Asco 457 User manual

Surge Protective Devices Installation & Operation Manual
Model 457

Installation, Operation and Maintenance Manual IO-70063 RevD 03-182
V
Safety First – Hazardous Voltage & Shock Hazard
WARNING – IMPORTANT – PLEASE READ – WARNING
• Only qualified licensed electricians should install or service SPDs
• Hazardous voltages exist within SPDs
• SPDs should never be installed or serviced when energized
• Use appropriate safety precautions including Personal Protection Equipment
• Failure to follow these instructions can result in death, serious injury, and/or
equipment damage
• This manual shall be read in its entirety prior to installing
Bonding and Grounding Hazard
Verify that the neutral conductor in the service entrance equipment is bonded to ground in accordance
with the National Electric Code (NEC®), Canadian Electrical Code (CEC) and all applicable codes.
Verify that the neutral terminal (XO) on the secondary side of distribution transformers are grounded to
the system ground in accordance with the NEC®, CEC and all applicable codes.
During installation into an electrical system, the SPD must not be energized until the electrical system is
completely installed, inspected and tested. All conductors must be connected and functional including
the neutral (if required). The voltage rating of the SPD and system must be verified before energizing
the SPD.
Failure to follow these guidelines can lead to abnormally high voltages at the SPD. This may cause the
SPD to fail. The warranty is voided if the SPD is incorrectly installed and/or if the neutral conductor in
the service entrance equipment or downstream of separately derived systems is not bonded to ground
in accordance with the NEC® or CEC.
Do Not Hi-Pot Test SPDs
Any factory or on-site testing of power distribution equipment that exceeds normal operating voltage
such as high-potential insulation testing, or any other tests where the suppression components will be
subjected to higher voltage than their rated Maximum Continuous Operating Voltage (MCOV) must be
conducted with the SPD disconnected from the power source. For 4-wire systems, the neutral connection
at the SPD must also be disconnected prior to performing high-potential testing and then reconnected
after test completion.
Failure to disconnect SPD and associated components during elevated voltage testing will damage the
SPD and will void the warranty.

Installation, Operation and Maintenance Manual IO-70063 RevD 03-183
ASCO SURGE PROTECTIVE DEVICE
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
TABLE OF CONTENTS
INTRODUCTION
Major Industry Nomenclature Changes Eective 2008-2009
Figure 1: NEC® Article 285 & UL 1449-4
4
4
4
PRE-INSTALLATION & INSTALLATION PLANNING
Operating Environment
Audible Noise
Mounting, Dimensions, and Weight
Service Clearance
Maximizing SPD Performance
Cascade Surge Protection
Overcurrent Protection
Circuit Breaker and Disconnect Switch
Wire Size and Installation Torque
6
6
7
7
7
7
8
8
8
8
SPECIAL ENCLOSURE CONSIDERATIONS
Removing and Reconnecting the Ribbon Cables
NEMA Type 4X Enclosure
Figure 2: Flush Mount Front & Side View
Flush Mount Option
Terminals
Shortest Leads Possible
Voltage Rating
System Grounding
UL 1283 Required Language Concerning the Installation of EMI Filters
8
8
9
9
9
10
10
10
11
11
GENERAL INFORMATION
Simplified Explanation of Operation
Precautionary Statement Regarding SPDs on Ungrounded Systems
Cascade Surge Protection
Parallel Connection
Unpacking & Preliminary Inspection
Storage Environment
Table 1: Model Number Decoder
5
5
5
5
5
5
5
6
MAINTENANCE
Troubleshooting & Service
Figure 16: Troubleshooting Flowchart
Module Removal & Replacement Instructions
Display/Diagnostic Board Removal and Replacement
Preventive Maintenance (Inspection and Cleaning)
Corrective Maintenance (Repair)
Limited Warranty
Table 2: Replacement Parts
18
18
18
19
19
19
19
20
21
INSTALLATION
Figure 3: Typical Panel Installation
Figures 4-9: Electrical Connection Diagrams
Figure 10: Display Panels
Control and Diagnostic Panel
Service LED and the Audible Alarm
Figure 11: SPD Dimensions: NEMA Type 1, 4, And 4X Stainless Steel
Figure 12: SPD Dimensions: NEMA Type 3R
Figure 13: SPD Dimensions: NEMA Type 4X Plastic
Surge Counter Options
Figure 14: Module LEDs
Supplemental LED Indicators on Modules
Figure 15: Pinout Diagram For Dry Contacts Of SPD
Dry Contact Option
Remote Monitor Accessory Option
12
12
13
14
14
14
15
15
15
16
16
16
17
17
17

