Current Technology CurrentGuard CG-120/240-2G Series User manual

CurrentGuard™
CurrentGuard™
Surge
Protective
Devices
Installation,Operation
and Maintenance Manual
PN 750-0098-001
CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual
®
™
CurrentGuard
Plus

Installation Assistance
Importance of Correct Installation
Warnings
Before Installation
System Configuration Verification
Environmental Condition Verification
Wiring Connection Diagram
Split-Phase, 3-Wire
3-Phase, 4-Wire WYE
3-Phase, 3-Wire DELTA
3-Phase, 4-Wire High-Leg DELTA
Conductor Routing
Upstream Over-Current Protection Device
Conductor Sizing
Mounting
Conduit Openings and Enclosure / Mounting Dimensions
Electrical Connections
Connecting Form C Dry Contacts
Verification and Power Up
Troubleshooting
Technical Assistance
Return and Warranty Procedures
Warranty Statement
Table of Contents
CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual
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3
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3
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5-6
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WARNING! HAZARDOUS VOLTAGES PRESENT Improper
installation or misapplication may result in serious person-
nel injury/or damage to electrical system. Read the com-
plete installation instructions before proceeding with instal-
lation. Remove all power to the electrical panel before
installing or servicing the surge protective device (SPD).
W A R N I N G S !
Installation Assistance
The Importance of
Correct Installation
Thank you for choosing the Current Technology®CurrentGuard™
series Surge Protective Device (SPD). We look forward to fulfill-
ing your facility-wide surge protection needs.
Monday through Friday, 8:00 a.m. to 5:00 p.m. (EST) at
800.238.5000.
This manual provides guidelines for the proper installation of the
CurrentGuard family of devices. Proper product selection and
compliance with these guidelines will help your new suppression
system provide years of reliable service. If installers are unsure
about the facility electrical configuration or have other installa-
tion-related questions, it is recommended they consult with a mas-
ter electrician or other qualified electrical professional.
When shortcuts are taken or installation procedures are not fol-
lowed, the CurrentGuard system may be damaged or may not pro-
vide adequate protection. It is extremely important to follow these
installation procedures carefully.
CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual 3
!
IMPORTANT SAFETY INSTRUCTIONS All work must be per-
formed by licensed and qualified personnel. The electrical system
must be properly grounded in accordance with the U.S. National
Electrical Code, state and local codes or other applicable codes for
this SPD to function properly. Do not connect CurrentGuard device
to the line side of the main service breaker or disconnecting means.
This device is suitable for installation where the available short cir-
cuit current is 200,000 rms symmetrical amperes up to 600VAC or
less.
!
WARNING! The CurrentGuard™warranty is voided if the unit
is damaged as a result of improper installation or the
installer’s failure to verify the following conditions prior to
installation.
!
WARNING! Check to ensure that a proper bond is installed
between neutral and ground at the transformer upstream
from all 3-phase WYE, 3-phase high leg DELTA or split-phase
CurrentGuard device (See NEC Article 250). If the trans-
former is not accessible, check the main service discon-
nect/panel for the N-G bond. Lack of a proper bond will dam-
age CurrentGuard and void the warranty.

Confirm that the environmental conditions are consistent with the
following ranges:
•Ambient Temperatures: Between -40° and +158°F.
•Relative Humidity: Between 5% and 95% non-condensing.
• Altitude: Less than 13,000 feet.
Before Installation:
System Configuration
Verification
CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual
4
MODEL NOMINAL L-N L-L CONFIGURATION
VOLTAGE VOLTAGE VOLTAGE
RANGE RANGE
CG(P)xxx-120/240-2G 120/240 108-132 216-264 Split-Phase
3-wire+ground
CG(P)xxx-120/208-3GY 120/208 108-132 187-229 Three-Phase WYE
4-wire+ground
CG(P)xxx-220/380-3GY 220/380 198-242 342-418 Three-Phase WYE
4-wire+ground
CG(P)xxx-277/480-3GY 277/480 249-305 432-528 Three-Phase WYE
4-wire+ground
CG(P)xxx-347/600-3GY 347/600 312-382 540-660 Three-Phase WYE
4-wire+ground
Three-Phase
CG(P)xxx-120/240-3GHD 120/240 108-132 (A&C PHASES)216-264 high-leg DELTA
187-229(B PHASES)4-wire+ground
CG(P)xxx-240NN-3DG 240 NA 216-264 Three-Phase DELTA
3-wire+ground
CG(P)xxx-380NN-3DG 380 NA 342-418 Three-Phase DELTA
3-wire+ground
CG(P)xxx-480NN-3DG 480 NA 432-528 Three-Phase DELTA
3-wire+ground
CG(P)xxx-600NN-3DG 600 NA 540-660 Three-Phase DELTA
3-wire+ground
(P) for CurrentGuard Plus
xxx denotes surge rating per mode (40, 60, 80, 100, 150 or 200)
Confirm that the voltage(s) and service configuration shown on the
CurrentGuard product label are consistent with the voltage and service
configuration of the facility. A model number is on the right side of
the CurrentGuard unit. Each model number corresponds to the con-
figurations printed in the table below:
Example of a SPD model number: CGP150-120/208-3GY
Environmental Condition
Verification

