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CONTENTS
PUBLISHER
Danny J. Salchert OFFICE MANAGER
Anita Salchert ASSOCIATE PUBLISHER
Bart Beason bart@epsmag.net CREATIVE DIRECTOR
Derek Gaylard CIRCULATION DIRECTOR
Pam Fulmer
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CONTRIBUTING WRITERS
Jeff Jowett • Kaoru Kondoh • George Jang
FEATURES 6 A Spark of Inspiration “A new way to move wires”
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Increased Efficiency in Medium Voltage Insulation Testing By Jeff Jowett
WHITE PAPER 20 Non-Metallic Contact Power Measurement Ensures Safety at the Worksite
By Kaoru Kondoh
PRODUCT SPOTLIGHT 30 It’s Not Your Fault… but You Have to Find it! Stop guessing about circuit breaker tripping issues! By George Jang
DEPARTMENTS 24 Industry News 34 Product Focus 40 Ad Index ON THE COVER Photo provided by Nonconductive Tool Company
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Electrical Products & Solutions • February 2016
PRESIDENT
Danny J. Salchert Executive and Advertising Offices 3591 Cahaba Beach Road Birmingham, AL 35242 toll free: 800.981.4541 phone: 205.981.4541 fax: 205.981.4544 www.epsmag.net • danny@epsmag.net Electrical Products & Solutions™ is published twelve times a year on a monthly basis by ABD Communications, Inc., 3591 Cahaba Beach Road, Birmingham, Alabama, 35242, USA. Electrical Products & Solutions™ is distributed free to qualified subscribers. Non-qualified subscription rates are $57.00 per year in the U.S. and Canada and $84.00 per year for foreign subscribers (surface mail). U.S. Postage paid at Birmingham, Alabama and additional mailing offices. Electrical Products & Solutions™ is distributed to qualified readers in the electrical contracting industry. Publisher is not liable for all content (including editorial and illustrations provided by advertisers) of advertisements published and does not accept responsibility for any claims made against the publisher. It is the advertiser’s or agency’s responsibility to obtain appropriate releases on any item or individuals pictured in an advertisement. Reproduction of this magazine in whole or in part is prohibited without prior written permission from the publisher. POSTMASTER: Send address changes to ABD Communications, Inc., P.O. Box 382885 Birmingham, Alabama 35238-2885
PRINTED IN THE USA
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FEATURE • Nonconductive Tool Company
A Spark of Inspiration “A new way to move wires”
A
union trainer told us a story of when he was a young and inexperienced electrician. He was working on an outlet and didn’t know enough to turn off the breakers. He reached in with a pair of needle-nose pliers, created a big spark and shocked the heck out of himself. He went to his supervisor and said, “There has to be a better way.”
A Spark of Inspiration The big spark of inspiration that started Nonconductive Tool Company and its quest for the “Better Way” came from an electrical apprentice who was working on an electrical junction box. He simply said, “I wish I had a toothbrush-like tool to reach inside the junction box and pull the wires out.” He said, “We could cut a notch on the side of the handle and make a hook out of it”. It was simple. Reach in, hook the wires and pull them out. We were fortunate to have a friend who is a great inventor and product developer. He heard the concept, understood it and within a few weeks the first prototype was complete. It was better than anything that we had ever imagined. The tool even had a wire-connector wrench in the middle of it. Simply slide the tool over a wire connector, twist it and loosen or tighten the connector. We tested out the wire-connector wrench on an exterior landscape lighting job. The wire-connectors were tightly corroded on. We slipped the wire-connectors into the middle on the tool, twisted and unloosed the connectors with ease.
A Second Spark - The T-groove When the inventor showed us another prototype we noticed a change at the end of the tool. There was a T shaped groove fabricated into the tip. We asked him what the function was. “It’s for 12 gauge Continued on page 8 6
Electrical Products & Solutions • February 2016
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FEATURE • Nonconductive Tool Company
Continued from page 6
wires”, he said. “Simply slip the T-groove around a wire and rotate the tool. It grabs the wire and grips it tight. You can move the wire, push the wire and pull the wire. It works great. What makes the T-groove really handy is it allows you to easily bend the wire into almost any shape you want.” We tested it out on a breaker panel. After turning off the power, we bent the wires exactly where we wanted them. We laid the wires near the edge of the panel and bent them perfectly towards the breakers. We tightened the wires under the screws without touching the wires with our hands. It was like magic. “Also”, the inventor said, “if you need to reach in a breaker panel and pull a wire out, you just slide the T-groove over the wire, rotate and pull it out. It’s sort of like that game called Operation except the voltages are higher.” (Note: Always turn off power before working on electrical systems) Another project that we tested the Tgroove on was a GFCI receptacle in a slightly overcrowded work box. Often, there is not a lot of space inside the boxes to reload the devices. So one by one we slid the T-groove around the wires and we bent them to the exact shape of the box. We pushed them as deep as possible into the box. It was sort of like making a nest for the GFCI to rest in. After the initial sparks of inspiration and 20+ prototypes, the final VoltClaw designs were sent to a tool maker in Southern California. An injection mold was made. The modern materials used in the VoltClaw have been laboratory tested for strength and non-conductivity. When the shot-sample came out of the machine, we held it for the first time. The grip felt perfect in our hands.