Installation, Operation and Maintenance Manual IO-70063 RevD 03-184
INTRODUCTION
Thank you for choosing an ASCO Surge Protective Device (SPD). This is a high quality, high energy surge
suppressor designed to protect sensitive equipment from damaging transient overvoltages.
Proper installation is important to maximize performance. Please follow steps outlined herein.
This entire Operation & Maintenance Manual should be read prior to beginning installation. These
instructions are not intended to replace national or local codes. Follow all applicable electrical codes to
ensure compliance. Installation of this SPD should only be performed by qualified electrical personnel.
ASCO SPDs are extensively tested in accordance with industry standards such as ANSI/IEEE C62.41.1,
C62.41.2, C62.45, C62.62, C62.72, UL 1449, UL 1283, IEC 61643, etc.
This SPD is a single-port parallel-connected device intended for service entrance, panelboard or
downstream installation for IEEE Category C, B or A applications.
Major Industry Nomenclature Changes Eective 2008-2009
Be aware that UL 1449 Fourth Edition and 2008 NEC® Article 285 generated substantial changes.
• The term TVSS changed to SPD
• Types 1, 2, 3 & 4 SPDs are created
• UL 1449 clamping voltage performance testing changed from 500A to 3,000A
• UL 1449 added new I nominal testing (In), which consists of more rigorous duty-cycle testing
This SPD complies with the latest regulatory actions and is UL Listed as such.
For further information, please review latest editions of NEC® Art. 285, UL 1449 or contact ASCO Tech
Support at [phone].
FIGURE1: NEC® ARTICLE 285 & UL 14494
SPD Types: Types 1, 2, & 3
Based on Location within electrical distribution system
(also coincides with ANSI/IEEE C62.41.2 - 2002 Categories C, B & A)

Installation, Operation and Maintenance Manual IO-70063 RevD 03-185
GENERAL INFORMATION
This is a Type 2 SPD. It includes internal overcurrent protection. Type 2 SPDs are suitable for installation
on the load side of the service disconnect overcurrent device.
This device features internal overcurrent and overtemperature protection that will disconnect eected
surge suppression components at the end of their useful life, but will maintain power to the load – now
unprotected. If this situation is undesirable for the application, follow these instructions for servicing or
replacing the device.
Service of this unit consists of replacing internal modules and/or display assembly.
There are no user-serviceable parts inside the replaceable modules. Do not attempt to disassemble the
module as it stores charge and is potted.
Simplified Explanation of Operation
SPDs sense overvoltage and create a momentary short circuit to redirect harmful surge energy to earth
ground. Then they reset automatically and wait for the next surge. This is similar to the pressure relief
valve on a water heater: pressure goes up, valve opens to relieve pressure and then resets. In an electrical
system, an SPD senses overvoltage, shorts temporarily sending energy to ground and then resets. SPDs
are capable of repeating this function thousands of times.
Parallel Connection
This is a Parallel connected SPD – not series connected. As outlined above, an SPD ‘drains o’ excessive
voltage from an electrical system. Because of parallel connection, installation of the SPD near the
equipment to be protected is satisfactory. This eect is similar to flushing any toilet in a house; pressure
in the shower goes down. In an electrical system, a parallel connected SPD will remove excessive voltage
o the entire system (assuming reasonable proximity).
Tip: It is critically important that wiring leads be configured as short & straight as possible. Avoid long leads.
Avoid sharp bends. Route SPD conductors in the same conduit. Leads do not have to be sized for the entire load
– this SPD is parallel connected, not series connected. As a generalization, 6 AWG works fine.
Precautionary Statement Regarding SPDs on Ungrounded Systems
Caution – Ungrounded systems are inherently unstable and can produce excessively high line-to-ground
voltages during certain fault conditions. During these fault conditions, any electrical equipment including
an SPD, may be subjected to voltages which exceed their designed ratings. This information is being
provided to the user so that an informed decision can be made before installing any electrical equipment
on an ungrounded power system.
Unpacking & Preliminary Inspection
Inspect the entire shipping container for damage or signs of mishandling. Remove the packing materials
and further inspect the unit for any obvious shipping damages.
If any damage was found and is a result of shipping or handling, immediately file a claim with the shipping
company and forward a copy to ASCO.
Storage Environment
This SPD should be stored in a clean, dry environment. Storage temperature range is -40°C (-40°F) to
+60°C (+140°F). Avoid exposure to high condensation.

