EPS Magazine, June 2012

0612EPSpC1:Layout 1

6/8/12

11:23 AM

Page C1

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:17 AM

Page C2

FOR FREE INFO, CIRCLE 1 ON READER SERVICE CARD

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:17 AM

FOR FREE INFO, CIRCLE 4 ON READER SERVICE CARD

Page 1

0612EPSp02.qxd:Layout 1

6/8/12

10:52 AM

Page 2

CONTENTS

PUBLISHER

Danny J. Salchert OFFICE MANAGER

Anita Salchert ASSOCIATE PUBLISHER

Jerry DiChiara jerryd@epsmag.net CREATIVE DIRECTOR

Derek Gaylard CONTRIBUTING WRITER

Jeff Jowett CIRCULATION DIRECTOR

Pam Fulmer

18 FEATURES 6 Ramp Testing in Identifying and Preventing Insulation Failure

By Jeff Jowett

18 26

Solar Farm Underground Wiring to Last as Long as the Sun with HDPE Conduit Beyond Lighting – Sustaining Energy Efficiencies in Your Facility

DEPARTMENTS 30 Industry News 34 Product Focus 40 Ad Index ON THE COVER Megger MIT1025 10kV Insulation Tester Photo courtesy of Megger

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

2

Electrical Products & Solutions • June 2012

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:17 AM

Page 3

FOR FREE INFO, CIRCLE 5 ON READER SERVICE CARD

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:18 AM

Page 4

FOR FREE INFO, CIRCLE 6 ON READER SERVICE CARD

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:18 AM

FOR FREE INFO, CIRCLE 7 ON READER SERVICE CARD

Page 5

0612EPSp06,08,12,14,16:Company Spotlight

6/8/12

10:21 AM

Page 6

FEATURE • Megger

Ramp Testing in Identifying and Preventing Insulation Failure

By Jeff Jowett

T

HE TESTING OF ELECTRICAL INSULATION has seen the development of numerous specific procedures with the intent of examining and stressing insulation quality in different ways in order to call attention to different possible issues and problems. Insulation resistance is, of course, designed to be of a high value in order to keep circuitry isolated from other circuitry and from ground. Over time, just the wear and tear of normal usage will cause insulating material to degrade and reduce its insulating quality. Added to this process are localized and sometimes catastrophic events such as voltage spikes and surges, water ingress and the incursion of contaminants that will both speed and heighten the process of degradation. Consequently, insulation resistance is tested both as a maintenance procedure, to keep equipment within desired operational parameters, and as a troubleshooting function, in response to known or suspected problems.

6

Electrical Products & Solutions • June 2012

Simply taking a spot resistance reading with a megohmmeter is often all that is required of a given situation. But at other times, more exhaustive testing is in order to identify the problem.

These are typically the bedeviling “intermittent faults”, where equipment successively runs and trips. An added goal of preventive electrical maintenance is to anticipate such contingencies before they develop and take measures to head them off. Accordingly, numerous procedures have been developed that make use of the insulation tester to give information well beyond the mere resistance number at a given time.

By way of quick review, insulation resistance testing is accomplished by the application of a comparatively high voltage (typically on the order of system-rated to twice system-rated) across a body of insulating material and measuring the amount of current, called “leakage”, that gets through the material; in essence, going where it’s not supposed to go if Continued on page 8

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:18 AM

Page 7

FOR FREE INFO, CIRCLE 8 ON READER SERVICE CARD

0612EPSp06,08,12,14,16:Company Spotlight

FEATURE • Megger

6/8/12

10:22 AM

Continued from page 6

equipment were operating well. The amount of current is miniscule; micro- or even nano-amps. By the time the natural degradation process has permitted leakage current to reach levels as “high” as milli-amps, the insulation is breaking down and soon will no longer be doing its job. On a 120V circuit, the human body normally begins to fell a “tingle” at about half a milli-amp.

One of the fundamental test procedures developed early in the use of megohmmeters (circa 1950) is the familiar and popular Step Voltage Test. Put simply, this is an examination of the response of the insulating material, in terms of resistance, to increasing voltage stress. Within broad parameters, “good” insulation should be able to stand up to increases in voltage. But if the material is deteriorated, each voltage increase will exploit additional leakage paths by pulling current through more and more cracks, burn tracks, water trees and the like. As voltage increases, current increases, and resistance drops accordingly.

As the testers themselves have developed over the years, the implementation of this test has become simpler. As long as more than one test voltage is available, a simple Step Voltage Test can be performed manually. But modern testers have multi-voltage selection that reads directly, without having to adjust the reading to the voltage as was necessary with older models. Such units can easily perform the test manually, by turning the selector switch, noting the time and marking down measurements. Even more advanced megohmmeters do the whole thing automatically. Typically, only the voltage ceiling need be selected and the Step Voltage mode engaged, and such models will run the test automatically, displaying all relevant data at the conclusion. Accordingly, an industry-standard procedure has evolved where five successive voltages are applied for one minute each. If a 5 kV ceiling is selected, the test will run at 1, 2, 3, 4, and 5 kV for one minute each, a total of a five-minute test. As always with insulation resistance testing, comparison to previous results is the best evaluation, but for sake of perspective, a general rule is that more than a 25% change indicates an excess of contaminants (Fig. 1).

One of the principle values of this test is that it can With insulation reveal problems that may have been overlooked in resistance testing, the results of other tests.

An example is the single a general rule is point of localized damage that more than in otherwise good insulation. A voltage spike may a 25% change have caused a pinhole.

With air (a good insulator) indicates an now filling the space preexcess of viously occupied by insulating material, a spark gap contaminants. exists that may go unnoticed by a simple resistance measurement. This can also be the source of an aggravating intermittent failure problem. But the Step Voltage Test may well arc the spark gap and expose the flaw. Similarly, aged insulation, by virtue of drying out, may yield a deceptively high value against a single resistance test. But such material often has cracks and similar flaws that make the equipment poised on the verge of breakdown. A Step Voltage Test will pull more current through more of these 8

Page 8

Electrical Products & Solutions • June 2012

Figure 1

flaws with each increase, and readily reveal an impending failure.