Prototype #2: A strip of wood and an aluminum channel The Goal: Create a sliding thumb mechanism that grips the wires. Slide the thumb mechanism forward and the hook closes around the wire. Pull the thumb mechanism back and the wire is released. The concept came in a workshop in Los Angeles. There was a piece of aluminum channel and a strip of wood that fit perfectly into the channel. We cut a hook into the aluminum channel and inserted the piece of wood. With a little bit of blue masking tape, the strip of wood slid down and gripped the wire perfectly. Well, al8
Electrical Products & Solutions • February 2016
most perfectly. Because it was an aluminum channel it cut though the insulation of the wire. But we knew what to do… make it out of the same modern materials as the VoltClaw12 One of the greatest things about materials used in the VoltClaw is it doesn’t damage the wire insulation. It doesn’t cut through the plastic coating and expose the copper wire like metal tools do. You can push or pull wires pretty aggressively and not tear the insulation. Of course, always be careful when working with electrical wires. I remember working as a young electrician and getting yelled at for pushing the wires back into the junction box using the handle of my lineman pliers. When I asked my supervisor if there was a better way he said to use my fingers. Sometimes when he wasn’t looking, I would use the back of my screwdriver, but that would always slip off and not work very well. Continued on page 12 Welcome VoltClaw
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FEATURE • Nonconductive Tool Company
Multi-gauge. With the thumb groove it grips the wire firmly. The V-groove tip helps push the wires back into the box. Fits 6 to 14 gauge wires. For use with 0-600 Volts.
The Team Every great invention needs a great team to support it. Nonconductive Tool Company, llc (NTC) is a family business with a great extended family. We have “Made in the USA” tools and an allAmerican dedication to quality. It is NTC’s goal to create products that help keep electricians safer and make their projects easier and more professional. Grateful for all the support along the way, NTC stands behind all of its tools. Quality guaranteed. The VoltClaws are tough, light-weight and ergonomic.
Continued from page 8
“Electricity can be dangerous. My nephew tried to stick a penny into a plug. Whoever said a penny doesn’t go far didn’t see him shoot across that floor. I told him he was grounded.” — Tim Allen
was using a VoltClaw Multi-gauge. It worked great. I lived another day” VoltClaws are now in the hands of apprentices and journeymen alike. Receiving great support from electrical magazines and union teachers, the VoltClaw Wire Management Tools can be found in the tool-belts of electricians who In the Hands of Electricians are looking for the next level of protecAnother electrician told a story, “I tion. turned off the breaker and locked down the circuit then proceeded to work on a Fun Story… junction box. What I didn’t know was that The owner of Nonconductive Tool there was another circuit in the junction Company asked his 12 year old daughter box that was on a light switch. The busi- to write a testimonial for the VoltClaw. ness owner turned on the light. The wire She sat down at the computer and furihit the side of the metal box, sparks flew.” ously typed. With great wit this is what The electrician continued by saying, “I she said… 12
Electrical Products & Solutions • February 2016
“THE POWERFUL GODS ABOVE HAVE WATCHED US GET SHOCKED AND BE IN AWE OF HOW INCREDIBLY STUPID WE ARE FOR NOT COMING UP WITH SOMETHING TO PUT AN END TO THIS MADNESS. I GIVE YOU… THE VOLTCLAW!!! Wire well my friends!
❏
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FEATURE • Megger
Increased Efficiency in
Medium Voltage Insulation Testing
By Jeff Jowett, Megger
I
nsulation testing is one of the most fundamental and useful tools for electrical maintenance and troubleshooting. It can be applied to any electrical equipment: wire, cable, motors, transformers, generators, and any electrical apparatus. The insulation keeps the current traveling in the designated circuit, protects people from shock and electrocution, and helps electrical equipment to function efficiently and within the design parameters. Insulation tests are relatively easy to perform, but do require a basic knowledge of the “rules”, so to speak. An insulation tester applies a selected test voltage across the insulation. No insulation is perfect; current flows. Commonly referred to as “leakage” current, because it is current that is escaping from the designated circuit path, it is normally at a very low level, in the nano-amp range. The insulation tester measures the leakage current and calculates the resistance of the insulation against the applied voltage; pure Ohm’s Law. If leakage current exceeds more than a few milliamps, the insulation is no longer performing effectively as insulation. Consider: the human body typically reacts to a mere 5 milli-amps as a “shock”. Not lethal, but not anything anyone wants to experience. As a result, insulation testers can put out considerable test voltages in order to stress the capabilities of the insulating material, but need negligible current to do it. This property has vital consequences for the instrumentation: it can be light, portable, easily operable, and above all, safe. In the early days of such instrumentation, common testers were 1 kV and 5 kV, corresponding to building-wiring tests and medium-voltage equipment tests respectively. In this century there has been a trend
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toward higher voltage tests. Around the turn of the 21st century, IEEE upgraded their motor testing standard (IEEE 43-2000) to 10 kV, meaning that any motor in the world could be tested to satisfactory IEEE standards with an insulation tester that could be set up to 10 kV. Of course, you may test at even higher voltages if you wish, but IEEE was allowing for practicality. Since that time, the application of even higher test voltages has expanded. Newer synthetic insulating materials have altered the expected responses during testing and made higher test voltages useful and desirable. Testing up to 15 kV is now common. Because test current is limited by a resistive output, higher test voltages are readily achieved. If the load is insulation of poor quality that could pass more than the maxi-
Electrical Products & Solutions • February 2016
mum test current, since no more current is available, voltage collapses. This has an added benefit of protecting a damaged test item (IUT) so that it may be restored to service. The quality of a tester may be indicated by the load curve, which shows voltage rise against load resistance. As a general rule, insulation should be at least one Megohm per kV of operating voltage, and well-designed testers will show a load curve where voltage begins to drop at a resistance just below the edge of minimum acceptable. That is to say, a quality tester will exhibit a sharp voltage rise against load, not a lazy rise that doesn’t reach selected voltage until well into the megohm range. (A note: insulation testers, also called megohmmeters, are DC output. AC testers, commonly much larger, heavier, costly and unwieldy to operate, are primarily breakContinued on page 16 down testers or “high-
