buildings. Thisrepresents a fundamental shift from sell-ing a commodity product to a durableproduct with innovation behind it.”The A19 lamp is backed by Toshiba’s

120-year heritage as a preferred lightingmanufacturer in Japan and by Toshiba’sreputation worldwide as a reliable man-ufacturer of quality electronics products.As one of the largest lighting companiesand LED lamp manufacturers in theworld, Toshiba is dedicated to creatinghigh quality light, while keeping energyconsumption low. One hundred percentof Toshiba’s current lighting product of-fering and lighting product developmentin the U.S. is based on LED technology.To demonstrate their commitment to

LED technology as the superior choicefor lighting, Toshiba abandoned produc-tion of incandescent light bulbs in March2010. Toshiba was the first major light-ing manufacturer to proactively discon-tinue the production of incandescentlight bulbs in favor of energy-efficientLED lamps.

Industry NEWS


Toshiba’s NewA19 LED Lamps to beFeatured on Best BuyWebsite and in

Special Sections of Select Best Buy Stores


0112EPSp32,33.qxd:Company Spotlight 1/13/12 2:34 PM Page 32

Energy-saving light control manufac-turer Lutron Electronics announced todaythat its Washington, DC Commercial Ex-perience Center has been awarded LEEDGold Certification by the U.S. GreenBuilding Council (USGBC). LEED is theUSGBC’s leading rating system for de-signing and constructing the world’sgreenest, most energy-efficient and high-performing buildings.Lutron Experience Centers are show-

cases of Lutron’s most impactful residen-tial and commercial products andsolutions. The Washington, DC facilityspecifically showcases commercial prod-ucts in use in a variety of vignettes (con-ference rooms, offices and more).“We’re pleased to have achieved US-

GBC’s LEED Gold Certification,” saidAndy Wakefield, Director of Government

Relations at Lutron. “Knowing that ourproducts contributed not only to our Goldcertification, but to dozens of other build-ing certifications throughout the country,shows how impactful Lutron products andsolutions can be to a building’s controlstrategy.”The Experience Center was designed

by DC-based architectural firm InterplanIncorporated to achieve LEED certifica-tion for energy use, lighting, water andmaterial use as well as incorporating a va-riety of other sustainable strategies. LEEDverifies environmental performance, oc-cupant health and financial return. LEEDwas established for market leaders to de-sign & construct buildings that protect andsave precious resources while also mak-ing good economic sense.“The strength of USGBC has always

been the collective strength of our leadersin the building industry," said RickFedrizzi, President, CEO & FoundingChair, U.S. Green Building Council."Given the extraordinary importance of

climate protection and the central role ofthe building industry in that effort, Lutrondemonstrates their leadership throughtheir LEED certification of their Wash-ington, DC Experience Center.”

LEED certification of the Lutron facil-ity was based on a number of green de-sign and construction features thatpositively impact the project itself and thebroader community. These features in-clude: optimization of energy perfor-mance through the use of lighting power,lighting controls and HVAC, plus the useof daylight.Per the rating system, the space scored

63 out of 110 possible points. Of those 63points, Lutron products and solutions con-tributed 19 points. Lutron products canhelp contribute up to 41 points on a pro-ject, making them effective, energy-sav-ing solutions for any space.

January 2012 • epsmag.net 33

Lutron’s Washington, DC CommercialExperience Center Awarded LEED®

Gold Green Building Certification


0112EPSp32,33.qxd:Company Spotlight 1/13/12 2:34 PM Page 33

Product FOCUS


FOR FREE INFO, CIRCLE 45 ON READER SERVICE CARD FOR FREE INFO, CIRCLE 46 ON READER SERVICE CARD

Bridgeport Fittings Introduces Mighty-Aiign™ ‘Slip’ Style CouplingsAllows EMT to be coupled in tight locations or where there is limited accessibility

Bridgeport Fittings announces new Mighty-Align™ “Slip” Style Couplings. The UL-Listed couplings allow EMT to be coupled in tight locations or where there is limited

accessibility.Designed to join together two ends of ¾ inch or one-inch EMT, the coupling’sback-out center screw permits 241-DCSLP and 242-DCSLP to be temporarily

located on one cut end while adjacent end is slid into place. The contractorbacks out the center screw, as necessary, to slip the coupling over the conduit,ensuring both ends of the conduit are visible in the sight hole, beforetightening all set screws.

The Mighty-Align™ “Slip” Style Couplings are part of Bridgeport’s exclusiveand innovative “Mighty-B”™ line of high-quality, high-performance productsfocused on getting a contractor’s job “done fast, done right.”The Mighty-B™ line is comprised of labor saving or problem solving devices

– unique in their design – that cover a full range of connectors, couplings andother innovative product categories.

For more information, visitwww.bptfittings.com

0112EPSp34-40.qxd:Company Spotlight 1/13/12 2:44 PM Page 34

Product FOCUS



IDEAL Combo Head™ Screwdriver Fits VirtuallyAny Combination Fastener, Eliminates Need toPurchase Additional ToolsDifferent sizes of combination fasteners mean using different tools, right?

