Intermatic SG160 User manual

R
R
LISTED LISTED
TRANSIENT SURGE SUPPRESSORS FOR
AC POWER PANEL APPLICATIONS
USER MANUAL
1449 2nd Edition
HARDWIRED SURGE PROTECTION DEVICES
SG Modular Series

GGEENNEERRAALL
This document provides detailed information on how to install and operate the SG Modular
Series of Surge Protective Devices (SPD).
Units should be mounted as close as possible to the AC panel to be protected. It is recom-
mended that conduit, preferably metallic, be utilized to accomplish this connection.
The SG Modular Series Protectors are installed and connected in parallel ("shunt") across the
AC supply to be protected. Connecting wires do not carry the supply current, only the short
duration currents associated with the suppression of a transient event.
Identified or indicated terminals must be connected exactly with respect to the AC Power
feeding the SPD. Failure to do so may result in damage to the device or pose a danger to
personnel.
Incorrect installation may significantly impair the performance of the Surge Protective
Device. It is particularly important that all installation procedures and guidelines be followed
exactly.
INSTALLATION OF THIS DEVICE SHOULD ONLY BE PERFORMED BY A
QUALIFIED LICENSED ELECTRICIAN.
Before starting any installation procedures, verify service voltages with an AC Voltmeter to
ensure that the correct SPD Model has been selected.
DO NOT CONNECT WITHOUT SECURING POWER FROM THE DISTRIBUTION PANEL.
CHECK TO ENSURE THAT ALL CONNECTIONS ARE CORRECT AND SECURE BEFORE ENERGIZING. DO
NOT ENERGIZE WITH DOOR OPEN.
KEEP THIS MANUAL IN A SAFE DRY PLACE FOR FUTURE REFERENCE.
A.)
B.)
C.)
D.)
E.)
F.)
G.)
H.)
I.)
J.)
After determining a position to mount the device that
will minimize the length of the connecting wires,
drill a hole in the cabinet for the conduit to run the
wires from the distribution panel to the connecting
lugs inside the SPD. Installation is simplified if the
wires enter the enclosure at the top (see figure #2) of
the enclosure. Securely mount the TVSS unit using
1/4-20 bolts in the four (4) mounting holes provided
in the enclosure's mounting flanges.
CONSTRUCTION
14 Gauge steel with continuous hinge.
UL 50 Type 12 and Type 13.
NEMA/EEMAC Type 12 and Type 13.
JIC standard #GP-1-1967.
CSA Type 12.
IEC 529, IP65. [Figure #2: Cabinet Top View]
[Figure #1: Cabinet Front View]
10.00"
(254mm)
14.75"
(375mm)
15.50"
(394mm)
12.94"
(329mm)
3.00"
(76mm)
6"
(152mm)
MMOOUUNNTTIINNGGIINNFFOORRMMAATTIIOONN
((AALLLL MMOODDUULLAARR SSGG MMOODDEELLSS))
Page: 2
FINISH
ANSI 61 Gray polyester.
Powder coating inside and
out over phosphatized sufaces.
1.030"
(26.162mm) Dia.
APPLICATION or TECHNICAL ASSISTANCE
Contact Intermatic at 1-800-391-4555 or on the web at www.intermatic.com

Page: 3
Before starting the installation, measure the Line voltage with an AC voltmeter to ensure the
correct device has been selected for the current application. The MCOV (maximum continuous
operating voltage) Cannot exceed the maximum limits for the following service voltages:
INSTALLATION INSTRUCTIONS
120/208Vac, Three Phase Wye, 4 Wire + Ground
277/480Vac, Three Phase Wye, 4 Wire + Ground
120/240Vac, Three Phase Delta, 4 Wire + Ground
240 or 480Vac, Three Phase Delta, 3 Wire + Ground
120 or 240Vac, Single Phase, 2 Wire + Ground
Requires a 1 Pole Breaker
Requires a 2 Pole Breaker
Requires a 3 Pole Breaker
120/240Vac, Split Phase, 3 Wire + Ground
PHASE A
NEUTRAL
GND
120 VAC
120 VAC PHASE B
120 or 240 VAC PHASE
NEUTRAL
GND
PHASE A
NEUTRAL
GND
PHASE B
PHASE C
120 or 277
VAC
208 or 480
VAC
PHASE A PHASE B
PHASE C
NEUTRAL
208
VAC
240
VAC 240
VAC
(High Leg) “Orange”
240 or 480
VAC
PHASE B
PHASE A
PHASE C
GND
GND
OR
240 or 480
VAC
240 or 480
VAC
208 or 480
VAC
120 or 277
VAC 120 or 277
VAC
208 or 480 VAC
Requires a 3 Pole Breaker
Requires a 3 Pole Breaker
[Figure #6]
[Figure #7]
[Figure #5]
[Figure #4]
[Figure #3]
STANDARD ELECTRICAL CONFIGURATIONS
120VAC=150MCOV
220VAC=320MCOV
230VAC=320MCOV
240VAC=320MCOV
277VAC=320MCOV
480VAC=550MCOV
NOTE
Wye Configuration is applicable for:
220/380VAC
230/400VAC
240/415VAC
120 VAC 120 VAC

