Industrial automation systems integrate multiple technologies and devices to achieve automated control and monitoring of production processes or equipment. Key components include controllers, sensors, actuators, HMIs, communication networks, and control software. Lightning protection focuses on hardware components such as on-site controllers, sensors, actuators, and communication networks, which are vulnerable to lightning-induced damage.
Key Components:
Controllers: PLCs, DCS systems, industrial computers, and microcontrollers are typically installed in control cabinets. These cabinets act as critical distributed control hubs, requiring protection for both power and signal lines.
Power Lines: Single-phase power supplies (100–240V AC, depending on regional standards) must be protected using KILOAMP KPB385-4020R single-phase surge protectors.
Signal Lines: I/O ports require KILOAMP KSC24-201 signal surge protectors, which are rail-mounted with a minimum width of 8mm, optimizing space utilization. These devices feature three-level protection technology (Imax up to 10kA), limiting voltage to within 300V to ensure maximum controller safety.
Key Components:
Sensors: Temperature sensors, flow meters, pressure sensors, and other types require surge protection at the transmitter front end.
Power Lines: Primarily 24V DC, protected by KILOAMP KPD24-2020R DC power surge protectors.
Signal Lines: 4–20mA/RS485 signals are safeguarded using KILOAMP KSC24-201 surge protectors (Imax up to 10kA), which are rail-mounted, high-temperature resistant, and offer robust protection.
Key Components:
Actuators: Motors, valves, cylinders, and hydraulic cylinders are controlled via electrical signals, making their power and signal lines susceptible to lightning electromagnetic pulses (LEMP).
Power Lines: Single-phase supplies (100–240V AC) are protected by KILOAMP KPB385-4020R surge protectors.
Signal Lines: KILOAMP KSC24-201 surge protectors (Imax up to 10kA) are used to shield control signals, especially for outdoor actuators, which require metal enclosures and shielded cables in metal conduits.
Key Components:
Industrial Switches: Installed in control cabinets, these switches support 4–24 ports and require KILOAMP KSE05-404 network surge protectors.
Technical Specifications:
Protection: Uses GDT+TVS multi-level protection technology.
Performance: Supports data rates up to 1 Gbps, with Imax ≥5kA and withstands overvoltages up to 6kV.
Critical Requirements:
Shielding:
Use shielded cables for power and signal lines, with both ends grounded.
Long-distance cables should be armored with metallic sheathing or run through galvanized steel conduits.
Isolation:
Control signals use opto-isolators or relays for electrical isolation.
Critical signals employ redundancy (e.g., twisted-pair + fiber backup).
Grounding:
Ground resistance must be <4Ω (use deep-well grounding or resistivity-reducing agents in high-resistance areas).
Surge protector grounding wires must meet:
Signal protectors: ≥4mm² copper, length ≤3m.
Power protectors: ≥10mm² copper, length ≤3m.
Industrial automation systems achieve seamless control and monitoring through the synergy of sensors, controllers, actuators, HMIs, data processing systems, and communication networks. While these systems enhance efficiency and reduce costs, they require robust lightning protection to mitigate risks from surges and electromagnetic interference. The proposed solution combines layered surge protection (KILOAMP series), shielding, and precise grounding to ensure system reliability. Key products include:
KPB385-4020R (single-phase power protection),
KSC24-201 (signal protection),
KSE05-404 (network protection),
KPD24-2020R (DC power protection).
By implementing this solution, industrial automation systems can maintain high availability, reduce downtime, and ensure safe operation in harsh environments.
Note: Product specifications and configurations should align with local standards (e.g., IEC 61000-4-5, IEC 62305). Regular testing and maintenance are recommended to ensure system integrity.
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