Superior Electric STABILINE CS1 Series User manual

STABILINE
Installation, Operation
and Maintenance Manual
STABILINE®
CS1 Series
®
Surge
Protective
Devices

2
Table of Contents Your Guide to Installation
Pre-Installation Checklist
Installation Methods
Service Configurations
3-Phase, 4-Wire WYE
3-Phase, 3-Wire DELTA
3-Phase, 4-Wire High-Leg DELTA
1-Phase, 3-Wire SPLIT-PHASE
Plan Your Installation
Conductor Sizing and Overcurrent Protection
Conduit Openings
Typical Enclosure Configurations
Mounting
Electrical Connections
Connecting Form C Dry Contacts
Before Applying Power
Verify Proper Operation
Troubleshooting
Installation Assistance
Operation/Maintenance
Options
Warranty, 7-Year Limited
Specifications
Standards and Listings
3-4
5
6
6-8
6
7
7
8
8
9
10
11
11
11
12
13
14-15
16
16
17
17
17
17-19
19

3
Today’s sophisticated electronic equipment requires superior
suppression filter systems. By selecting Superior Electric’s
devices, you have taken a critical step toward decreasing down-
time and ensuring longer product life for your equipment.
The CS1 series STABILINE ®Surge Suppression System is
designed to be connected to your electrical distribution system to
protect connected sensitive electrical and electronic equipment
against the harmful effects of lightning strikes, internally generat-
ed transients and high frequency noise. The reliable CS1 fulfills
the single-pulse surge current capacity testing recommendations
per NEMA LS1-1992, paragraphs 2.2.9 and 3.9.
It combines easy and flexible installation with many special
features to deliver more performance than other devices in its
class.
The CS1 offers a full range of monitoring options from the
most basic phase indicator lights and audible alarms to the most
sophisticated power quality monitoring features offered in any
surge suppression product. These features include
the following:
• Display of true RMS phase voltages
• Display of neutral-to-ground voltage and current
• Counting of swells, surges, sags and outages
• Display of percent available protection remaining
The CS1 series incorporates redundant MOV fusing that
prevents individual component failure from rendering the protec-
tion mode useless. Instead, the failed component safely removes
itself from the circuit and all remaining protection is allowed to
continue operating as designed. Special circuitry allows the
percent remaining protection to be measured and automatically
alarmed if capacity drops below 50 percent.
The standard CS1 is available in a fiberglass-reinforced
polyester NEMA 4X enclosure. It is available with or without an
integral disconnect. Units equipped with disconnects are available
only with a metallic NEMA 4/12 enclosure.
Thank you for choosing a CS1 series STABILINE Surge
Suppression System. We look forward to fulfilling your facility-
wide surge suppression filter system needs.
Your Guide to Installation
of the TVSS Series STABILINE®
Surge Suppression System
CS1
®

4
Monday through Friday, 8:00 a.m. to 5:00 p.m. (EST):
800.787.3532 or 860.507.2025, ext.70782
®products are warranted for a
period of seven years from date of purchase.
The CS1 series is designed to provide surge suppression to
all connected loads within a distribution system. The CS1 uses
proven Metal Oxide Varistors (MOVs) and an efficient capacitive
filter system to reduce or eliminate transients, impulses, and high-
frequency noise within a building’s electrical system.
This manual provides guidelines for the proper installation of
the CS1 series of devices. Proper product selection and compli-
ance with these guidelines will help your new suppression system
provide years of reliable service. If installers are unsure about
the facility’s electrical configuration or have other installation-
related questions, it is recommended they consult with a master
electrician or other qualified electrical professional.
When shortcuts are taken or installation procedures are not
followed, the CS1 system may be damaged or may not provide
adequate protection. Improper installation may also void the war-
ranty. It is extremely important to follow these installation proce-
dures carefully.
This manual is designed to assist you with the installation of
the CS1 product and connecting it to your electrical system.
However, should you have questions about installing the
WARNING! The TVSS series 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.
Installation Assistance
Seven-Year Limited Warranty
Purpose and Applications
of the TVSS Series Stabiline®
Surge Suppression Products
The Importance of Correct
Installation
W A R N I N G !
CS1 series STABILINE
CS1, please call Superior Electric at 800.787.3532.
CS1
CS1

