Hello Brian,

I've employed spark gaps, like you, not because you 'have' to but because it 
seemed good practice. It involved a control installation with cables strung 
externally.

My advice is to use propriatory discharge tubes. They're cheap and their 
performance is more predictable than engineering your own air gap across PCB 
tracks or using pointy pins and are much less influenced physical and 
environmental conditions such as temperature and humidity, etc. And should they 
ever be needed, the consequences can be much less messy.

I found a good selection available and looked at PCB mounting tubes with 
breakdown voltages of between 3 and 12 kV. I finally used 4kV, 5kA/10kA (10/1 
discharges) devices having been influenced by what professional LAN & GPS 
installers were using which largely ranged between 3 and 6 kV.

Just my thoughts.
T

----- Original Message -----
From: Kunde, Brian
Sent: 09/06/13 04:56 PM
To: EMC-PSTC@LISTSERV.IEEE.ORG
Subject: [PSES] Spark Gap PCB Layout on AC Mains

Our engineers are working on an AC Mains Distribution PCB. Like most electronic 
devices, we have seen the damage caused by lightning strikes. So we are 
increasing our creepage and clearance distances as wide as we can and still 
meet other requirements.
But no matter what spacing you design to, there is a lightning bolt out there 
that will exceed the design and it will arc somewhere. So the question came up 
to whether it makes sense to deliberately make a weak spot, or an area where 
the clearance is slightly smaller to control where a lightning/surge pulse will 
arc and/or discharge, like a Spark-Gap.
I have seen spark-gap lay outs on PC boards on I/O connectors; usually for ESD 
protection, but not on AC Mains. Is this a bad bad idea or something worth 
doing? Pros and Cons? Other suggestions??
Thanks to all for your help.
The Other Brian
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