The increasing sophistication of modern megohmmeters has led to a refinement of the Step Voltage concept to a whole other level, the Ramp Test. Rather than increasing test voltage in discrete jumps (industry standard are 500 V and 1 kV increments), the ramp test applies voltage in a continuous increase at a constant rate, up to the selected maximum. The response of the insulating material to voltage can be assessed in a much subtler and more detailed manner, without the jarring effects of quantum leaps. Small defects can be detected more readily, and equipment that is on the verge of breakdown can be analyzed without risking damage. Leakage current is graphed continuously against voltage rise. Normally, the relationship would be expected to be linear, but if current begins to rise more sharply, the material is breaking down and the test can be terminated prior to the occurrence of full breakdown.

Continued on page 12

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

FOR FREE INFO, CIRCLE 9 ON READER SERVICE CARD

11:18 AM

Page 9

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:18 AM

Page 10

FOR FREE INFO, CIRCLE 10 ON READER SERVICE CARD

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:19 AM

FOR FREE INFO, CIRCLE 11 ON READER SERVICE CARD

Page 11

0612EPSp06,08,12,14,16:Company Spotlight

FEATURE • Megger

6/8/12

10:22 AM

Continued from page 8

Figure 2

The Ramp Test has been evaluated by standards agencies, and is described in IEEE 95-2002, The IEEE Recommended practice for insulation testing of AC electric machinery (2300 V and above) with high direct voltage. The recommended rate of voltage rise from the standard is 1 kV per minute. Some testers may also permit adjustment of this rate. The IEEE standard conveniently provides graphs of current curves of typical problems, for comparison of test results. Defects like cracks, voids, delamination, moisture ingress, surface contamination and uncured resin may all be detected. The IEEE has recommended the method especially for epoxy-mica, polyester, and asphalt maFigure 4

Figure 5

12

Page 12

Electrical Products & Solutions • June 2012

Figure 3

terials. (The standard also prescribes that the equipment under test be first subjected to an insulation resistance or Polarization Index test according to IEEE 43-2000 so as to assure that the equipment is suitable for higher voltage testing.)

The evaluation of test results first prescribes that insulation in good condition should produce a smooth, almost linear rising current curve against the applied voltage. Any deviation should be viewed as a warning that the test could be approaching a possible breakdown. A sudden increase in current usually indicates imminent breakdown, and it has been possible to approach as closely as 5% below breakdown voltage. An abrupt drop in current is rare, but if it occurs when test voltage is above peak operating voltage, it can also be an indication of imminent breakdown. Comparing the curves of asphalt-mica to epoxymica shows that asphalt-mica has a higher level of absorption current, resulting in a steeper curve. But both produce clean, linear graphs when in good condition (Figs 2 & 3).

By contrast, insulation having absorbed moisture produces a sharp rise in current, and the test would have been stopped (Fig. 4). Old asphalt may produce a slightly non-linear response showing small deviations as “blips”, whereas significant localized weaknesses will show a sudden, larger increase (Fig. 5). The test would be terminated as the graph approached vertical. Cracks in ground wall insulation will show a sudden near-vertical rise, often preceded by small spikes (Fig. 6). It is also useful to compare Continued on page 14 the current curves from different phases.

Figure 6

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:19 AM

Page 13

FOR FREE INFO, CIRCLE 12 ON READER SERVICE CARD

0612EPSp06,08,12,14,16:Company Spotlight

FEATURE • Megger

6/8/12

10:22 AM

Continued from page 12

Figure 7

All three should provide comparable results. A phase that shows a different response usually indicates a problem with insulation condition (Fig. 7).

Among the ticklish problems that this technique has been successfully used to identify are tape separation, end-arm partial discharge and contamination, delamination and lack of resin cure. As an example, an 11 kV 21 MVA hydro transformer installed in 1928 was tested and yielded an acceptable PI of 3.8 on asphalt-mica insulation. A simultaneous ramp test graph, how-

FOR FREE INFO, CIRCLE 40 ON READER SERVICE CARD

14

Page 14

Electrical Products & Solutions • June 2012

Figure 8

ever, showed instability as low as 5 kV (Fig. 8). The winding was prone to overheating due to the cooling ducts in the core becoming blocked by oily dirt. The stator was eventually rewound. Similarly, tests were made on an asphalt-mica-insulated 13.8 kV winding of a hydro generator installed in 1961. After 37 years in service, repairs were made near the stator frame, and involved the use of water. Testing revealed leakage current in excess (Fig. 9), and a dry-out did not improve the measurements.

The results of partial discharge and ramp tests Continued on page 16

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:19 AM

FOR FREE INFO, CIRCLE 13 ON READER SERVICE CARD

Page 15

0612EPSp06,08,12,14,16:Company Spotlight

FEATURE • Megger

6/8/12

10:22 AM

Page 16

Continued from page 14

Figure 9

Figure 10

suggested the loss of a bond between layers of mica tape. A In such manner, ramp test results are a useful tool in clarifyrewind was finally performed, with a rating increase from 37.5 ing vague or conflicting data from other tests, and in identifying to 50 MVA. Another example is that of a 13.8 kV roebel bar specific problems on equipment known to be faulted yet showwinding in a hydro generator that was not ramp tested upon in- ing acceptable results against other procedures. ❏ stallation. Ramp testing was performed shortly after the results of 3 and 1 short circuit tests (Fig. 10), and physical damage Source of information and examples: in the end arm area was suspected. This proved not to be the W. McDermid & J. C. Bromley, Manitoba Hydro, case, and a ramp test still showed leakage 2 years later. But afThe Ramp Test – Its Origins, Development and ter another 5 years, the condition had disappeared. The concluApplication, IEEE Transactions on Dielectrics and sion was that test results reflected the curing of epoxy-mica.

Electrical Insulation, Vol. 17, No. 5, Oct. 2010.