Installation, Operation and Maintenance Manual IO-70063 RevD 03-186
TABLE 1: MODEL NUMBER DECODER TABLE 1: MODEL NUMBER DECODER
PRE-INSTALLATION & INSTALLATION PLANNING
Operating Environment
The standard unit is in a Type 1 enclosure. Other enclosure types are available as options. Before installing,
ensure that your enclosure type and application are appropriate per NEMA 250 with regard to moisture,
dirt, excessive dust, flammable materials or atmospheres, corrosive vapors, etc.
This SPD is designed in an ambient temperature range of -40°C (-40°F) to +60°C (+140°F) with a relative
humidity of 0% to 95% (non-condensing). Excessive temperature may inadvertently operate internal
thermal overtemperature protectors.
Audible Noise
SPD background noise is negligible or non-existent, and does not restrict the location of installation.
Mounting, Dimensions, and Weight
This SPD is designed to be wall mounted. The standard enclosure is: 12” x 12” x 7.5” (L/W/D), and the
weight is 25 lbs.
Example: 457120SP16ACAE20 - Model 457, 240/120V Split Phase, 160kA, Standard Modes, Compression Lugs or Terminals,
LEDs/Audible Alarm/Relay, NEMA 1/12/3R/4, Type 2, No Accessories or Options

Voltage Codes
P
Per Phase
kA Rating
System

Modes of
Protection

kA Rating
Per Phase
A = All Standard
Modes for that
Product Line &
Voltage Code
Series/
Product Line
457
Common North American Systems
120S = 240/120V Split Phase - 1Ø, 3W+Grnd, (Fig 1)
120Y = 208Y/120V Wye - 3Ø 4W+Grnd, (Fig 2)
240H = 240/120V High Leg Delta (B High), (Fig 3)
277Y = 480Y/277V Wye - 3Ø 4W+Grnd, (Fig 2)
347Y = 600Y/347V Wye - 3Ø 4W+Grnd, (Fig2)
480D = 480V Delta - 3Ø 3W+Grnd, (Fig4) & HRG Wye
Other Available Systems - Confirmation Encouraged
120N = 120V Single Phase, 1Ø 2W+G (Fig 5)
240N = 240V Single Phase, 1Ø 2W+G (Fig 5)
220Y = 380Y/220V Wye - 3Ø 4W+Grnd (Fig 2)
240C = 240V B Corner Grnd Delta, 3Ø 3W+Grnd (Fig 6)
240D = 240V Delta - 3Ø 3W+Grnd (Fig 4)
480C = 480V B Corner Grnd Delta, 3Ø 3W+Grnd (Fig 6)
600C = 600V B Corner Grnd Delta, 3Ø 3W+Grnd (Fig 6)
600D = 600V Delta - 3Ø 3W+Grnd (Fig 4) & HRG Wye
16 = 160kA
24 = 240kA
09 = 90kA (SAD)
13 = 130kA (SAD)
17 = 170kA (SAD)
(SAD available in 120S
& 120Y)

Installation, Operation and Maintenance Manual IO-70063 RevD 03-187
TABLE 1: MODEL NUMBER DECODER TABLE 1: MODEL NUMBER DECODER
Figure 1
SPLIT
2 Phase, 1 Neutral,
1 Ground
Phase B (Black)
Phase A (Black)
Neutral (White)
V
V
}
}
Ground (Green)
Figure 2
WYE
3 Phase, 1 Neutral,
1 Ground
}
Phase A (Black)
Phase B (Black)
Neutral (White)
Phase C (Black)
Ground (Green)
A
C
N
V
B
Figure 3
HI-LEG DELTA (B High)
3 Phase, (B HIGH),
1 Neutral, 1 Ground
Phase A (Black)
Phase B (Orange)
Neutral (White)
Phase C (Black)
Ground (Green)
}
V
Figure 5
SINGLE POLE
1 Phase, 1 Neutral,
1 Ground
V
}
Neutral (White)
Phase A (Black)
Ground (Green)
Figure 4
DELTA & HRG WYE
3 Phase, 1 Ground
Phase A (Black)
Phase C (Black)
Phase B (Black)
Ground (Green)
}
V
Figure 6
CORNER GROUND
DELTA (B grounded)
2 Phase, 1 Ground
Phase A (Black)
Phase C (Black)
Ground (Green)
V
}

Connection
Type
C = Compression
Lugs or Terminals
(No Wires Included)