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FEATURE • Megger
Continued from page 14
pots”, and are more concerned with removing questionable equipment from service than in taking a measurement.) For field workers on the job, time is money. The faster and simpler a tester operates, the more lucrative and efficient is the job. Ergonomics are most important in this respect. For field work, selector switches can make the job significantly easier. The main selector sets the test voltage. You might normally expect five or six selections. These are the prime test voltages for most generic applications, based on operating voltage of the equipment tested. Over the years, this capability has expanded notably with improved technology. The earliest testers could perform a straight test at only one voltage, and other selections had to be marked with a multiplier or divider to adjust the reading against the voltage. Talk about slowing up a job! Later models could then read directly at all selections. But the number of selections was limited. The alternative was a tester with continuously adjustable variac, but while adding almost
infinite voltage settings, this technology brought the operator back to adjusting readings with a multiplier at all but one voltage. Modern testers are the best of both worlds. They may have a voltage adjustment function that is refined to tiny increments, typically 10 or 25 volts, thereby making the tester almost continuously adjustable while able to read direct at any voltage. And finally, if the operator gets distracted, a mere glance at the panel tells him or her what test is being run and how it has progressed. Selector switches provide a definite advantage in speed and efficiency during field work. Industry authorities and regulators may adopt specific test voltages that are separate from standard selections. In such cases, it is eminently convenient to be able to set and retain that specific voltage for easy access. On such testers, the main selector switch will have a setup position as well as a blank voltage selection. The operator can go to the setup, select the desired odd voltage, lock it, and it becomes a convenient selection on the main switch.
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Electrical Products & Solutions • February 2016
Sophisticated testers may have a second selector switch for individual industry-standard procedures. These include polarization index (PI), step voltage (SV), dielectric absorption ratio (DAR), dielectric discharge (DD), and ramp test. PI, SV, and DAR tests could be run manually on old testers, but this is time-consuming and open to operator error. Ramp and DD tests require a specifically designed tester. PI is a long-established favorite that frees the operator from dependence on the actual resistance readings, which can cover an enormous span and be difficult to interpret. Instead, the one-minute reading is divided into the tenminute, and the ratio tells whether the insulation is healthy or suspect. DAR does essentially the same thing with shorter time intervals, in response to newer materials that come to full charge in much less time. SV increases the test voltage in 1-minute intervals. These stress increments can exploit localized damage in otherwise “good” insulation, like cracks and pinholes, that Continued on page 18 might be missed by a
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FEATURE • Megger
Continued from page 16
test at a single voltage. DD measures discharge current that flows from the capacitive and absorptive charges that are stored on the IUT as a result of the test. It is a specialized test particularly good for multi-layered cable where a deteriorated layer is surrounded by good layers that mask its effect. Static charge is stored evenly across good layers, but a bad layer will distort the charge distribution and is recognizable upon discharge. Finally, the ramp test is a more sophisticated version of step voltage, where voltage is steadily increased in 1 volt increments, and the results plotted on a curve. Small defects can be more readily detected, the nature of the flaw can be determined, and the test can be terminated short of breakdown by watching for the departure of current and voltage from a linear function (sometimes called “tip up”). A quality tester will perform these tests automatically. No watching the display and writing down data. The operator can work on something else. You want to run a test at an uncommon voltage? Set the mode selector for a standard insulation test and the main selector to setup. Use arrow keys to move the voltage to the desired level and hit OK. Turn the selector to the open voltage position and hit the test button. You’re good. You want to run a dielectric absorption test? Move the mode selector to DAR and the main selector to setup. Use the arrow keys to select time one of the ratio and time two. Hit OK. Move the selector to the desired voltage and engage the test button. Walk away. The test will be run automatically, the ratio calculated, and the data retained. Similarly, all the various special tests can be set to relevant parameters and run automatically, including timed insulation tests for large equipment that has a long charge time. The operator is freed to work on other tasks and the process is protected from operator error. Another consequence of modern materials is that much higher resistances can be attained. Older testers often top out at a few Gigohms of measurement, leading to the popularity of infinity (∞) readings. But infinity is not a measurement; it merely indicates that the actual value is beyond the measuring sensitivity of the tester. For pass/fail, go/no-go, good / bad testing, this may be enough. But to get the most out of the tester’s capabilities, long range trending of readings provides the ability to head off failures by spotting an unusual 18