FOR FREE INFO, CIRCLE 41 ON READER SERVICE CARD

16

Electrical Products & Solutions • June 2012

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:19 AM

Page 17

FOR FREE INFO, CIRCLE 14 ON READER SERVICE CARD

0612EPSp18,20,22,24:Company Spotlight

6/8/12

10:24 AM

Page 18

FEATURE • Plastics Pipe Institute

Solar Farm Underground Wiring to Last as Long as the Sun with HDPE Conduit

Vermont Governor Peter Shumlin spoke at the commissioning of the solar farm.

T

HE LARGEST SOLAR FARM of its kind in North America elected to locate power and control cables in underground conduit made from high-density polyethylene (HDPE) as a way to increase the life of the facility.

Coming online in July 2011, the 2.2 MW solar farm covers 25 acres and includes 382 solar trackers. Cables convey power from the solar trackers to the electric grid.

AllEarth Renewables, Inc. (Williston, VT), designed the solar farm and manufactured the AllSun Trackers™ Series 24 solar trackers.

“From a sustainability standpoint,

18

HDPE pipe and solar power are a unique partnership,” stated Tony Radoszewski, executive director of the Plastics Pipe Institute, Inc. (PPI), the major trade association representing all segments of the plastic pipe industry.

“Like solar, a plastic pipe system is a sustainable and environmentally responsible choice that will serve generations to come. The HDPE conduit is ecologically efficient during manufacturing. The conduit is also strong, durable, light-weight and flexible while providing excellent protection for the power and fiber cables inside, and requires significantly less en-

Electrical Products & Solutions • June 2012

ergy to fabricate, transport and install than other pipe products. And here in Vermont, HDPE conduit is the perfect choice to stand up to the extreme cold weather and frozen earth, plus it was the key to a successful trenchless run in one section.”

Installation of the HDPE conduit was done using cut and cover, and horizontal directional drilling (HDD) under a forested area. All low voltage wiring used UL 1990 certified Cable In Conduit (CIC) provided by Blue Diamond Industries, LLC (Lexington, KY). Blue Diamond is a member company of the PPI. The AllSunTracker Continued on page 20

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

FOR FREE INFO, CIRCLE 15 ON READER SERVICE CARD

11:19 AM

Page 19

0612EPSp18,20,22,24:Company Spotlight

6/8/12

10:24 AM

FEATURE • Plastics Pipe Institute conduit included nearly 70,000 feet of 3/4 inch CIC pipe with three 6AWG cables black, green and white - and 5,000 feet of 2.5-inch diameter CIC with 4/0 wiring for the panel feeder lines. Blue Diamond supplied Cable In Conduit on reels ranging from 2,000 to 10,000 feet. The company is listed by UL for specification UL 1990, Nonmetallic Underground Conduit

Page 20

Continued from page 18

with Conductors and its CIC is manufactured under ASTM D 3485.

“Most solar farms use underground PVC pipe,” stated Doug MacDonald, engineering technician for AllEarth. “Wire is pulled onsite after conduit installation.

HDPE conduit saves in multiple ways that includes less labor to install. For this project, the HDPE conduit came

FOR FREE INFO, CIRCLE 42 ON READER SERVICE CARD

20

Electrical Products & Solutions • June 2012

preloaded with the wire, so it was really just a one step process after digging the trench. It also enabled us to use a smaller conduit size, reducing the cost of materials. In addition, less handling meant more savings.”

“Typically when other types of conduit are used, it can turn into a very labor-intensive project,” explained Radoszewski.

“This is because a trench must be dug, the conduit installed and then a pull rope is blown through the conduit so that each wire can be pulled back through. Because the HDPE conduit can have the wire installed when the pipe is being extruded, it comes to the job site ready to go. This saves considerable time.

“Custom lengths can be ordered and sometimes a single reel will hold thousands of feet, which puts more conduit at the site to further expedite installation,” he continued.

“Installing the cable in the conduit at the factory ensures that a clean and damage-free cable is delivered to the field.

CIC also eliminates the added expense of pulling the cable onsite under muddy and dusty field conditions which aren’t the best for a good clean installation.”

The AllSun Trackers are pole-mounted, dual axis trackers that follow the sun throughout the day guided with a GPS system. Each of the 382 units move from east to west and up and down, tracking the sun in order to maximize efficiency as it transforms solar energy into electrical energy. Total power produced by the South Burlington Solar Farm is estimated to be approximately 3,000,000 kilowatt hours a year — 45 percent more than the amount of electricity that could be produced by a fixed roof-top photovoltaic system of the same size. The project is owned and operated by the Chittenden County Solar Partners, LLC. The value of the electricity generated by the farm has been tagged at $924,000 a year and is enough to power more than 400 homes.

While most of the installation was accomplished using cut and cover, the HDPE conduit also provided the solution to go under a heavily forested section of private property and a section of wetland.

“We directionally drilled two, 400-foot runs of five-inch diameter HDPE pipe used for the main power feed and communication cables,” explained Aaryn French, project manager Continued on page 22

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:19 AM

Page 21

FOR FREE INFO, CIRCLE 16 ON READER SERVICE CARD

0612EPSp18,20,22,24:Company Spotlight

6/8/12

10:24 AM

FEATURE • Plastics Pipe Institute for Engineers Construction, Inc. (Williston, VT).

French agreed having CIC was a benefit.

It took his four-person crew just a month to install all the low and medium voltage conduit at an average depth of three feet.

“The trenching, which was the majority of the work, went very smoothly as well. It was nice because we’d just start pulling the wire out and leave the proper length at the end and just lay it right in the ground. This was more efficient than using sticks of PVC - probably five to ten times faster.

“And because we had the cable already in the conduit, it saved us a lot of time.

We were killing two birds with one stone.

Installing the pipe and wire at the same time — that was a huge benefit.

“This is probably one of the biggest applications of using CIC in this specific manner. In this application it was cost efficient, time efficient and it just worked really well.” French continued. “That’s because we weren’t trying to put together Continued on page 24 PVC, and putting a

Page 22

Continued from page 20

AllSun Tracker units are solar panels mounted on poles and use an internal GPS system to move with the sun as it crosses the sky, keeping the solar panel at a perpendicular angle to the sun’s rays. The use of HDPE Cable In Conduit sped installation and reduced costs while increasing the lifetime of the 25-acre, 382-unit system.