FRONT PANEL DIAGNOSTICS
Page: 4
AG
R
O
U
N
D
C
N
E
U
T
R
A
L
B
1. CONNECT THE GROUND WIRE TO THE
SERVICE PANEL GROUND BUS.
2. CONNECT THE NEUTRAL WIRE FROM THE SERVICE PANEL NEUTRAL BUS TO
THE LUG LABELED NEUTRAL. (Except for Delta Application)
3. CONNECT THE PHASE (HOT) WIRES FROM A 3 POLE BREAKER TO THE SPD
DEVICE CONNECTORS LABELED PHASE "A", "B" AND "C", as appropriate.
CAUTION:
BEFORE ENERGIZING THE SPD:
ENSURE ALL CONNECTIONS ARE CORRECT.
DO NOT ENERGIZE WITH FRONT COVER OPEN.
8 8 8 8 8 8
A CB
GREEN=PROTECTED OFF=NO PROTECTION
SYSTEM
FAULT N-G
VOLTAGES
RESET
ENABLE
TEST EVENT COUNTER
TEST
DISABLE
ENABLE
STATUS INDICATORS AUDIO ALARM
[Figure #10: 3 Phase Wye Configuration Shown]
1) For Single Phase Models:
Only 1 Green LED, in the
Phase “B” position, is provided.
3) For Delta Models:
There is no Yellow,
N-G, LED.
2) For Split Phase Models:
2 Green LEDs, in Phase “A”
& “C” positions, are provided.
NOTES:
NOTES:
1) For Single Phase Models, Phase “A”
& Phase “C” lines are left vacant.
2) For Split Phase Models, Phase “B”
is left vacant.
3) For Delta Configurations, the Neutral
position is left vacant.
[Figure #9: 3 Phase Wye Wire Hook-up]
G
PHASE
FAULT N-G
FAULT
TEST
DISABLE
ENABLE
PHASEPHASE
3 POLE BREAKER KEEP WIRES
AS SHORT
AS POSSIBLE
CONDUIT
N
E
U
T
R
A
L
[Figure #8: 3 Phase Wye Breaker Hook-up]

GREEN LEDs: When the SPD is securely connected and operating properly, the GREEN LEDs,
under the heading "PHASE INDICATORS", will be illuminated. No other indicator should be
illuminated if the unit is operating normally.
RED LED: If a problem develops with the internal monitoring circuitry or, in the unlikely event
that there should be a loss or reduction in the protection elements, the RED LED over the words
"SYSTEM FAULT" will illuminate.
YELLOW LED: If the Yellow LED illuminates, at any time, there could be a hazardous system
wiring fault. The YELLOW LED does not indicate a suppressor failure; however, it does signal
that there maybe dangerous Neutral to Ground Voltages present. Consult with a qualified
electrician to verify the integrity of the installation's wiring. (Not present on Delta Configurations.)
AUDIBLE ALARM: The Alarm will sound if protection should be lost on either the L-N or L-G
Modes. Control of the Alarm is managed with a switch located on the front panel next to the
Alarm. The switch has three (3) settings: Up (momentary only) for testing, which will sound the
alarm. Center, this is the Disable position and turns the Alarm off. Down, this Enables the Alarm
and sets it for constant monitoring.
STATUS INDICATORS
COUNTER: The Surge Counter will show the number of transient events that the suppressor
encounters. Control of the Surge Counter is managed with a switch located to the left of the count-
er display. The switch has three (3) settings: Up, (momentary only) for RESET. Center, this is the
ENABLE position and turns the Counter on and sets it for constant monitoring. Down, (momen-
tary only) this tests the Counter and will increase the count by 1 increment each time it is activated.
TROUBLE SHOOTING GUIDE
There is little or no trouble shooting required for this Series of products. However, there are
situations where there could arise a scenario where the Front Panel Diagnostics does not operate
as intended. In such a case follow these directions...
PROBLEM:
No Front Panel Diagnostics or improper operation:
Ensure that SPD unit is properly connected to the AC Service Panel and that all connections
are secure.
Confirm that the breaker in the AC supply panel is in the ON position.
If problem still persists: TURN OFF BREAKER, open the SPD door and verify that all VISI-
BLE cable connections are properly secured, no loose wires. This is especially critical for the con-
nectors on the Sensor Cable as they interface with the SG modules. When the SG module is prop-
erly connected the 2 Green LEDs should be illuminated and the center Yellow LED (not applica-
ble on Delta Units) should not. DO NOT attempt to trouble shoot inside individual SG Modules.
In the unlikely event that these measures have failed to correct the problem contact your dealer or
the factory for additional information.
Page: 5