drop in resistance early in the process of deterioration. For this, you need extra range, commensurate with what the result would be if the equipment was tested brand new. Modern materials now produce test results in the Tera-ohm (TΩ) range. It isn’t just specmanship; those high readings can be most valuable. Ergonomics are also an important consideration as to the casework enclosing the instrumentation. Even a 15 kV tester can now be made light and portable. But not at the sacrifice of field ruggedness. Test equipment can take a real beating in the “real world”, apart from laboratory conditions. In addition to the physical risk of banging equipment around, testing also presents the electrical danger of arc flash. But protective casework design works at cross purposes when trying to meet these challenges. Fire retardant materials added to casework cause it to be brittle and crack under the rough handling of field work. Dual casework is the answer to this dual problem. An inner case of fire retardant material can suppress arc flash, while an outer shell meets the challenges of rough handling. Power source has always been a major consideration, especially in term s of convenience and practicality. The old on-board hand-cranked generators still command the respect of veteran operators, but for testing up to 15 kV, they just aren’t practical. The size of the typical IUT makes for a lot of cranking! To spare the operator’s arm, motor-driven cranks were developed. Of course, line power is always a good choice, just not always available. The development of dependable, long-lasting batteries addressed that problem, but created another... the dead battery. Again, the best of both worlds now prevails! Dual-powered testers can now run from line or rechargeable battery, even with battery totally discharged. Non-profit agencies establishing standard specifications have proliferated in recent years. These can sometimes appear in short-sight as a nuisance, but actually, they help make testing safe, reliable, and repeatable. Most prominent for insulation testing is the IEC 61010 “CAT” rating. This indicates how protected is the tester against arc flash and arc blast. Always be aware of the CAT rating and don’t assign equipment to a job for which it is not rated. An “event” on the distribution line that day could prove tragic. Not for the
Electrical Products & Solutions • February 2016
operator’s safety, but for the life of the instrument is the IP rating. This indicates how well the instrument is designed to resist environmental attack from dirt, dust and moisture. Be aware of IP ratings. In demanding environments (mines, quarries, manufacturing involving water sprays) replacement of a cheap instrument will quickly chew up whatever price advantage was initially gained. While it is performance that is on everyone’s mind, safety is the bottom line. This article has emphasized safety at several points, and will close on that note. Possibly the best way to be safe is to not be there at all. Sounds ridiculous, but is now actually achievable. For challenging environments... substations a good example because of the danger of arcing... testers can now be operated remotely by a computer. Also, make sure that the CAT rating applies without caveat to all aspects of the process. Some models cut cost by designing the CAT rating to the + and – terminals only. Medium voltage testers typically have a third terminal, the guard. This serves as a shunt to eliminate parallel leakage paths, like surface leakage, from the measurement. The CAT rating may not apply to this terminal. Be certain that it does! On the opposite end of the technology scale are the simplest elements in an insulation test, the leads. Easily overlooked or taken for granted, faulted leads can leave the operator scratching his head, or worse. Leakage between deteriorated leads can adversely affect the measurement, and is easy to overlook. An effective safeguard is double insulation, where the layers are of different colors. As the outer layer wears away, a differently colored layer appears, readily warning the operator that the leads may be deteriorated and coming due for replacement. Locking terminals are also a desirable safety feature. Should a lead become dislodged during testing, as may happen by a passerby stumbling over them, the normal reflex action is to reach for the lead. But a dangerous or lethal static charge may have been built up on the IUT during test. Locking terminals preclude this potential danger. There is much more to insulation testing than can be covered in an article. Major manufacturers offer training courses as well as generic testing manuals that describe the entire process. These are well worth consulting. ❏
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WHITE PAPER • Hioki
Non-Metallic Contact Power Measurement Ensures Safety at the Worksite By Kaoru Kondoh, Sr. Technical Writer, Hioki E.E. Corporation
Introduction Highly conductive metallic contact on voltage clips has always presented inherent risks to both the operator and surrounding equipment, but its use has been unavoidable for analyzing energy usage. New innovations in voltage sensing technology that eliminate metal-to-metal contact coupled with current clamp sensors now make it possible to safely and conveniently measure power without fear of electric shock, production blackouts, or worst of all, injury or loss of life. Power measurement is carried out by calculating the two elements of voltage and current. Because their utilization of clampon sensors to measure current allows them to offer a dramatically improved level of convenience and ease of use, portable power meters have entered into widespread use. This popularity, which derives from the fact that they can be set up and used to perform measurement without disconnecting the target circuit (i.e., while the wires are still live), has transformed power measure-
ment into a more familiar and efficient process. However, it has remained necessary to clip sensors directly to exposed metal in order to measure voltage (for example, cable connections), and those locations are ordinarily thoroughly covered inside distribution panels for safety reasons. The result is a cumbersome series of steps: unlock the panel, remove the cover, put on insulated gloves, and clip on the voltage sensors. The process sometimes causes sparks to fly when the sensors are clipped on as well as short-circuits, which can lead to outages and claims from customers for compensation for resulting damages, and even electric shock. The work causes even professionals with extensive electrical expertise to flinch. All of these problems could be resolved if it were possible to measure voltage from outside wires’ insulation, as it is with current. It would be possible to make measurements without removing distribution panel covers, or even under some circumstances to make measurements from out-
Metal-to-metal contact poses many risks
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Electrical Products & Solutions • February 2016
side the distribution panel. Such capability would give power meter users significantpeace of mind and a new level of convenience. The new technologies being introduced in this article bring a new level of safety and familiarity to power measurement by allowing voltage to be measured from outside the insulation. Figure 1 (on page 22) illustrates the construction of a new type of voltage sensor as well as the measurement principles on which it operates. The voltage sensor has an electrode in the form of a metal plate built into it. When a potential difference exists between the line under measurement and this electrode, a current will flow due to capacitive coupling and electrostatic induction. This phenomenon does not occur with DC currents, but power meters are generally designed for use with 50 Hz or 60 Hz AC circuits, which do exhibit this behavior. The current is extremely small and safe, so much so that you could not feel it. It flows even with the wire’s insulation and Continued on page 22