FOR FREE INFO, CIRCLE 43 ON READER SERVICE CARD

22

Electrical Products & Solutions • June 2012

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:20 AM

Page 23

FOR FREE INFO, CIRCLE 17 ON READER SERVICE CARD

0612EPSp18,20,22,24:Company Spotlight

6/8/12

10:24 AM

FEATURE • Plastics Pipe Institute

Page 24

Continued from page 22

plications. Plus, there is a strong move today for communities to take existing overhead lines and bury them to eliminate ‘wire blight’ and provide safer and more secure power and telecom systems, which are also protected from severe weather.”

For more information, please visit www.plasticpipe.org. ❏

pull string in and pulling the wire....this was a one shot deal....you complete the trenching, you know your two end locations, tie it in, backfill and you’re done.”

“We’re seeing more and more power

and fiber optic cables being put underground,” Radoszewski said. “This is especially true of new housing and building construction. CIC is also very popular for installing FAA lighting for airport ap-

FOR FREE INFO, CIRCLE 44 ON READER SERVICE CARD

24

Electrical Products & Solutions • June 2012

About PPI: The Plastics Pipe Institute Inc. (PPI) is the major trade association representing all segments of the plastic pipe industry and is dedicated to promoting plastics as the material of choice for pipe applications.

PPI is the premier technical, engineering and industry knowledge resource publishing data for use in development and design of plastic pipe systems. Additionally, PPI collaborates with industry organizations that set standards for manufacturing practices and installation method.

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

FOR FREE INFO, CIRCLE 18 ON READER SERVICE CARD

11:20 AM

Page 25

0612EPSp26,28:Company Spotlight

6/8/12

10:25 AM

Page 26

FEATURE • Acme Electric®

Beyond Lighting – Sustaining Energy Efficiencies in Your Facility

W

ITH RISING ENERGY COSTS and an increased focus on environmental responsibility, maximizing energy efficiency is becoming more important in today’s business world. Companies seeking to reduce their utility costs and achieve their sustainability goals are taking a closer look at every aspect of their facilities to improve efficiency wherever possible.

However, many companies don’t realize that a good place to find savings is in the transformers that power a facility. Transformers are typically energized 24 hours a day, and have a significant impact on energy consumption. To that end, Acme Electric has developed an energy efficient solution; the Acme POWERWISE C3 Transformer.

The C3 will help make a positive difference in bottom-line profitability and environmental impact. Manufactured with high-grade electrical steel, the C3 delivers dependable, sustainable perfor-

26

Acme transformers have 30% lower losses than the older TP-1 transformers since they are fabricated with higher-grade electric steel which maximizes performance and efficiency. mance and fewer no-load losses than the typical TP-1 efficient transformer.

Long-Term Reliability and Energy Efficiency The transformers of the Acme POWERWISE C3 are copper wound, 3-phase common-core, dry-type, ventilated isola-

Electrical Products & Solutions • June 2012

tion transformers. These transformers have 30% lower losses than the older TP1 transformers since they are fabricated with higher-grade electric steel which maximizes performance and efficiency.

With higher transformer efficiencies, more of the power delivered to the facility is converted to useful power—for running lights, computers, processing equipment and other applications essential to the organizational needs—versus being lost into the environment in the form of heat. Moreover, reducing heat means less HVAC power is required to cool the room enclosing the transformer.

In addition to energy efficiency, C3 transformers are built to keep up with new technologies. Electronic lighting ballasts have grown in popularity, and variable speed drives have become the standard in motor-drive applications.

These technologies, and others such as switch mode power supplies used in computers, produce harmonic Continued on page 28

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:20 AM

Page 27

FOR FREE INFO, CIRCLE 19 ON READER SERVICE CARD

0612EPSp26,28:Company Spotlight

6/8/12

10:25 AM

FEATURE • Acme Electric® currents in the electrical circuits. If the design does not take into account these harmful currents, transformers can overheat, further reducing the transformer’s efficiency. The Powerwise C3 transformer is K- Factor 13 rated to ensure that the transformer runs cool, quiet, and efficiently under non-linear loads.

Page 28

Continued from page 26

Cost Savings—Year After Year The total cost over the life of the transformer, or life cycle cost, should be the most important factor when deciding which type of transformer to install. Depending on the size of the transformer, the number of transformers used in an installation, and the load on the transformer, the total savings from

implementing a POWERWISE C3 could amount to thousands of dollars per year.

Life cycle costs are comprised of the upfront purchase cost plus annual energy use costs. Often in the commercial market, upfront costs alone are the major factor in the purchasing decision. This generally results in the installation of a lower efficiency transformer where losses become embedded into the electrical system for the life of the transformer. By factoring in full life cycle costs—beyond the upfront purchase expense which may only be 4% of the total lifecycle cost— facility users can enjoy lower annual energy expenses which becomes significant over the typical 25-year field life of a transformer.

It is also important to consider the inflationary trends in electrical rates, and the already high rates—or cost per kilowatt hour—for electricity when considering the purchase of a transformer.

When accounting for all these factors, the long-term cost savings of the C3 more than makes up for the initial purchase price difference of the TP-1. Such substantial lifetime savings come from the C3 meeting and exceeding the US Department of Energy’s Candidate Standard Level 3, commonly called C3, efficiency standards.

Going Green The high-grade electrical steel and the wound core construction enables the C3 transformer to generate 30% lower core losses than typical TP-1 transformers.

The reduction in these core losses results in energy savings year after year. Because transformers typically operate at approximately 35% of full load during hours of operation and 20% during off hours, core losses (also called no-load losses) of the transformer make up a significantly larger portion of the total transformer losses. Because no-load losses are present even when transformers are lightly loaded, they are critical to overall efficiency UL and CSA listed, the Acme POWERWISE C3 transformer is constructed to ANSI/IEEE Standards.