Wrong. The Combo Head Cushioned-Grip Screwdriver from IDEAL fits snug-gly into multiple sizes of Combination Screws, eliminating the need to buymore tools."With the increasing popularity of Combo Fasteners, contractors are faced

with the dual problem of buying and then carrying different screwdriversto fit each individual fastener," explained Rachel Douglas, Associate ProductManager for IDEAL. "The Combo Head™ allows users to forego the cost ofpurchasing several different screwdrivers, plus it lightens and de-clutterstheir tool carriers."The screwdriver's patented Combo Head™ tip is vapor blasted and preci-

sion-machined to ensure full fastener engagement. Among the competi-tion, the Combo Head™ features the most touch points, minimizing cam-outand stripping. It is the perfect solution for professional contractors, especiallyelectricians who can employ the Combo Head™ to easily fasten junctionbox and conduit screws.The new Combo Head™ Cushioned-Grip Screwdriver (#33-204) is 100%

made in the United States. It is also available in insert and power bits.

For more information, visitwww.idealindustries.com


January 2012 • epsmag.net 37


T&B® Fittings Form 7 and Form 8 Conduit OutletBodies with BlueKote® Finish Facilitate WirePulling, Resist CorrosionNew T&B® Fittings Products from Thomas & Betts FeatureMultiple Protective Layers

T&B® Fittings Form 7 and Form 8 Conduit Outlet Bodies fromThomas & Betts feature the interior BlueKote® finish, which cre-ates a smooth surface that facilitates wire pulling and preventswire damage, while also providing an additional layer of corrosionprotection. The BlueKote® finish is in addition to three layers of in-terior and exterior protective coatings, including two layers ofepoxy.

“The BlueKote® finish makes the fitting’s interior slick, so that less force is needed to pull wires,” said Bogdan Dia-conescu, product manager for Thomas & Betts. “This makes installation faster, and reduces the risk of strain on the in-staller.”

BlueKote® Form 7 and Form 8 Conduit Outlet Bodies resist corrosion with three layers of protection:1. Zinc electroplating, which protects the cast-iron body from rust and rust creep;2. Baked-on epoxy powder coating, which penetrates the cracks and crevices of the body’s surface, is scratch resistant and

tolerates exposure to harsh chemicals;3. Baked-on epoxy paint, the final exterior layer that provides additional corrosion resistance. The final, baked-on BlueKote®

layer on the body’s interior not only facilitates wire pulling, but also provides an additional layer of corrosion protection.

For more information, visitwww.tnb.com


Product FOCUS



Introducing ULTim8®Programmed Start T8 LinearFluorescent Ballasts fromUniversal LightingTechnologiesFor controllability and energy savings in

frequently switched applications, Universal LightingTechnologies introduces the new ULTim8¨ Programmed StartSeries of T8 linear fluorescent ballasts. Ideal for office settings, classrooms,bathrooms, hallways, and more, these programmed start ballasts make it simple tocomply with legislative and code requirements that call for controllable lighting technologiessuch as occupancy sensors.

Featuring parallel lamp operation and ultra fast start times (<700 milliseconds), the new ULTim8 ProgrammedStart Series is engineered to reduce maintenance costs and extend lamp life in applications where lamps are being turnedon and off throughout the day, whether manually or via lighting controls. Plus, these ballasts are part of the NEMA PremiumElectronic Ballast Program that identifies the most energy-efficient T8 fluorescent ballasts on the market today. This new ad-dition to the ULTim8 High Efficiency ballast family includes 2-, 3-, and 4-lamp models with both .88 (HE) and .71(EL) ballastfactor options available.

For more information, visitwww.unvlt.com



Company PG# RS# Company PG# RS#

AEE SOLAR 11 11AEMC INSTRUMENTS IBC 2ALBER CORPORATION 25 18ALCAN CABLE BC 3ARPI OF USA 36 47BATTCON 2012 CONFERENCE 40 52BYTE BROTHERS 4 6CONNECTRAC 32 43COPPER DEVELOPMENT ASSOCIATION 17 14COPPER WIRE STRIPPER 34 46ERICSON MFG. CO. 35 22EXTECH INSTRUMENTS / FLIR SYSTEMS 3, 9 5, 9E-Z METER 36 48GENERATOR INTERLOCK TECHNOLOGIES 7 8HIOKI USA 15 13ICC 19 15KRENZ & COMPANY 38 50MEGGER 1, 23 4, 17

NORTHWEST LIGHTING SYSTEMS 31 21PG LIFELINK IFC 1PHASE-A-MATIC 38 51PHILIPS EMERGENCY LIGHTING 30 42PLC MULTIPOINT 33 44PRUF LED 29 20SNAPNRACK 21 16SOKKIA 5 7SOUTHWIRE COMPANY 27 19STEELMAN INDUSTRIES 34 45STRIP-TEC 14 40T3 INNOVATION 24 41THE HOME DEPOT 13 12U.S. TUBE DOORS 37 49UNDERGROUND DEVICES 20 53UTILITY METALS 10 10YOKOGAWA 39 23

This advertisers index is compiled as a courtesy to our readers. While every effort is made to provide a complete and accurate listing of companies, page numbers andreader service numbers, the publisher is not responsible for errors.

Advertiser INDEX



eps magazine, january 2012

Documents

reader service

pm page c2for free info

page c1for free info

company spotlight

toll free

electricalproducts solutions

technology opportunities

public safety