Safer non contact voltage sensors eliminate potential hazards
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WHITE PAPER • Hioki
Continued from page 20
the voltage sensor’s plastic enclosure between the electrode and the wire under measurement. Naturally, this current increases with the voltage, but it decreases with the distance between the wire and electrode, even if the voltage remains constant. Consequently, direct measurement of the current does not yield data that can be used to calculate the voltage value. New technologies address this issue by
adding a voltage generator to the voltage sensor. The minute current that flows in the electrode as described above is then measured while a voltage is generated inside the voltage sensor. That voltage is adjusted until the current value reaches zero so that they are balanced and no current flows, and the voltage value at that point is measured. Since current flows from areas of high voltage to areas of low voltage, the voltage value under conditions that result in zero
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Electrical Products & Solutions • February 2016
current is equivalent to the measurement target’s voltage. This measurement method has been made possible by technology for measuring minute currents at a high level of precision, accurately controlling and generating voltages, and incorporating these capabilities into a compact measuring instrument. In this way, it is now possible to measure the target voltage without readings being influencedby the thickness of the insulation and without the need to make contact with metal parts. The inherent hazards of power measurement have been greatly reduced as a result, and the range of choices in terms of measurement locations has been greatly expanded. Hioki E.E. Corporation, the developer of this technology, has applied for numerous patents related to these innovative methods, which serve to increase the safety and ease of use of power meters and to popularize power measurement among a larger number of users. They are featured in the Hioki PW3365-20 Clamp On Power Logger. ❏
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Industry NEWS
Advanced Test Equipment Rentals Now Rents Fluke 1736 Power Loggers
A
dvanced Test Equipment Rentals (ATEC) now rents Fluke 1736 power loggers for data collection of power, voltage, current, harmonics and other power quality values. ATEC—a leading rental company of test and measurement equipment for a variety of industries including power, energy, and utility—has added the Fluke 1736 to an extensive inventory of rental equipment. The Fluke 1736 is the latest in a line of Fluke power loggers. This three-phase power logger delivers comprehensive data to optimize system reliability and savings, automatically capturing and logging more than 500 power quality parameters for analysis of power quality and energy consumption. Along with Fluke Connect system of software and wireless tools, technicians can wirelessly transmit measurement data from the 1736 device to their smartphone. ATEC has provided companies with test and measurement equipment rentals
other manufacturers products for rent at www.atecorp.com. ❏ About Advanced Test Equipment Rentals
for 35 years. Renting equipment saves time and money, and renting the latest Fluke 1736 from ATEC can save even more over renting older power loggers. ATEC provides experienced technical and customer support to deliver the products and accessories customers need for performing their tests and analysis. ATEC also offers a large variety of Fluke and
Advanced Test Equipment Rentals is a leading high tech equipment rental company with ISO-9001, ISO/IEC 17025-2005, and ANSI/NCSL Z540 accreditation that provides complete general and special purpose test equipment solutions for analysis, inspection, measurement, monitoring, simulation, powering, certifying, and commissioning of electrical and fiber optic infrastructure as well as product development. ATEC serves an incredibly diverse customer base, made up of aerospace, automotive, biomedical, communications, consumer electronics, defense, environmental, engineering, marine, power grid, transportation, utility and compliance testing companies. To find out more about ATEC visit www.atecorp.com.
Advanced Ephesus LED Systems Light Up Hockey All-Star Games
P
ower management company Eaton announced recently that the biggest names in the National Hockey League (NHL®) and American Hockey League (AHL) will play their all-star events this weekend under its innovative and energy-efficient light-emitting diode (LED) digital lighting system. Bridgestone Arena in Nashville, Tennessee, hosted the NHL All-Star Skills Competition™ on Saturday, Jan. 30, and the NHL All-Star Game on Sunday, Jan. 31. The 2016 AHL All-Star Classic activities took place on Jan. 31 and Monday, Feb. 1, in Onondaga County War Memorial Arena in Syracuse, New York. The two venues are among the latest sports facilities to adopt Eaton’s Ephesus LED system technology to improve lighting, operational flexibility, energy-efficiency and fan engagement. “The combination of improved lighting and fan entertainment elements – coupled with the environmental benefits and lower operating costs – made Eaton’s Ephesus LED system an easy choice to add to our upgrades at the Bridgestone Arena,” said
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Electrical Products & Solutions • February 2016
Tim Friedenberger, vice president, Facility Operations, Bridgestone Arena. “We were especially excited about showcasing the new system during the NHL All-Star Weekend, when the eyes of Continued on page 26 the hockey world were upon Nashville.”
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Industry NEWS
Advanced Ephesus LED Systems Light Up Hockey All-Star Games Continued from page 24
“It’s no surprise that both of these all-star events are at venues illuminated with our digital lighting solution,” said Mike Lorenz, president, Eaton’s Ephesus Lighting business. “We offer specific benefits that are unique to hockey, including the ability to change the color temperature of the light. Also, because our lights emit no heat, there’s less strain on the HVAC system, which results in the best ice condition available.” Every year, the biggest sporting events, like the 2015 professional football championship and this year’s college football national championship games, are played under Eaton’s Ephesus LED system. The two facilities hosting the mid-season hockey festivities are among the most recent professional hockey venues to install an LED lighting solution. In 2012, the War Memorial Arena at The Oncenter in Syracuse, home of the AHL’s Syracuse Crunch, was the first sports arena in North America to make the switch to LED lighting. Bridgestone Arena, home ice for the NHL’s Nashville Predators, installed the system this season. In between, more than a dozen other hockey arenas, including seven other AHL venues and the Canadian Tire Centre in Ottawa, Canada, have made the switch.