Monitoring
Options

Enclosure

UL 1449
Type1/Type 2

Accessory/
Option(s)
2 = Type 2
(Includes
UL1283 Filter)
0 = No Accessory/Option
X = Yes Accessory/Option
Service Clearance
Service clearance is needed at the front of the Model 457 unit only, 36 inches minimum is the required
distance for clearance pursuant to the NEC®.
Maximizing SPD Performance
SPD’s must be located as close to the circuit as possible to minimize parasitic losses. Surges are high
current, high frequency events that cause substantial voltage drops across conductors. This hurts SPD
performance. Use the shortest & straightest possible leads. Pre-Plan installations and ensure that nearest
breaker positions are used. If new construction, adjust breaker locations as appropriate.
Tip: Voltage drops for normal 120V or 277V lines might be 2-3V per hundred feet. In surge applications, voltage
drops might be 100-150V per foot. These voltage drops add to clamping voltage, thus hurting performance.
Make every eort to keep leads short and straight.
As distribution gear becomes larger, shorter leads are more diicult to accomplish. When longer leads are
unavoidable, gently twist leads together (one to two twists per foot), or tie-wrap leads together.
E = NEMA 1/12/3R/4 (metal combo)
Size - 12” x 12” x 7.5”
J = NEMA 4X (polycarbonate, display inside door)
Size - 14” x 12” x 6”
H = NEMA 4X (stainless, display inside door)
Size - 12” x 12” x 6”
Q = Flush Mount, Wall Cavity Size - 12” x 12” x 6”
X = Smaller Enclosure, Size - 10” x 10” x 6”
N = No Enclosure (includes aluminum backplane)
U = LED(s)/Aud. Alarm
A = LED(s)/Aud. Alarm/Relay
C = LED(s)/Aud. Alrm/Relay/
Surge Counter

Installation, Operation and Maintenance Manual IO-70063 RevD 03-188
Tip: surges create magnetic fields per the ‘right-hand rule’. When current goes in direction of thumb, magnetic
field is in direction of curl of fingers. As surge current goes to SPD, fields are created in one direction. When the
SPD sends those currents to neutral and/or ground, current goes in the opposite direction. If ‘coming & going’
are on the same axis, the magnetic fields can be cancelled, thus avoiding performance decrease. Gentle twists,
bundling & tie-wraps accomplish this.
Cascade Surge Protection
For optimum surge protection, cascade or staged surge suppression should be implemented at the
service entrance and downstream locations as appropriate. Known or expected surge sources, as well as
sensitive loads, should also have localized surge suppression. For interconnected electronic loads (data
cabling), SPDs should also be utilized to protect the devices on either end of the interconnecting data
cables.
Overcurrent Protection
SPDs draw very little current under normal conditions and conduct for a brief duration upon encountering
a transient surge current. This SPD contain internal overcurrent and overtemperature protection to
protect against abnormal voltage conditions.
Supplemental overcurrent protection is not required to protect this SPD. However, connecting conductors
require protection in Type 2 or 4 applications. Follow applicable codes.
Circuit Breaker and Disconnect Switch
This Model 457 family SPD is tested and qualified as a Type 2 SPD per UL 1449 Fourth Edition and 2008
NEC®. This SPD can be installed on the load side of the service overcurrent device per 2008 NEC® Article
285.
When connected on load side of main disconnect, we suggest connecting via a 60A circuit breaker. The
circuit breaker is the intended disconnect switch and provides short circuit protection to the connecting
conductors. Model 457 has internal overload protection elements within the product. A breaker or
disconnect is not required for the SPD’s overcurrent protection. Model 457 SPDs have demonstrated
200kA Short Circuit Current Ratings (SCCR). Confer to label on unit.
Wire Size and Installation Torque
This is a parallel-connected SPD; it is not series-connected. The size of the SPD wiring is independent of
the ampere rating of the protected circuit. Recommended wire is 6 AWG for phase, neutral and ground
connections. Torque connections to 18 inch-pounds. Conductor length should be as short as possible.
If other wire sizes are used, we recommend that all conductors be the same gauge. Note that larger
conductor might appear to be beneficial; however, it tends to have the same inductance as smaller
conductor and is more diicult to work with.
Terminals accept 14 - 2 AWG conductor with 6 AWG being preferred. Coordinate conductor size and
overcurrent
SPECIAL ENCLOSURE CONSIDERATIONS
Removing and Reconnecting the Ribbon Cables
The ribbon cables are marked with matching phase connections. If any of the cables are removed,
reconnect the cables as marked.