Figures 1-4 show the electrical relationship between CurrentGuard and
these four basic service configurations: Split-phase, 3-wire;
Three-phase, 4-wire WYE; Three-phase, 3-wire DELTA and Three-phase,
4-wire high-leg DELTA.
Wiring Connection Diagrams
CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual 5
2
L1
1
Fig. 1: Split-Phase, 3-Wire
2
ORN
RED
1
Fig. 2: 3-Phase, 4-Wire WYE
ORN
RED
1
2
Fig. 3: 3-Phase, 3-Wire DELTA

Conductor Routing
CurrentGuard™and CurrentGuard Plus™Installation, Operation and Maintenance Manual
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CAUTION: CurrentGuard’s performance will be limited
severely if the conductors are (a) too long, (b) are of too small
a wire gauge, (c) have too many bends or (d) have sharp
!
The factors listed above should be addressed during the design of an
installation to reserve a suitable place for CurrentGuard next to its
point of connection to the electrical system. The selected mounting
location should allow for the shortest possible conductor runs and a
direct route with a minimum of bends. If bends are required, they
should be sweeping bends. Do not make sharp 90° bends for appear-
ance purposes because they will severely decrease the effectiveness of
CurrentGuard.
Binding or twisting conductors together using tie-wraps or electrical
tape increases the protection performance of the device.
G
RED
1
2
Fig. 4: 3-Phase, 4-Wire High-Leg
DELTA
1. Optional – All CurrentGuard Plus units can be connected without an upstream
breaker/fuse.
2. Only 40 kA units are furnished with 10 AWG conductors. All other products are
furnished with compression lugs that can accept up to #3 AWG wire.
Upstream Over-Current
Protection Device
All CurrentGuard series units must be connected in parallel with the
electrical system. CurrentGuard units have built-in over-current fusing
rated at 200,000 rms symmetrical ampere up to 600VAC or less and can
be connected directly to the electrical distribution system bus without
an upstream over-current protection device (OCPD). However, the use
of an external OCPD is recommended.
If the SPD is connected to a dedicated overcurrent protection device, a
60A breaker is recommended (30A minimum, 200A maximum). The
advantage of using a dedicated over-current device for the SPD (even if
the upstream breaker is 200A or less) is that it allows the SPD to be de-
energized during service without disturbing the electrical service to
the rest of the facility.

CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual 7
Mount the CurrentGuard to the building structure using construction
methods and hardware appropriate for your site. Install the conduit
and pull the conductors as specified above or according to the engi-
neer’s design.
If desired, punch holes at this time for the conduit or nipple or
wait until the CurrentGuard is mounted to the building structure.
Punch holes only in the designated areas as shown in the following
illustration.
Mounting
Conduit Openings
Conductor Sizing Current Technology recommends installing CurrentGuard by using
the following conductor size for phase, ground and neutral connec-
tions. The conductor length should be as short as possible to ensure
the maximum level of protection. Use a larger conductor (not to
exceed the maximum allowed per a given model) where space and
bending radii permit.
Example of a SPD model number: CGP150-120/208-3GY
PRODUCT SURGE
LABEL CURRENT CONDUCTOR SIZE
DESIGNATION CAPABILITY RECOMMENDED MAXIMUM MINIMUM
CG40-xxxxx 40kA/mode1#10AWG #10AWG #10AWG
CG(P)60-xxxxx 60kA/mode2#6AWG #3AWG #10AWG
CG(P)80-xxxxx 80kA/mode2#6AWG #3AWG #10AWG
CG(P)100-xxxxx 100kA/mode2#6AWG #3AWG #10AWG
CG(P)150-xxxxx 150kA/mode2#4AWG #3AWG #10AWG
CG(P)200-xxxxx 200kA/mode2#3AWG #3AWG #10AWG
(P) for CurretGuard Plus
140kA units are shipped with #10AWG leads. Leads should be shortened
during installation in order to minimize conductor length.
260 through 200kA units are shipped with compression box lugs.
CAUTION: Careful consideration must be made when select-
ing an area for conduit entry. There are several components
inside the enclosure that may interfere with the conduit
entry path, therefore, ensure the path is clear of all objects
before drilling. Damages caused by installation errors are
not covered under the product warranty.
See Fig. 5 for conduit openings and enclosure dimensions.
!