Eaton’s Ephesus Lighting business has led the LED lighting explosion at sports and entertainment facilities across North America by engineering digital lighting solutions that provide a significant increase in illumination when compared to all other lighting systems. Ephesus’ LED lighting is brighter than traditional systems and through its industry-leading glare-control innovations, its fixtures shine more uniformly on the playing surface, creating a better stage for players and fans both in the stadium and those watching on high-definition television. The versatility of LED also allows for operational flexibility and the creation of programmable light shows for fan entertainment. Ephesus LED solutions are easy-to-install, virtually maintenancefree for years and offer facilities the lowest total operating costs compared to other sports lighting systems. Since lighting the first sports venue with LED technology in North America in 2012, Eaton’s Ephesus luminaires have been operational for over 200 million hours at indoor and outdoor sports and entertainment venues across North America including the University of Phoenix Stadium, the Canadian Tire Centre, Duke University, Cornell University and many more. For more information, visit www.ephesuslighting.com. ❏
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Industry NEWS
Madison Electric Products Acquires Smart Pathways LLC Madison’s latest acquisition helps the company bridge the gap between the electrical and data communication industries
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adison Electric Products announced recently the acquisition of Smart Pathways LLC, a leading manufacturer and distributor of Smart LB telecommunications conduit bodies. Smart Pathways LLC is the second company Madison has acquired through the Sparks Innovation Center, the company’s crowdsourced product development platform. Conduit bodies have long been part of the installers’ toolbox, but Smart Pathways offers a more advanced solution that solves numerous problems they face on a daily basis. Designed by Ken Bing, managing member of Willow Rest LLC, who drew from his experience as a contractor in both the electrical and data communication areas, the Smart LB conduit body has a built-in elbow that helps prevent cables from getting caught
or damaged when they’re pulled around corners. Unlike traditional LBs that have a sharp 90-degree corner, this helps save time and labor during installation. “We recognize the long-term potential and opportunity in the data communication industry,” said Brad Wiandt, president of Madison Electric Products. “Smart LB conduit bodies complement the existing products we promote in that segment, positioning Madison to establish a much greater presence in this new and growing market.” Smart Pathways’ existing product portfolio consists of six different SKUs, all of which Madison plans to continue manufacturing after the acquisition is complete. Additionally, Madison will work closely with Bing to determine the best way to take the concept further into the market in the future.
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“Madison is the ideal partner to take Smart LB to the next level. I look forward to working with their team to really maximize the potential and reach of our product line,” said Bing. “Smart Pathways is exactly the type of partner we look to work with at Madison. Their vision to revolutionize installation practices underscores our ongoing commitment to innovation and pushing the electrical and data communication industries forward. Further, this acquisition reinforces the success and potential of our Sparks Innovation Center,” added Wiandt. For more information on Madison’s full product portfolio, visit meproducts.net. To submit an idea for consideration through the Sparks Innovation Center, visit sparks.meproducts.net. ❏
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PRODUCT SPOTLIGHT • Platinum Tools
It’s Not Your Fault… but You Have to Find it!
Stop guessing about circuit breaker tripping issues! By George Jang, Platinum Tools
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he bane of every electricians’ existence is the “No Fault Found” scenario: the condition where a circuit breaker will trip without warning and regardless of what you’ve tried, it keeps tripping. You hope when you got the call, that it would be a cake walk; an overloaded circuit, maybe a bad breaker but a day passes, two days… a week later after repeating your troubleshooting routine multiple times, you give up and tell your customer that you have to rewire the entire circuit because there was, “No Fault Found.” These situations are vexing and finding the root cause of the tripping in the first place can be a hassle. You didn’t wire the site so each scenario is different, and the time and cost of finding the problem varies from job to job, leaving you in a precarious situation. Today’s tools and testers can only bring
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you so far to fixing a fault in a line. Without a consistent or reliable way for circuit breakers or connected electronics to “see” certain potentially dangerous events, you are unaware that a fault may be dependent on specific factors and conditions that happen when you are not there. You’re at a point where in order to be able to tell why something’s happened, you need to know what, when and where it happened. All three of these data points are crucial to make sure an electrical line is safe and will not fail or trip circuit breakers due to arc faults or intermittent shorting conditions.
Where Are We Headed? Circuit breakers are improving. Beyond industry requirements, which specify the broadened usage of a new type of sensor called an Arc Fault Circuit Interrupter (AFCI), technology is ever changing and evolving for the better, sometimes keeping up with the industry, and sometimes taking a giant leap forward ahead of new standards. One such advancement has been the introduction of Spread Spectrum Time Domain Reflectometry (SSTDR) to monitor live circuits. SSTDR is designed to be able to see within an electrical line, ignoring the ambient noise created by the power being delivered and see impedance discontinuities that are created with the aforementioned electrical problems such as opens, shorts and arc faults. Patented algorithms and unique methods of application make SSTDR the only technology capable of getting the vision necessary within a live cable/circuit to find faults and show where they are originating from. With such rapid advancement of technology, it’s only a matter of time before SSTDR will reside in circuit breakers, “smart” meters, power transformers, switchgear, and possibly everyday ap-
Electrical Products & Solutions • February 2016
pliances and entertainment devices. The result will be a safer and more transparent electrical system that will save lives and make electricity easier to use from all sources. Until then, there needs to be a stop-gap that will allow technicians a way to find shorts at any given time and even for nonsustained events, especially if the intermittent problem does not trip the circuit breaker. Unknown problems are the worst of all as those tend to be the ones that cause the most damage since they can’t be fixed until it’s too late. With electrical events that happen randomly, or that don’t occur when you are at the site, unattended continuous monitoring has become crucial, but painfully non-existent, until now.