With an unsurpassed, 25-year pro-rated warranty the C3 will be performing well into the future. ❏ For more information visit acmetransformer.com.

FOR FREE INFO, CIRCLE 45 ON READER SERVICE CARD

28

Electrical Products & Solutions • June 2012

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

FOR FREE INFO, CIRCLE 20 ON READER SERVICE CARD

11:20 AM

Page 29

0612EPSp30,32,33:Company Spotlight

6/8/12

10:26 AM

Page 30

Industry NEWS

Kaiser Electric Building New Water Treatment Plant in Staunton, IL

Kaiser Electric is on track with its portion of a new water treatment plant under construction in Staunton, IL. Work on the $8 million facility began in December 2011 and is expected to be completed in February 2013. The new facility is located at 935 North Easton Street, approximately 25 minutes north of Downtown St. Louis along Hwy. 55 and Illinois Rt. 4.

The new Staunton Water Treatment Plan will utilize a stateof-the-art Dissolved Air Flotation (DAF) Clarification system that works to remove a significant amount of algae at the beginning of the treatment process, thus drastically reducing the need for expensive treatment chemicals, often used in a traditional sedimentary process. Approximately 80 percent of the facility will be located underground, with major structures and piping out of view and designed to blend in with its surroundings.

The total project includes installation of one building to house the water treatment plant, installation of the Clari-DAF system, three dual media gravity filters, one standby generator, one bridge crain, one buried sand wastewater filter, one chemical feed system, two high service pumps; and installation of pipe for process sewers, storm sewers, chemical feed, process water, potable water, non-potable water and sludge.

Kaiser Electric’s crews are charged with installing electrical service for the new plant, plus providing new service to an existing pump station. Additionally, Kaiser will install two standby generators and all of the power, lighting, distributive control system for all pumps, aeration, filters, tanks, valves and chemical feed systems at the new facility.

Kaiser Electric has also previously worked on the O’Fallon water treatment plant project, as well as the Coldwater Creek, Lemay, Washington and Lower Meramec waste water treatment facilities.

The general contractor on the Staunton project is Korte & Luitjohan Contractors, Inc. of Highland, IL and the architect/engineer is Heneghan & Associates of Columbia, IL. ❏ FOR FREE INFO, CIRCLE 46 ON READER SERVICE CARD

30

Electrical Products & Solutions • June 2012

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

FOR FREE INFO, CIRCLE 21 ON READER SERVICE CARD

11:20 AM

Page 31

0612EPSp30,32,33:Company Spotlight

6/8/12

10:26 AM

Page 32

Industry NEWS

Cooper Lighting’s LED Solutions Boost Long-Term Sustainability at Hartsfield-Jackson Atlanta International Airport Airport officials aim to optimize energy savings while also providing a safe and well-lit parking environment for passengers.

Officials at Hartsfield-Jackson Atlanta International Airport recognized a need for upgrading the parking garage lighting that would optimize energy savings, while con-

tinuing to provide a safe and well-lit environment for its passengers. Analyzing multiple products and their performance to find the best solution, they selected LED fixtures

from Cooper Lighting, an industry leader committed to delivering innovative products and driving transformational technology in the lighting industry.

Funded by the City of Atlanta Green Loan Fund, Hartsfield-Jackson Atlanta International Airport officials decided to replace each of the 4,342 210-watt metal-halide fixtures with Cooper Lighting’s 80-watt McGraw-Edison Valet LED fixtures in its north and south parking decks.

This decision would not only lead to greater energy-efficiency, but also cost savings of almost half a million dollars each year. According to the City of Atlanta’s Office of Sustainability, the Airport’s financial and environmental partner, the carbon reduction associated with the project is equivalent to taking 500 cars off of the road.

“Replacing parking garage lighting with more energy-efficient options is one of the most practical upgrades a city can make to save energy, reduce costs and lower CO2 emissions,” said Mark Eubanks, President, Cooper Lighting. “This project has been a great opportunity to showcase how Cooper’s innovative LED products can increase overall efficiencies and performance to provide a safe and well-lit environment, all while helping the City of Atlanta save almost $500,000 each year in energy costs.”

Cooper’s modular LightBAR™ technology, featuring patented AccuLED Optics™ system, delivers uniform and energy conscious illumination. Both factors were key to Airport officials who hoped to improve the distribution of the lighting in the Airport parking garages while also optimizing energy savings. ❏ FOR FREE INFO, CIRCLE 47 ON READER SERVICE CARD

32

Electrical Products & Solutions • June 2012

0612EPSp30,32,33:Company Spotlight

6/8/12

10:27 AM

Page 33

Rosendin Electric Begins Phase 2 of a Major Data Center Build-Out in Virginia’s High-Tech Corridor DPR Construction Contracts Rosendin Electric to Complete the Next Phase of Design/Build for a New High-Performance Data Colocation Center The Mid-Atlantic office of Rosendin Electric, one of the nation’s largest private electrical contractors and a 100% employee-owned company, announced that the company has been awarded the second phase of a major data center build-out in the Northern Virginia High-Tech Corridor. Rosendin Electric is subcontracting to DPR Construction to complete the data center design and construction project for an unnamed data colocation service.

Rosendin Electric recently completed the successful first phase of the design/build project. This second phase of construction includes five 2 megawatt pods designed to

tier 3 data center specifications and is delivery of the finished pod this fall.” ❏ scheduled for completion by October 2012.

This contract strengthens Rosendin ElecAbout Rosendin Electric tric’s presence in the burgeoning Mid-At- Rosendin Electric, Inc., headquartered lantic market, and provides another proof in San Jose, California, is a 100% point for the company’s strength in data employee-owned electrical engineering, center design/build. power and communications provider “We’re immensely gratified at the and is one of the largest privately held confidence that DPR Construction exelectrical contractors in the United presses in Rosendin Electric with the States. With over 2,500 employees, award of this important contract,” said Rosendin Electric has offices and Alan Linder, Division Manager for experience nationwide and has built Rosendin Electric, “We’re eager to upon a 90-year reputation for quality move quickly through design and pre- design and installations. For additional construction and on toward successful information, visit www.rosendin.com.