Electrical Connections
CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual
8
Following all applicable National Electrical Code standards as well as
state and local codes, connect phase, neutral* and ground to
CurrentGuard. The 40kA units come with 36 inches of #10 AWG con-
ductors. Each phase conductor is labeled (Phase A, B or C). The 60kA,
80kA, 100kA, 150kA and 200kA units come with compression box lugs.
The installer must provide the appropiate conductors. Ensure that the
conductor lengths are kept as short and straight as possible. On all
high-leg delta systems, the high-leg (208V L-N) must be connected to
the Phase B of the SPD. (color-coded orange according to NEC)
* The 3-wire plus ground Delta CurrentGuard does not have a neutral conductor.
CAUTION: Prior to installation ensure the system configu-
ration and voltage is equivalent to the CurrentGuard unit
being installed.
!
Fig. 5:
Conduit Openings and
Enclosure/Mounting
Dimensions
(D)
(W2)
(H1)
(H2)
(H3)
ø0.31 (7.87)
(W1)
1.36"
(34.5mm)
3.20"
(83.8mm)
ALLOWABLE AREA FOR CONDUIT ENTRY
Dim CG40 CGx60-80 CGP100-200
H1 8.00 (203.2) 10.00 (254.0) 14.00 (355.6)
H2 8.75 (222.3) 10.75 (273.1) 14.75 (374.7)
H3 9.50 (241.3) 11.50 (292.1) 15.50 (393.7)
W1 6.00 (152.4) 8.00 (203.2) 12.00 (304.8)
W2 4.00 (101.6) 6.00 (152.4) 10.00 (254.0)
D 6.20 (157.5) 6.20 (157.5) 6.20 (157.5)
Weight 20.0 (9.07) 30.0 (13.6) 40.0 (18.2)
All measurements in inches (mm) and pounds (kg)

CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual 9
Connecting Form C
Dry Contacts
Fig. 6 Remote Monitoring
Terminal Block
Contacts shown in energized normal state
(no fault condition).
COVER REAR VIEW
All CurrentGuard units come standard with one set of Form "C" dry
relay contacts for the surge protective device status. These contacts are
for connection to a user-provided remote alarm and monitoring cir-
cuit. The relay contacts are rated 150VDC/125VAC with maximum
switching power of 30WDC/60VA AC. See Figure 6 for the form C con-
tact configuration and terminal location on the monitor board. The
annotations on the diagram match the markings on the terminal
block.
When input power is present on all phases, terminals “NO” and “COM”
are an open circuit and terminals “NC” and “COM” are a closed circuit.
The contacts change state when the unit has encountered failure to
one or more phases.
The installer must provide the appropriate raceway and wiring for the
monitoring circuit, observing the restrictions and conduit openings
illustrated in an earlier section of this manual. The installer must
route the monitoring conductors to the terminal blocks on the door-
mounted main monitoring board. Route the wires to allow the door
to be opened and closed properly. Tighten screws on terminals to
3.5 in-lbs (0.4 Nm). This terminal block will accept wire sizes #28AWG
to #16AWG. #18 – #20 AWG is recommended.