Installation, Operation and Maintenance Manual IO-70063 RevD 03-189
NEMA Type 4X Enclosure
On rare occasions in high temperature climates, Model 457’s inside clear-cover polycarbonate
enclosures have experienced internal temperatures exceeding 200°F. This inadvertently operates the
overtemperature safety disconnectors inside the SPD. We recommend positioning the unit so that the
clear front avoids direct summer sunlight by shading or not facing west.
The NEMA Type 4X enclosure is shipped with its mounting brackets and installation screws packaged
inside it. Use the enclosed 1/4-20 x 1/2 in. slotted screws to secure the brackets to the enclosure before
installing the Model 457 SPD device. Torque these screws to a maximum of 50lb-in. (6N·m). When
installing the cover for the NEMA Type 4X enclosure, torque the cover screws to a maximum of 25lbs-in.
(3 N·m).
Flush Mount Option
Remove the display panel and barrier before making any electrical connections. Replace the barrier and
display panel before energizing the device.
Model 457 is approximately 5.25 in. (133 mm) deep. It will not flush mount unless there is at least 5.25 in.
(133 mm) of clearance. Model 457 is not designed to flush mount on a typical 2 x 4 stud wall.
Follow steps 1-5 to flush mount Model 457.
1. Before removing the trim, disconnect the ribbon cables and ground wire from the modules.
2. Mount the device as close as possible to the panel being protected. Create a wall opening slightly
larger than 12 in. high by 12 in. wide (305 mm high by 305 mm wide). See figure 2.
3. Install a backing plate inside the wall cavity 5.25 in. (133 mm) from the wall face such that Model 457
will be supported from its back. See figure 3. Note the mounting holes on the back of the enclosure.
Also note that Model 457 weighs 25 lb (12 kg) maximum.
4. Configure the electrical conductor and conduit connections consistent with the wiring instructions
beginning on page 7.
5. Carefully reattach the ribbon cables and the ground wire to the modules and reattach the display
panel/cover before energizing and testing the device ground at the service equipment or other
acceptable building earth ground such as the building frame in the case of a high-rise steel-frame
structure.
FIGURE 2: FLUSH MOUNT FRONT & SIDE VIEW

Installation, Operation and Maintenance Manual IO-70063 RevD 03-1810
Terminals
Terminals will accept 14 - 2 AWG conductor and are provided for line (phase), neutral (if used), and
equipment safety ground connections. 8 AWG is the minimum recommended wire size because UL
testing and evaluation was performed using 8 AWG.ators to ensure proper operation. We also recommend
keeping the SPD clean as appropriate.
Shortest Leads Possible
• Leads must be as short and straight as possible - See NEC® Article 285.12
• Pretend wire is $1000 per foot coming out of your pocket
• No long leads
• No sharp bends
• No wire nuts
• How short is short enough? As short as you can make it
• How long is too long? If anyone else can make it shorter
Voltage Rating
Before installing SPD, verify that it has the same voltage rating as the power distribution system. Compare
the SPD’s nameplate voltage or model number and ensure that SPD configuration matches the intended
power source. See Table 1.
The specifier or the user of the device should be familiar with the configuration and arrangement of the
power distribution system in which any SPD is to be installed. The system configuration of any power
distribution system is based strictly on how the secondary windings of the transformer supplying the
service entrance main or load are configured. This includes whether or not the transformer windings
are referenced to earth via a grounding conductor. The system configuration is not based on how any
specific load or equipment is connected to a particular power distribution system.
480V System Example: SPDs should be installed per the electrical system, not per a load or motor’s wiring
connection. For example, a 480V three phase motor might appear to be connected as a 480V Delta. In
actuality, the serving distribution system might be a 480Y/277V grounded Wye, with or without a neutral
pulled to the motor or MCC. The system is still a 480Y/277V Wye, even though the load is connected
as a Delta. A grounded Wye has a defined reference to ground (i.e., neutral is bonded to ground). Some
Delta systems are ungrounded, which have no reference to ground and are known to become unstable
in certain situations. Such instability can cause line to ground voltage fluctuations that may prematurely
fail SPDs. For this reason, the NEC® Article 285 has placed SPD restrictions on ungrounded systems. As
generalizations, SPDs for ungrounded systems can be installed on grounded systems with a clamping
performance penalty. However, SPDs for grounded systems installed on ungrounded systems are
almost certainly destined for premature failure. Call ASCO Tech Support at [phone] for further
information.