Hawaii Pacific Solar installs Conergy Solar Modules and Mounting Systems for Department of Education at Aeia High School in Honolulu PPA for 122.675kW roof-top installation project provided by RC Energy In an effort to bring down costs while showing its commitment to sustainability the State Department of Education has partnered with Hawaii Pacific Solar, Conergy and RC Energy to complete a series of solar electric installations at public schools on Oahu in Hawaii. The 122.675kW installation at Aiea High School completed by local clean-energy integrator Hawaii Pacific Solar (HPS) marks the completion of the first of many installations to come in Hawaii for the DOE and HPS. DOE and HPS selected partners Conergy to supply quality product and RC Energy to secure funding for the projects. With 522 Conergy modules attached to a Conergy SunTop mounting system, the solar installation will produce approximately 174,000 kWh annually preventing 264,600 pounds of carbon dioxide from entering the atmosphere – equivalent to the CO2 emissions from 13,428 gallons of gasoline or from 270 barrels of oil.

With this installation, Aiea High School will realize a substantial cost savings on its current energy usage.

The school is estimated to save more than $500,000 over the 20-year life of the photovoltaic system.

“We are very pleased to be part of the State Department of Education’s effort to conserve energy at our schools,” said Bob Johnston, president and CEO of HPS. “Aiea High School’s staff and students have really embraced energy conservation and other sustainability efforts, and it’s a distinct pleasure to be working with them.”

HPS was awarded a Department of Education (DOE) contract to install solar energy systems at Aiea, Kahuku, Kaimuki and Waianae high schools under a Power Purchase Agreement (PPA) whereby the system is owned, operated and maintained

by RC Energy.. Because of the PPA Agreement, the installation comes at no upfront cost to the DOE. And, as part of the PPA agreement between Conergy and RC Energy, Conergy has guaranteed the construction and performance of the project to RC Energy.

Additional sites awarded by the DOE will be completed over the next 12 months.

“Hawaii Pacific Solar has done more than just provide a PV system. They have given us curriculum materials on solar energy, a sun safety program and a flat screen monitor that allows student to do

real-time monitoring to the see the amount of power being generated and the amount of carbon reduction and energy saving as a result of the solar panels,” noted Aiea High School Principal Michael Tokioka. ❏ About HPS Hawaii Pacific Solar (HPS) is a leader in the development, design and installation of solar photovoltaic power solutions for commercial businesses, educational facilities, government, military and utility grade installations. HPS designs and provides financing for both grid connected photovoltaic systems and hybrid systems.

If you have industry news that you would like published in Electrical Products & Solutions magazine please email it to danny@epsmag.net for review.

June 2012 • epsmag.net

33

0612EPSp34-40.qxd:Company Spotlight

6/8/12

10:44 AM

Page 34

Product FOCUS New CHANNELLOCK® 7.5” 758 Flush Cutter Offers Professionals Clean, Precise Cuts in Hard-to-Reach Spaces Channellock Inc., the company known worldwide for manufacturing quality pliers, introduces the 7.5” 758 flush cutter as the latest addition to its product catalog. The plier is specifically designed to cleanly cut plastic ties and up to 10-20 AWG copper wire in difficult-to-reach spaces, leaving behind clean edges that won’t snag skin or clothing for professionals who commonly work with these materials.

“Professionals appreciate tools that make their job both easier and safer, and that is the motivation behind the 758 flush cutter’s design,” said Ryan DeArment, vice president of sales and marketing at Channellock, Inc. “The 758 flush cutter is an extension of our 728 long reach plier, a tool that is already widely used for jobs in tight spaces.”

Ideal for the electric, auto mechanic, aviation, information technology and general construction trades, the 7.5” 758 flush cutter is a solution for cutting wire closer to solder joints and snipping plastic zip ties. Its laser heat-treated cutting edges cleanly shear through plastic and up to 10-20 AWG copper wire, while its small nose enables close, precise cuts that eliminate any sharp tips.

Like all CHANNELLOCK® pliers, the new 7.5” 758 flush cutter is fiercely made in Meadville, Pa., featuring drop-forged, highcarbon C1080 North American steel and the signature CHANNELLOCK BLUE® comfort grips.

For more information, visit www.channellock.com

FOR FREE INFO, CIRCLE 48 ON READER SERVICE CARD

34

Electrical Products & Solutions • June 2012

FOR FREE INFO, CIRCLE 49 ON READER SERVICE CARD

0612EPSp34-40.qxd:Company Spotlight

6/8/12

10:44 AM

Page 35

Extech Intros 2-in-1 Insulation Tester & Multimeter with Wireless Datalogging Combo Meter Improves Insulation Resistance Testing Practices Extech Instruments, makers of the best handheld test and measurement tools, announce the new MG300, a true RMS multimeter with built-in insulation resistance tester and the added safety of wireless datastreaming for remote monitoring and datalogging.

By adding insulation testing capabilities to the ubiquitous digital multimeter, electricians are always equipped for insulation testing, helping to make it a more routine part of predictive maintenance with faster troubleshooting and repairs without additional tools.

The rugged and waterproof (IP67-rated) combination meter includes a digital insulation resistance tester (or megohmmeter) with 4 different test voltages for measuring resistance up to 4 GΩ with 0.001MΩ resolution. The full-function, true RMS digital multimeter includes useful extras like duty cycle measurements and milliamp readings for analog 4-20mA current loops in industrial analog process controls.

The CAT-IV-rated meter’s wireless datastreaming enables safer troubleshooting and maintenance on dangerous moving equipment and one-person operation of remote safety switches. Technicians can focus on finding problems by monitoring real-time readings on a laptop or computer screen from safe distances – up to 30 feet away.

The meter comes complete with remote USB receiver, Windows® compatible software, test leads with alligator clips, Type K bead wire temperature probe with adapter, carrying case, and 6 x AA batteries. The MG300 is available with NIST-traceable certification (model MG300-NIST). For users outside North America, the MG302 which transmits data at 433MHz instead of 915MHz is also available. The new meters are available from authorized Extech distributors around the world.