Enter the New Fault Trapper™ For the first time with a portable or installed tester, a technician can now detect the type of fault, timestamp when the fault happens, and locate the position of an electrical “event” that causes intermittent/persistent circuit breaker trips and No Fault Found (NFF) conditions…the critical information needed to reduce call backs for circuit breaker trips. Utilizing SSTDR technology, the Fault Trapper™ is the first of a new class of live circuit monitoring testers intended to locate the distance to a circuit anomaly that is either intermittently causing a change in the circuit’s characteristics or blowing the circuit breaker itself. Running on system, inline power for extended battery life, it captures time and distance to Opens, Shorts, and Arc Faults before saving the event information in memory for later investigation. The last faults can be viewed off-line using the back-up battery. The in-line 40 Amp Module isolates the Continued on page 32
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PRODUCT SPOTLIGHT • Platinum Tools circuit being monitored from the breaker panel and all other breakers. As mentioned earlier, the Fault Trapper™ can now capture and save both types of events separately. If the circuit breaker trips, the backup battery powers the Fault Trapper™ to allow for an orderly shutdown. The last faults can be viewed using the battery power. The In-Line Adapter iso-
Continued from page 30
lates the circuit being monitored from the breaker panel and all other breakers. The Fault Trapper™ is optimized to detect shorts and opens in a dedicated circuit whether or not it trips the circuit breaker. If there’s an intermittent short or open up to the receptacle, it will detect it. And what is most beneficial is the fact that Fault Trapper can be left in place for unattended monitoring of the circuit for hours, days weeks, or even months. All that’s needed is to just set it up, press the Start button to begin monitoring, and walk away. Come back later or the next day/week to find out the why, when, and, where’s of circuit breaker trips and NFF conditions. It runs off system power so it does not draw on its internal battery, which is there to only light up the unit when the “display” button is pushed to see what happened when the breaker trips. The Fault Trapper™ is easy to install, no cutting or stripping of wires, and can be installed in less than 2 minutes. Once set, it will monitor an electrical line of up to 500 feet in length, and capture electrical events that happen along the line or at the load. Even if the breaker does not trip, any energy event will be recorded so that the contractor can see what occurred even though the circuit breaker did not get enough energy to trip itself. The Fault Trapper (P/N TFT100) connects to a 120V/240V AC circuit between the tripped circuit breaker and the load. It is small enough to fit inside the panel for extended monitoring, and is TUV and CEtested to comply with UL and EU safety standards for devices used inside a load center.
Conclusion Once again, the industry will get to a point when circuit breakers will be entirely self-contained and include its own monitoring technologies. Until then, whenever that may be in the years, or even decades ahead, there are an extremely limited amount of options to keep the amount of once potentially unrecognizable hazards and call backs to a minimum. Fortunately, there is a field solution in the form of the Fault Trapper™, available now from Platinum Tools. For more information visit www.platinumtools.com or call 800-749-5783. ❏ FOR FREE INFO, CIRCLE 46 ON READER SERVICE CARD
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Product FOCUS Milwaukee Broadens Its Pliers Offering with 5 Trade-Specific Designs Milwaukee continues to rapidly expand its Hand Tool offering with the introduction of (5) new pliers to its pliers line. The new additions broaden Milwaukee’s current pliers line, and are designed from the ground-up as solutions for trade-specific applications. “Since the launch of our newest generation of pliers earlier this year, we’ve seen a tremendous response from professionals in all trades. These pliers essentially disrupted and revitalized a previously stagnant tool offering, opening doors to incredible jobsite productivity,” said Bobby Shaw, Director of Marketing for Milwaukee Tool. “We are excited to be able to build off that success by broadening the line with 5 additional solutions that combine the best in ergonomics with capabilities specific to trade needs, leading to a more comfortable and efficient user experience.” Milwaukee’s new lineup of pliers will consist of five trade-specific tools: Crimping Pliers, Fencing Pliers, Ironworker’s Pliers, 7” Nipping Pliers, and PVC/Oil Filter Pliers. The Crimping Pliers feature a cutter at the tip for more efficient access into electrical boxes, and have the ability to crimp both insulated and non-insulated wire during the install of stranded wire connections. A patent-pending reaming head design also allows for quicker deburring of EMT. The multi-purpose Fencing Pliers offer maximum versatility with its 6 integrated capabilities: staple puller and pincher, gripping wire, wire cutter, wire puller, and hammer. Specifically designed to stand up to all-day abuse, the Ironworker’s Pliers are designed with an angled handle for better leverage while twisting rebar. The smooth head of the new 7” Nipping Pliers will not mar finished surfaces during pulling and prying. Finally, the new PVC/Oil Filter Pliers feature a versatile 3.5” jaw capacity in a compact 9” size, offering a solution for multiple plumbing and automotive applications. Featuring comfort grips that will not peel, forged designs for rust protection and increased durability, as well as on-board reaming functionality, these new models offer best-in-class performance to the professional user. The new Pliers are backed by a limited lifetime warranty and confirm Milwaukee’s commitment to best-in-class durability and innovation. Dedicated to delivering advanced solutions to increase productivity, Milwaukee’s Hand Tool category now features more than 400 solutions for the trades. For more information, visit www.milwaukeetool.com FOR FREE INFO, CIRCLE 47 ON READER SERVICE CARD
