In this edition: Conventional Relay + Dedicated Relay — mandatory, not mutually exclusive. The evolution of electrical protection architectures toward real-time prediction.

THE CONCEPT

Two layers, one purpose: to protect and anticipate

In industrial electrical systems, the conventional protection relay remains the guardian against faults. It interprets currents and voltages, coordinates shutdowns in short circuits and overloads, and acts with precision, but always after the fault has manifested itself.

This is where the complementary layers of protection come in, providing advance warning and response in microseconds.

From reaction to prediction

Just as in aviation, sensors that monitor temperature, vibration, and pressure do not replace the autopilot, they feed it with predictive data. In modern electrical systems, the same principle applies: dedicated relays and smart sensors are able to see what conventional relays cannot: gradual heating and incipient arcs in pre-formation.

This new generation of relays acts before failure, preventing damage, fires, and unscheduled downtime!

The dedicated relay as a real-time agent

The dedicated relay for continuous (online) thermal monitoring and arc flash protection forms a sensory layer of the electrical system. It observes the panel in real time, detects hot spots, and recognizes the ultraviolet radiation of the arc the moment it arises—before visible light and before the fault current is established.

This integration creates an intelligent and predictive protection architecture, where continuous analysis complements reactive action.

THE PRODUCT

The challenge: see before failure!

In low and medium voltage systems, asset reliability depends on the ability to detect thermal risks and electric arcs before they cause damage. While conventional relays act after the fault, ZYGGOT® THM+ARC acts before, continuously monitoring the thermal and optical parameters of the electrical panel.

ZYGGOT^® THM + ARC — Protection and Prediction in a Single Platform

Varixx embodies this concept in ZYGGOT^® THM+ARC, a dedicated relay that combines continuous thermography and ultra-fast electric arc detection using UV radiation.

Technical Highlights:

• Monitoring of up to 4,100 combined sensors (100 temperature sensors + up to 4,000 arc sensors. There are 40 gateways, and each gateway supports up to 100 sensors, for a total of 4,000).

• Response time < 300 µs, even in the pre-arc phase.

• Performance up to 150x faster than current-based systems.

• Multiple independent trip zones, with selective logic between compartments.

• Up to 40 connected gateways, allowing adaptation to panels of different sizes and complexities.

• No current measurements required, simplifying the architecture.

• Multi-protocol communication: Modbus RTU/TCP, EtherNet/IP, MQTT, and IEC 61850.

• EMC immunity according to IEC 61000-4, operating with stability even under severe disturbances.

• Advanced interface: more than 200 interactive screens for configuration, supervision, and real-time analysis.

Applications

Suitable for industrial substations, distribution panels, CCMs, data centers, critical electrical systems, heavy mining, utilities, among others.

ZYGGOT^® THM+ARC guarantees continuous thermal and optical protection, ensuring reliability and selectivity even in environments with high electromagnetic stress.

Reference standards: NFPA 70B, IEC 61439-2, IEEE 493, and Uptime Institute reliability guidelines.

An integrated solution for protection and prediction

ZYGGOT^® THM+ARC combines two critical technologies:

• Continuous thermographic monitoring using non-contact temperature sensors.

• Electric arc detection using ultraviolet (UV) radiation, with instantaneous response and no need for current measurement.

This hybrid approach enables preventive and emergency action, ensuring that abnormal heating and UV emissions are detected in microseconds, before they develop into a short circuit or fire.

Compact and flexible architecture

Available in Mono and Multi-Gateway versions, it adapts to different industrial architectures. In the Multi-Gateway version, each compartment receives an independent gateway, coordinated by a master relay — which reduces complexity, cost, and installation time, in addition to ensuring total selectivity between zones.

High safety and availability

Combining high-precision thermal sensing and ultra-fast optical detection, ZYGGOT^® THM+ARC raises the bar for industrial electrical safety. Its selective operation minimizes unnecessary shutdowns, preserves equipment, and significantly increases operational availability.

CONCLUSION

ZYGGOT® THM+ARC represents the convergence of protection and prediction, integrating thermal and optical technologies into a single platform. More than just a relay, it is a sensory layer that sees risk before it manifests.

ZYGGOT® THM+ARC — protection that sees before risk.