For more information, visit www.extech.com/mg300

FOR FREE INFO, CIRCLE 51 ON READER SERVICE CARD

June 2012 • epsmag.net

35

0612EPSp34-40.qxd:Company Spotlight

6/8/12

10:44 AM

Page 36

Product FOCUS Klein Tools® Introduces Demolition Screwdrivers Save Your Other Tools from the Abuse These Can Take Klein Tools for professionals since 1857, introduces a new series of demolition screwdrivers designed to take and deliver a beating. Engineered, manufactured and tested for prying and chiseling, the unique screwdriver design transfers impact force directly to the work surface. A plated metal strike cap protects the handle from hammer blows.

Typical electrician applications include banging out knockouts in a junction box as well as tightening up locknuts. Utility lineman can hammer the screwdriver into a wood pole to hang their tool bag for easy access while working.

“Every professional tradesperson has one or two screwdrivers that get frequent hits from a hammer.” states Jon Ginsberg, product manager. “The signs of beaten or chipped handles is all the evidence needed. With Klein demolition drivers, end users get the superior screwdriver standards demanded by professionals with the construction engineered to take the high abuse often necessary on the job-site”.

Made in the USA, these slotted drivers are available in 4” (602-4DD) and 7” (602-7DD) blade lengths, 1⁄4” and 5⁄16” tip sizes with the same features and quality Klein delivers. For more information including , visit our website at or contact your local distributor.

For more information, visit www.kleintools.com

FOR FREE INFO, CIRCLE 52 ON READER SERVICE CARD

36

Electrical Products & Solutions • June 2012

FOR FREE INFO, CIRCLE 53 ON READER SERVICE CARD

0612EPSp34-40.qxd:Company Spotlight

6/8/12

10:44 AM

Page 37

Platinum Tools® Launches VDV MapMaster™ 2.0 Length Measurement Voice/Data/Video Tester Now Shipping, the Updated VDV MapMaster Now Includes Cable Length Measurement, and Combines Continuity Testing, Mapping, and Tone Generator into a Single Unit Platinum Tools®, the leader in solutions for the preparation, installation and hand termination of wire and cable, is proud to announce the launch of the new VDV MapMaster™ 2.0 voice, data, and video tester. Now with cable length measurement, the VDV MapMaster™ 2.0 is now shipping with an MSRP of $129.95. (p/n T129).

“The VDV MapMaster 2.0 now combines cable length measurement with continuity testing, mapping, and tone generator functions into a single unit,” explained Lee Sachs, Platinum Tools, Inc. president and general manager.

“Made in the USA, the VDV MapMaster is capable of identifying and mapping 19 locations at one time. Whether the job is commercial or residential, the versatility and added features of the VDV MapMaster 2.0 makes it an installer’s best friend.”

Length Mode is used to measure the length of entire cables and its pin pairs and allows for viewing and adjusting the length constant value for video, data, and voice cables. The VDV MapMaster tests Cat-6, Cat5e, Cat-5, Cat-4, Cat-3, and coax cables, as well as shielded cables. Video and data cables can be connected to their respective remotes at the same time to improve testing efficiency. Patch cables may be tested without removing the master remote from storage.

Numerous accessories for the VDV MapMaster 2.0 (p/n T129) are available.

For more information, visit www.platinumtools.com

New WattStopper Universal Room Controller Dims Lighting, including LEDs, for Code Compliance and More WattStopper has launched new universal dimming room controllers for line voltage lighting loads. The versatile devices can control virtually all load types including LEDs, and are part of the company’s Digital Lighting Management (DLM) suite of intelligent controls. With the addition of the new room controllers, DLM offers customers sophisticated energy saving control solutions for virtually every space type. Applications include daylight harvesting, lumen maintenance and scene control in areas from classrooms to offices, conference rooms, restaurants and galleries.

As more jurisdictions adopt new energy codes (ASHRAE 90.1-2010 and IECC 2012), professionals must comply with multi-level control mandates. WattStopper’s universal dimming room controllers provide easy-to-implement multi-level control solutions while also accommodating a variety of lighting types within each space. When a building-wide energy management system is in place, the devices communicate via BACnet with a building automation system for control, reporting and demand response.

The one load LMRC-221 and two load LMRC-222 Digital Universal Dimming Room Controllers mount in the plenum and provide distributed control for LEDs, magnetic low voltage, electronic low voltage, neon/cold cathode, dimmable two-wire or threewire fluorescent, or incandescent lighting loads. The LMRC-222 can control a different type of load on each output. Advanced features include three selectable dimming curves for each load as well as programmable trim levels and fade times. Dimming parameters may be conveniently customized from a wireless handheld configuration tool that can also be used to set up lighting scenes.

WattStopper’s DLM control suite includes on/off room controllers, 0-10V dimming room controllers and plug load controllers as well as occupancy sensors, photosensors, lighting control panels and more. In addition to the new universal room controllers, WattStopper is also launching five new DLM occupancy sensors including passive infrared (PIR) and dual technology low voltage wall switch sensors and an enhanced coverage ultrasonic ceiling sensor. Digital Lighting Management devices plug together using pre-terminated Cat 5e cabling, reducing installation time over 50% when compared to analog controls.

For more information, visit www.wattstopper.com June 2012 • epsmag.net

37

0612EPSp34-40.qxd:Company Spotlight

6/8/12

10:44 AM

Page 38

Product FOCUS

Steel City® Pre-Fab Dual Box Mounting Bracket Facilitates Mounting Power and Low-Voltage Boxes The Steel City® Pre-Fab Dual Box Mounting Bracket from Thomas & Betts enables installers to position both power and low-voltage boxes with one component, reducing material and installation costs. Accommodating both four-inch and 4 11/16-inch boxes, the Steel City® Pre-Fab Dual Box Mounting Bracket is ideal for installing power and low-voltage boxes in separate stud cavities.

