Voltage surge suppressors: what they are, uses, and benefits

A surge suppressor is a device that protects electrical equipment from sudden increases in voltage, known as transients. It detects excess energy and diverts it to ground before it reaches sensitive systems such as PLCs, drives, or UPSs. In Mexico, its installation is governed by standards such as NOM-001-SEDE-2012 and NOM-007-ENER-2004, ensuring safety and efficiency in industrial environments.

If the electrical system of an industrial company or manufacturing plant is unprotected, voltage spikes can cause high maintenance costs or irreparable damage to equipment. Imagine a sudden pressure overload in a pipe network: if there are no relief valves, everything floods.

In this sense, surge suppressors act as intelligent shields that keep industrial systems stable, safe, and productive.

Below, we explain in detail the benefits, uses, and regulations you should know about these devices to ensure an adequate supply of electrical power in a high-energy demand environment.

What are voltage surge suppressors?

It is important to know what a voltage surge suppressor is and what it is used for in an industrial environment, as these devices are designed to protect electrical installations from sudden increases in voltage known as transients.

These events can be caused by electrical storms, network maneuvers, internal switching, or the switching on of high-consumption equipment. The job of a suppressor is to divert these surges to ground, preventing them from circulating through critical systems or equipment and causing damage.

In Mexico, NOM-007-ENER-2004 includes surge suppressors within energy efficiency and electrical protection equipment, especially in switchboards and uninterruptible power systems.

How do surge suppressors work?

Generally, suppressors have components such as varistors, which act only when a voltage threshold is exceeded. Then, when a transient overvoltage occurs, the active device within the suppressor changes its impedance, allowing the excess energy to be conducted to ground. This principle protects devices connected downstream of the panel.

It is important to know that these devices do not replace voltage regulators or UPS, as they are designed only for short-duration transient events. Depending on their type, location, and discharge capacity (measured in kiloamperes), suppressors can offer different levels of protection. A recommended practice is to apply a cascade architecture.

Learn more about: Why use a surge suppressor?

Key benefits for industrial facilities

Remember that in industrial environments, electrical stability is not optional, but rather the basis for maintaining continuous production and protecting high-value assets. That is why surge suppressors provide measurable benefits that go beyond basic protection, directly influencing profitability, operational efficiency, and equipment life.

Reduced costs due to electrical damage

Voltage surges can damage sensitive components: drives, PLCs, sensors, UPS systems, and dry transformers. A suitable suppressor prevents costly failures and frequent replacements, reducing maintenance time and operating expenses.

Increased equipment service life

By eliminating the constant impacts of transients, equipment retains its operational integrity for longer. This is especially critical in machinery containing precision electronic components or automation systems.

Prevention of unscheduled downtime

A transient can cause untimely breaker trips or failures in automated systems. By preventing these spikes, suppressors prevent abrupt equipment shutdowns, which, in industrial environments, can result in very high production losses and indirect workflow costs.

Real industrial and commercial applications

A typical installation includes Type 1 suppressors in transformers, Type 2 in main panels, and Type 5 at points close to machinery or data centers. This tiered solution progressively reduces the intensity of the transient before it reaches the protected equipment.

However, in industries such as manufacturing, automotive, retail, healthcare, food, or critical services, suppressors are commonly used in:

• Low-voltage or distribution main panels.
• Motor control centers (MCCs).
• Electrical rooms with UPS systems.
• Industrial lighting systems.
• HVAC controllers.

In commercial environments, they are also installed in equipment such as cold rooms and refrigerator surge suppressors in food storage areas.

Find out here about the variety of surge suppressors that your electrical installation needs.

Relevant standards and certifications

In Mexico, the installation and use of surge suppressors must be based on the following standards, which ensure that these devices meet performance, safety, and efficiency criteria, as well as compatibility with other electrical power distribution systems.

• NOM-001-SEDE-2012: regulates electrical installations for use, including protection and coordination criteria.
• NOM-007-ENER-2004: this energy efficiency standard is for electrical systems in non-residential buildings, where TVSS suppressors are explicitly mentioned.
• International standards accepted in Mexico that ensure international compatibility and quality standards, such as: NEMA, ANSI, IEC, IEEE,
• NEMA (National Electrical Manufacturers Association): a US organization that defines types of enclosures and environmental protection levels for electrical equipment.
• ANSI (American National Standards Institute): for suppressors, this entity establishes safety, compatibility, and labeling parameters to ensure interoperability between manufacturers.
• IEC (International Electrotechnical Commission): IEC standards are key for export/import, as they are recognized in more than 80 countries. For surge suppressors, IEC defines test methods, surge protection levels, and performance criteria under different conditions.
• IEEE (Institute of Electrical and Electronics Engineers): classifies transients and establishes protection recommendations for different electrical environments.

Frequently asked questions about surge suppressors

How do I know if I need a surge suppressor?

It is important to conduct a power quality study to identify the source of internal and external electrical disturbances. In addition, if your industrial facility has any of these conditions, the use of surge suppressors is likely to be relevant:

• Geographic location with high electrical activity or frequent storms.
• Evidence of fluctuations, reboots, or damage to electronic systems.
• Use of machinery with sensitive electronics, variable speed drives, or PLCs.
• Presence of intermittent failures with no apparent cause.
• If you are required by internal or external regulations to implement transient protection.

Read also: how to choose the right surge suppressor

In summary, surge suppressors are silent shields that can protect your equipment from those “invisible blows” caused by electrical surges and are vital in critical environments. For proper installation and safe monitoring, at Industronic we have the best team to support you in your energy efficiency processes. Contact us!