Installing surge protection is only half the job. These devices absorb and divert harmful voltage spikes with every transient event, and that repeated effort gradually wears down their internal components. Without regular checks, your protection could quietly fail, leaving equipment exposed when the next storm hits.
This article covers how to keep your surge protection system in good shape, from inspecting devices like the Dehnguard and Dehngap, to caring for your KVA UPS, loadcell surge protectors, and 3-way filter plugs.
Why Surge Protection Maintenance Matters
Most surge protection devices rely on components like metal oxide varistors or spark gaps that absorb energy during a surge. Each activation degrades these components slightly. After enough events, or one large one, they may no longer clamp dangerous voltages. The device might look functional, but its protective ability could be gone.
This degradation is not always visible. A worn-out protector looks identical to a new one unless it has a status indicator or you test it. Proactive maintenance of surge protection equipment matters because waiting for failure means the damage is done.
Standards like IEC 62305 recommend inspecting surge devices at least every 12 months and immediately after any suspected lightning strike. For sites in Africa’s high-lightning regions, checking more often makes sense.
Inspecting Modular SPDs Like the Dehnguard and Dehngap
The Dehnguard and Dehngap are modular, plug-in devices installed at distribution boards. Each module has a visual indicator showing whether protection is active. Green typically means the module is functioning, while red signals it needs replacing.
Check these indicators during routine electrical inspections and look at the housing for damage, discolouration, or burn marks. Because the modules are plug-in, swapping a spent one is straightforward and does not require shutting down the board. Keep spares on hand for immediate replacement.
Also check that connections at the distribution board remain tight and corrosion-free. Loose connections add resistance and generate heat, reducing the effectiveness of your surge protection circuit.
Maintaining Your Grounding System
A surge protection device is only as effective as its grounding. The SPD needs a low-impedance path to earth to divert surge energy. If the ground connection is corroded or has high resistance, the device cannot do its job regardless of age.
Test earth electrode resistance annually using a ground resistance meter, aiming for 5 ohms or less for sensitive electronics. Inspect bonding connections, earth bars, and conductors for corrosion or damage, especially at outdoor sites.
For weighbridge installations, grounding is critical because load cells and signal cables span a large area. Make sure the earthing system is intact and all components bonded correctly. Any break in the grounding path leaves the weighing system vulnerable during a storm.
Caring for Your KVA UPS and Filter Plugs
Your KVA UPS needs its own routine. The battery is the most vulnerable component, with sealed lead-acid types typically lasting three to five years. Heat and deep discharges shorten that lifespan. Inspect batteries for swelling, leakage, or corrosion, and replace any showing these signs.
Run a battery self-test monthly if your UPS supports it, and schedule a full load test annually to confirm runtime capacity during an outage. Keep the unit clean with adequate ventilation, since heat is the primary cause of premature battery failure.
The 3-way filter plug is the simplest device in your setup but still has a finite lifespan. Inspect it for damage, discolouration, or warmth under load. If a status indicator changes, replace the unit, and avoid overloading beyond rated capacity as this wears filtering components faster.
Looking After Loadcell Surge Protectors
Loadcell surge protectors like the LT1260 are solid-state devices that reset automatically after a surge. They need less attention than a UPS but should still be part of regular inspections. Check the housing for damage and verify cable connections are secure.
If your weighing system shows unexplained reading drift or errors after a storm, a compromised protector on the signal line is worth investigating. These units guard the most sensitive components in your operation, so catching a failure early prevents costly load cell and indicator damage.
A maintenance log for all surge protection components ties everything together. Record inspection dates, test results, and replacements to plan budgets and demonstrate due diligence for insurance or compliance.
In Conclusion
Regular surge protection maintenance ensures every layer of your system is ready when it counts. From checking indicators on your Dehnguard and Dehngap, to testing earth resistance, caring for UPS batteries, and inspecting loadcell protectors and filter plugs, each step keeps protection reliable year after year.
At Sasco Africa, we supply a full range of surge and lightning protection products and can help you keep your weighing systems safe. Whether you need replacement modules, spare parts, or advice on protecting your site, our team is here to help. Get in touch today for a quote on industrial and commercial weighing solutions tailored to your needs.
Jonathan is a Kenyan born British national who acquired Sasco from Avery Berkel in 2002 and took on the challenge of revitalizing the then ailing company. Jonathan has been CEO of various listed companies, spent 10 years as an investment banker in London, is committed to innovation and in a firm believer in the exceptional growth prospects for Africa over the coming decades.