“We’ve designed the bracket so that two boxes are mounted in perfect alignment every time,” said Dan Michaelis, product manager for Thomas & Betts. “The bracket design enables the stud to function as a voltage divider if power and data are being installed at the same location.”

Additional features include a locator hole that enables the installer to position the box on marked studs for fast and precise installation. A built-in far-side support stabilizes the box and bracket assembly to ease installation and eliminate the need for extra components, reducing the number of SKUs needed.

The Steel City® Pre-Fab Dual Box Mounting Bracket is UL listed and is RoHS compliant.

For more information, visit www.tnb.com

FOR FREE INFO, CIRCLE 54 ON READER SERVICE CARD

38

Electrical Products & Solutions • June 2012

FOR FREE INFO, CIRCLE 55 ON READER SERVICE CARD

0612EPSp34-40.qxd:Company Spotlight

6/8/12

10:44 AM

Page 39

T3 Innovation Launches New Tel-Scope™ Telecomm Test Set Using Independent Technologies’ Patented ‘Data Defender’ System, the TLA300 Tel-Scope Offers a Complete Menu for Measuring Data, Actively Monitoring and Detection of High Line Voltages T3 Innovation, a leading provider of advanced handheld test equipment for the cable/telecommunications, datacom/networking, electrical design and maintenance, and residential/CEDIA custom install markets, has announced the launch of the new TLA300 Tel-Scope™ Telecomm Test Set. Scheduled to ship in May with an MSRP of $269.95, the Tel-Scope delivers more line condition and status information than any other telephone line tester in the world.

“The Tel-Scope includes the most sophisticated data in-line discovery and protection available today,” explained Ron Vogel, T3 Innovation CEO. “Using Independent Technologies’ patented ‘Data Defender’ system, the Tel-Scope offers a complete menu for measuring data, actively monitoring and detection of high line voltages. The Data Defender feature also includes Digi-Secure features that protect digital lines from disruption by outside test equipment.

The new TLA300 Tel-Scope Telecommunications test set comes with a slate of features not found on any other ‘butt’ set in the world. The large backlit display shows information clearly, and with a glow in the dark keypad the unit can be used in low light environments. And, it is 100 percent weather and rainproof for outside use anytime.

“The Tel-Scope is tough as well as talented,” added Vogel. “It is the first 21st Century telephone test set, and sets a new standard for telephone line analysis.”

For more information, visit www.t3innovation.com

Cooper Wiring Devices New Wall & Corner Mount Passive Infrared Occupancy Sensors Offer Performance, Increased Energy Efficiency Intuitive sensor offers real-time adjustments to maximize potential energy savings Cooper Wiring Devices, a leading electrical wiring device manufacturer for industrial, commercial and residential applications, has combined innovative design and energy savings to create its line of Wall & Corner Mount Passive Infrared Occupancy Sensors. Featuring self-adapting sensors, this great new solution offers complete, no-gap coverage to ensure proper illumination and increase efficiencies in any space.

Designed to detect motion from heat-emitting sources, Cooper Wiring Devices’ Passive Infrared sensor products rely on a segmented Fresnel lens that provides optimum sensitivity and performance. When utilized in the Automatic-ON mode, lights are turned on only when a person is detected in the room. For added efficiency and savings, certain models also include a day-lighting feature that prevents additional light sources from activating when the room is already adequately illuminated by natural light.

“Energy savings and efficiency are extremely important characteristics our end-users look for in a product,” said Laura Ulz, President Cooper Wiring Devices. “That’s why we’ve worked hard to develop our new Lighting Control sensors. Offering simplified operations and energy savings, they are the ideal choice for commercial buildings, schools and offices.”

For reliable performance and reduced commissioning times, Cooper Wiring Devices’ Wall & Corner Mount Passive Infrared Occupancy Sensors rely on Instinct Technology. This innovative technology continuously self-adjusts sensitivity and time delay in real-time allowing users to maximize potential energy savings.

For more information, visit www.cooperwiringdevices.com June 2012 • epsmag.net

39

0612EPSp34-40.qxd:Company Spotlight

6/8/12

10:44 AM

Page 40

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 ACME ELECTRIC AEE SOLAR AEMC INSTRUMENTS AMERICAN PIPE & PLASTICS, INC. ARPI OF USA BACKWOODS SOLAR BRADY WORLDWIDE BURNDY BYTE BROTHERS CONDUIT REPAIR SYSTEMS COPPER DEVELOPMENT ASSOCIATION COPPER WIRE STRIPPER ENERGIEBAU NORTH AMERICA EXTECH INSTRUMENTS/FLIR SYSTEMS E-Z METER GENERATOR INTERLOCK TECHNOLOGIES HATICON SOLAR HIOKI USA

PG#

RS#

Company

27 11 IFC BC 36 35 1 22 20 4 21 34 31 3, 9 36 7 16 15

19 11 1 3 52 51 4 43 42 6 16 48 21 5, 9 53 8 41 13

ICC KRENZ & COMPANY MEGGER MH RHODES/CRAMER COMPANY MINUTEMAN UPS MITCHELL INSTRUMENTS NATIONAL WIRE & CABLE PHASE-A-MATIC PLASTICS PIPE INSTITUTE PLC MULTIPOINT SCHNEIDER ELECTRIC SNAPNRACK SOKKIA STRIP-TEC THE HOME DEPOT UNDERGROUND DEVICES UTILITY METALS WATTSTOPPER

FOR FREE INFO, CIRCLE 56 ON READER SERVICE CARD

40

Electrical Products & Solutions • June 2012

PG#

RS#

23 38 IBC 34 25 29 30 38 28 40 13 17 5 14 19 24 10 32

17 54 2 49 18 20 46 55 45 56 12 14 7 40 15 44 10 47

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

11:21 AM

Page C3

FOR FREE INFO, CIRCLE 2 ON READER SERVICE CARD

0612EPSpFullPages.qxd:Company Spotlight

6/8/12

FOR FREE INFO, CIRCLE 3 ON READER SERVICE CARD

11:21 AM

Page C4