Page: 6
The SG Modular Series utilize Replaceable Protection Modules.
SENSOR CABLE INTERFACE
TO FRONT PANEL DISPLAY
PHASE BUS
KEYED (GROUNDED)
MOUNTING BRACKET
YELLOW LED
NEUTRAL TO GROUND WARNING INDICATOR
NORMAL OPERATION = OFF
(NOT PRESENT ON DELTA CONFIGURATIONS)
[Figure #12: Module Ø Side End Cap]
THERE ARE NO USER SERVICEABLE PARTS INSIDE MAIN HOUSING
SG160K, SG240K and SG320K Models:
The specific product you have in service may be configured for any one of the following voltages:
AC Service(s)
120 or 240Vac, Single Phase
120/240Vac, Split Phase
240 or 480Vac, Three Phase Delta
120/240Vac, Three Phase Delta (High Leg)
120/208Vac, 3 Phase Wye
NEUTRAL
BUS
Phase
"A"
RPM
GROUND
BUS
DRY CONTACT INTERFACE
NO
C
NC
277/480Vac, Three Phase,
4 Wire + Ground
AC Service:
LOCATION OF
OPTIONAL
SURGE COUNTER
AC
SURGE
RATING
160kA ( )
240kA ( )
320kA ( )
Phase
"C"
RPM
SURGE
RATING
160kA ( )
240kA ( )
320kA ( )
Phase
"B"
RPM
SURGE
RATING
160kA ( )
240kA ( )
320kA ( )
B
SENSOR
CABLE
[Figure #11: Internal Layout]
INTERNAL LAYOUT
1. Make Sure the power has been turned off to the SG unit.
Never work on the SPD unit while energized.
2. Disconnect the Sensor Cable from the module.
(Ø Side End Cap)
3. Remove the 1/4 20 bolts securing the module to the
phase and neutral tabs. One bolt at each end of the
module. The compression lug comes off also.
4. Remove the 2 #6 Screws (1 at each end of the unit)
securing the module to the Back Plane PC Board.
5. Remove the module from the SG unit.
6. To mount the replacement module reverse steps 4, 3
and 2. Do not forget to reinstall the compression lug.
7. Close the SG cabinet door and reconnect power.
MMOODDUULLEE RREEMMOOVVAALL && RREEPPLLAACCEEMMEENNTT
GREEN LED’s
PROTECTION MODE STATUS
(NORMAL OPERATION = ON)
277/480Vac, 3 Phase Wye
220/380Vac, 3 Phase Wye
230/400Vac, 3 Phase Wye
240/415Vac, 3 Phase Wye
MODULE
MODULE
MODULE

Page: 7
IMPORTANT DATA
DATE PURCHASED:
DEALER/DISTRIBUTOR'S NAME AND ADDRESS:
DATE INSTALLED:
PHONE #:
MANUFACTURED DATE:
MODEL #:
CONTRACTOR'S NAME AND ADDRESS:
CONTACT(S):
FAX #:
PRODUCT INFORMATION
SERIAL #:
PHONE #: FAX #:
MAINTENANCE INSTRUCTIONS
At intervals not to exceed two (2) months check and verify:
1. Diagnostic and Indication display.
2. Alarm Operation
3. Condition of ALL Connection Cables and Terminations
ANY ALTERATIONS, TAMPERING, MISUSE OR UNAUTHORIZED REPAIRS OF
THIS PRODUCT WILL VOID ITS ORIGINAL FACTORY WARRANTY.
INSTALLATION, SERVICE OR REMOVAL OF THIS DEVICE SHOULD ONLY BE
PERFORMED BY A QUALIFIED LICENSED ELECTRICIAN.

FIVE YEAR PRODUCT WARRANTY
WARRANTY AND LIMITATION OF LIABILITY
If within five (5) years from the date of purchase, this surge protection
device fails due to defect in material or workmanship, Intermatic
Incorporated will repair or replace it free of charge. The warranty does
not apply to: (a) damage caused by accident, abuse, mishandling,
dropping; (b) units which have been subject to unauthorized repair,
opened, taken apart; (c) units not used in accordance with directions;
(d) damages exceeding the cost of the product. Some states do not
allow a limitation of damages, so the foregoing limitations may not
apply to you. This warranty gives you specific legal rights and you may
also have other rights, which vary, from state to state. This warranty
service is available by either (a) returning the product to the dealer
from whom the unit was purchased, or (b) obtaining a Returned
Authorization from the Intermatic Service Center at 1-800-270-7227.
Contact the company or refer to the warranty sheet enclosed with
each product for complete warranty details.
INTERMATIC INCORPORATED
http://www.intermatic.com
INTERMATIC PLAZA, SPRING GROVE, ILLINOIS 60081
Printed in U.S.A. © Copyright 2000 158SG10520 PDF 8.01
NOTE
INSPECT FOR HIDDEN SHIPPING DAMAGE UPON RECEIPT OF UNITS. NOTIFY
THE SHIPPING COMPANY IMMEDIATELY IF DAMAGE IS DISCOVERED. RETAIN
ALL SHIPPING CONTAINERS AND PACKING MATERIALS FOR INSPECTION.