Verification and Power Up
CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual
10
Apply power to CurrentGuard by closing the over-current protection
device or switch feeding the suppressor.
WARNING: It is recommended that the cover of the
CurrentGuard unit along with its associated cabling be
installed prior to applying power. The monitoring harness,
which exits the epoxy and connects to J2 on
the monitor board, contains line voltage when power is
applied to the unit.
!
For CurrentGuard Units (model number begins with CG)
Verify that all "Phase Protection Status" indicating lights are illumi-
nated. The "Service Required" indicating light illuminates only upon
failure of one or more phases (indicating an alarm condition). Audible
alarm should not operate under normal conditions. The audible alarm
can be "muted" by pressing the "ALARM SILENCE" button, which sub-
sequently will illuminate the "ALARM SILENCED" light. Pressing the
"ALARM SILENCE" button again will enable the alarm.
For CurrentGuard Plus Units (model number begins with CGP)
The number of surges detected by the SPD is displayed on an eight-
digit LCD display on the front of the CurrentGuard Plus door. The
LCD counter is battery backed to maintain the number of surges even
during a power loss. Press the button on the counter to reset the
surge count.
Fig. 7 CurrentGuard Diagnostics
Fig. 8 CurrentGuard Plus Diagnostics

CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual 11
Troubleshooting
Technical Assistance
Your CurrentGuard system does not require scheduled maintenance. The
unit’s heavy-duty construction is designed to provide years of uninterrupted
service. The unit contains no serviceable parts.
Our staff is ready to support you and answer any questions.
Monday through Friday, 8:00 a.m. to 5:00 p.m. (EST) at 800-238-5000
CurrentGuard units are warranted for a period of 10 years from date of pur-
chase. CurrentGuard Plus units are warranted for a period of 15 years from
date of purchase. In the event that any module or subassembly within the
SPD fails to perform as specified during the warranty period, call our
Technical Support at 800-238-5000 to obtain a Return Material Authorization
number. We will immediately ship a replacement for the defective parts free
of charge (installation labor and site preparation excluded). Return the defec-
tive parts to Current Technology within 30 days of receiving the replacement.
Failure to return the defective parts will result in billing for the replacement
parts. To help expedite the return procedures, please have the following infor-
mation at hand when you contact Current Technology:
One or more phase protection status indicating
lights are off, service required indicating light
is on and form C alarm contacts have changed
state
Verify that the input power feeding
CurrentGuard is energized using a voltage
tester. If power is present, contact factory
for assistance: 800-238-5000
INDICATION PROCEDURE
Returns and Warranty
Procedures
INFORMATION EXAMPLE
Model Number CGP80-277/480-3GY
Serial Number 15478-0105-001
Date of Purchase January 2, 2005 (1st week)
Sales Order Number 15478
Description of Failure “Service Required” indicating light
illuminated
Desired Action from Current Technology Replace

CurrentGuard™and CurrentGuard™Plus Installation, Operation and Maintenance Manual
12
Warranty Statement Current Technology warrants that CurrentGuard and CurrentGuard
Plus surge protective device (the "Product"), shall meet applicable
industry standards and specifications and be free from defects in
materials and/or workmanship. Should any failure of the Product to
conform to this warranty appear within the warranty period, Current
Technology shall either repair or replace the defective Product, or
part thereof, upon return to Current Technology manufacturing
facility in Richmond, Virginia with transportation charges prepaid.
The applicable warranty period is outlined below in the warranty
period section.
Current Technology shall have no liability under this warranty for any
problems or defects directly or indirectly caused by misuse of the
Product, alteration of the Product (including removal of any warning
labels), accidents, or improper installation, application, operation, or
repair of the Product.
THIS WARRANTY REPRESENTS THE ENTIRE WARRANTY OF
CURRENT TECHNOLOGY. ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, ORAL OR WRITTEN, INCLUDING, BUT NOT LIMITED
TO, THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.
The liability of Current Technology under this warranty is expressly
limited to the replacement or repair of the defective part thereof, at
Current Technologys’ sole option.
IN NO EVENT SHALL CURRENT TECHNOLOGY BE LIABLE FOR
SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY
KIND OR CHARACTER, NOR SHALL CURRENT TECHNOLOGYS’
LIABILTY EVER EXCEED THE PURCHASE PRICE PAID FOR SUCH
DEFECTIVE PRODUCT.
This warranty is not transferable and may only be enforced by the sole
purchaser. Claims under this warranty must be submitted to Current
Technology within thirty (30) days of discovery of any CurrentGuard
product defect.
Warranty Period
CurrentGuard™10 Years from original date of purchase
CurrentGuard™Plus 15 Years from original date of purchase
®
Tel: [phone]
800.238.5000
www.currenttechnology.com
[e-mail]
Current Technology TVSS Products
5900 Eastport Boulevard
Richmond, VA 23231-4453
©2009 Current Technology®, CurrentGuard™and CurrentGuard™. Printed in U.S.A. All Rights Reserved. PN 750-0098-001 REV 3