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Product FOCUS Say Farewell to the Harsh, Blinking Overhead Light of Traditional Fluorescents Topaz’s NEW LED Flat Panels Offer Customers More Topaz announces the launch of the new 40and 50 watt LED Flat Panels, a contemporary, elegant and economical alternative to traditional fluorescent fixtures. Topaz LED Flat Panels provide a more evenly diffused, glare-free light that helps lessen eye strain and avoids the need for supplemental lighting sources. Available in three color temperatures from warm white to daylight, the cULus-listed fixtures produce a pleasing, edge-to-edge illumination much more conducive to productivity in a work or learning environment. Edge lit engineering with a high transmission diffuser provides an even light for optimal functionality. “These low profile LED flat panels are a practical solution for replacing fluorescent troffers, resulting in energy savings and reduced maintenance costs,” reports Topaz Lighting’s Product Manager, Michael Neary. “The clean look of these products is aesthetically attractive. They also provide excellent glare-free light distribution, allowing you to easily transition from fluorescent to LED without sacrificing on light output.” These slim profile fixtures are constructed with a white aluminum frame and are designed for easy drop in ceiling installations. The 2’ x 2’ or 2’ x 4’ LED panels offer savings of up to 45% in energy usage over fluorescent fixtures and are rated for use in damp locations. Consumers and add a standard 0-10V dimmer switch to realize additional energy savings; select models are DLC compliant and available with an emergency battery backup that provides up to 90 minutes of uninterrupted service during a power outage. For more information, visit www.topaz-usa.com
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Product FOCUS Southwire Launches New MC-PCS HCF Duo™ Cable for Healthcare Lighting Applications Southwire is first to launch MC-PCS cable for Healthcare facilities. This new metal-clad cable product, MCPCS HCF Duo™ Cable, combines power and control/signal conductors and includes redundant grounding paths to provide approximately 3.5 times better grounding performance than Type AC HCF Cable. “Southwire continues to lead the way in developing products that meet the needs of our customers,” said Norman Adkins, Southwire Electrical Division President. “Our MC-PCS HCF Duo™ cable is another example of Southwire’s innovation and it’s also the first product of its kind to reach the healthcare marketplace.” MC-PCS HCF Duo™ Cable is ideal for use with LED lighting with 0-10V dimming control in patient care areas of hospitals, nursing homes, dental offices, outpatient, and other healthcare facilities. MC-PCS HCF Duo™ Cable combines power conductors for lighting with 0-10V signal conductors for dimming control, and includes Southwire’s patented redundant grounding system comprised of an insulated copper ground and a bare aluminum bonding conductor that is in constant contact with the overall armor. The MC-PCS HCF Duo™ Cable is Made in America and constructed with 12 AWG or 10 AWG CU Type THHN/THWN power and ground conductors along with an oversized bare aluminum bonding/grounding conductor and a signal conductor assembly comprised of a 30 mil PVC jacket covering two 16 AWG CU Type TFN conductors. The power conductors, insulated green ground, and signal conductor assembly are cabled together and a binder tape bearing the print legend is wrapped around the assembly. A bare aluminum grounding/bonding conductor is located outside the binder tape, has the same lay as the insulated conductors, and maintains intimate contact with the overall armor. Green aluminum interlocking armor is applied over the cabled assembly. Yellow stripe/blocks are printed on the outside of the armor and circuit identifying print is applied on every fourth yellow stripe/block. The cable is also available in steel armor or with an overall PVC jacket and comes in 250-foot coils, 1000-foot reels, boxes, or prefab assemblies. For more information, visit mcpcsduo.southwire.com
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Advertiser INDEX 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 and reader service numbers, the publisher is not responsible for errors.
Company
PG#
RS#
Company
2016 BATTCON CONFERENCE AEMC INSTRUMENTS ALOKIN INDUSTRIES AMTEC CORPORATION CANADIAN FLEXIDRILLS CONDUIT REPAIR SYSTEMS CONSTRUCTION INNOVATIONS CONTINENTAL INDUSTRIES COPPER DEVELOPMENT ASSOCIATION DABMAR LIGHTING E-Z METER FACILITY RESULTS GENERATOR INTERLOCK TECHNOLOGIES HARTMAN PRODUCTS HB BRACKETS HERCULES INDUSTRIES, INC. HIOKI USA ITOOLCO
16 IBC, 15 5 34 32 4 22 17 13 38 22 28 7 25 11 38 BC, 9 35
40 2, 13 7 47 46 6 41 14 12 50 42 45 8 18 11 51 3, 9 23
KRENZ & COMPANY LARSON ELECTRONICS MILLER SAFETY CONSULTANTS, LTD MITSUBISHI ELECTRIC POWER PRODUCTS, INC. NET ZERO USA NONCONDUCTIVE TOOL CO., LLC NORTHWEST LIGHTING SYSTEMS ORBIT INDUSTRIES, INC. PHASE-A-MATIC PLATINUM TOOLS POWER & TEL RANDL INDUSTRIES ROCKET RACK ROLL-A-REEL SP PRODUCTS TCP TOPAZ UTILITY METALS
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PG#
RS#
28 23 39 3 37 IFC 31 26 36 19 27 33 40 36 1 29 21 10
44 17 25 5 24 1 21 43 48 15 19 22 52 49 4 20 16 10
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