Before beginning
➤ Confirm that the voltage(s) and service configuration shown
on the CS1 product label are consistent with the voltage and
service configuration of the facility to which it is being attached.
A model number is printed on the label affixed to the inside of
the CS1 enclosure. Each model number corresponds to the volt-
age and service configurations printed in the table below:
(B phase must be 208V)
Note: Indicate TVSS surge current rating by substituting 60, 80, 100, 125,150,
200, 250, or 300 for “xx” in the above model numbers.
➤Check to ensure that a proper Xo bond is installed between
the neutral and ground terminals at the transformer upstream from
all 3ø WYE, 3ø high-leg DELTA, or 1ø SPLIT-PHASE TVSS
devices (see NEC Article 250.) Lack of a proper bond will
damage the CS1 and void the warranty.
➤Confirm that the environmental conditions are consistent with
the following ranges:
• Ambient Temperatures: The CS1 must be
installed in an area with a temperature between -40°
and +140°F.
• Humidity: The CS1 must be installed in an area
with relative humidity between 5% and 95% non-
condensing.
• Altitude: The CS1 must be installed in a
location whose altitude is below 13,000 feet.
WARNING! Discontinue installation if (1) your conditions are inconsis-
tent with the checklist above or (2) your conditions cannot be veri-
fied. Call Technical Support at 860.507.2025, ext. 70782 if you have
any questions.
5
Pre-Installation Checklist
W A R N I N G !
PRODUCT LABEL DESIGNATION SYSTEM VOLTAGE, SERVICE CONFIGURATION
CS1-xx-120/240-2G 120/240VAC, 1ø 3-wire SPLIT-PHASE, w/ground
CS1-xx-120/208-3GY 120/208VAC, 3ø 4-wire WYE, w/ground
CS1-xx-220/380-3GY 220/380VAC, 3ø 4-wire WYE, w/ground
CS1-xx-277/480-3GY 277/480VAC, 3ø 4-wire WYE, w/ground
CS1-xx-347/600-3GY 347/600VAC, 3ø 4-wire WYE, w/ground
CS1-xx-120/240-3GHD 120/240VAC, 3ø 4-wire high-leg DELTA, w/ground
CS1-xx-240-3DG 240VAC, 3ø 3-wire DELTA, w/ground
CS1-xx-480-3DG 480VAC, 3ø 3-wire DELTA, w/ground
CS1

6
The CS1 is to be connected in parallel with the electrical
system. It may be connected via a circuit breaker, molded case
switch, fused switch, or connected directly to the bus of the pan-
elboard or switchboard it is protecting. If direct bus connection is
used, Superior Electric recommends that the CS1 be equipped
with the optional integral disconnect switch.
• Do not connect the CS1 to the line side of the
main service breaker or disconnecting means.
• Do not install the CS1 where the available short
circuit current to the unit is less than 1500
RMS symmetrical amperes.
Figures 1-4 show the electrical relationship between the
High-Leg DELTA and SPLIT-PHASE.
Installation Methods for
Common Service Configurations
for the Design Engineer and
the Installer
Service Configurations
FIG. 1:
3-Phase, 4-Wire WYE
B
N
CA
N
G
XoBOND
EARTH
GROUND
C
B
A
N
G
GABCN
LOAD
(without disconnect)
®
CS1 Series STABILINE Unit
CS1 and these four basic service configurations: WYE, DELTA,

7
FIG. 2:
3-Phase, 3-Wire DELTA
FIG. 3:
3-Phase, 4-Wire High-Leg DELTA
G
EARTH
GROUND
CA
B
C
B
A
G
LOAD
(without disconnect)
®
GABC
CS1 Series STABILINE Unit
XoBOND
C
N
G
A
N
B*
EARTH
GROUND *WARNING!
HIGH LEG MUST BE B PHASE
C
B
A
N
G
LOAD
(without disconnect)
®
GABCN
*
CS1 Series STABILINE Unit
Service Configurations (continued)

8
WARNING: The performance of the CS1 will be severely limited
if the conductors are too long, are of too small a wire gauge, have
too many bends or have sharp bends.
Conductor Routing: The above factors should be addressed
during the design of an installation to ensure that there is a
suitable place for the CS1 reserved next to its point of connec-
tion to the electrical system. The selected mounting
location should ensure short conductor runs providing a direct
route with a minimum of bends. If bends are required they
should be sweeping bends. Do not make sharp 90˚bends for
“aesthetic” purposes.
Plan Your Installation
FIG. 4:
1-Phase, 3-Wire
SPLIT-PHASE
N
L2 L1
XoBOND N
G
EARTH
GROUND
L2
L1
N
G
GL1 L2 N
LOAD
(without disconnect)
®
CS1 Series STABILINE Unit
Service Configurations (continued)

9
Conductor Sizing: Superior Electric recommends installing the
following conductor sizes for phase, ground, and neutral connec-
tions. Where space and bending radii permit use a larger conduc-
tor size:
Note: The above conductor sizing recommendations ensure that the effective
clamping voltage of the TVSS at the point of connection is kept to a minimum in
order to maximize protection. Increasing conductor size to compensate for dis-
tances over 10 feet has a negligible effect on minimizing clamping voltage.
Additionally, conventional voltage drop calculations appropriate for 60 Hz do not
apply to transients.
Overcurrent Protection: The design may require, or the installer
may choose, to connect the CS1 to a circuit breaker, molded
case switch or fused disconnect.
Superior Electric recommends feeding all CS1 models not
equipped with an integral disconnect with a circuit breaker, mold-
ed case switch or fused switch.
If a breaker or molded case switch is used for connecting
the phase conductors, Superior Electric recommends a 100 amp
rating.
WARNING: If the available short circuit current at the CS1 is less
than 1500 RMS symmetrical amperes, do not install the CS1.
Examples of systems with available short circuit currents less
than 1500 amperes include the outputs of small UPS systems and
small AC inverters.
Conductor Sizing and
Overcurrent Protection
W A R N I N G !
TVSS60 #8 AWG
TVSS80 #8 AWG
TVSS100 #6 AWG
TVSS125 #6 AWG
TVSS150 #6 AWG
TVSS200 #2 AWG
TVSS250 #2 AWG
TVSS300 #2 AWG
Model Use conductor lengths less than 10 feet
CS1 using conductors less than 10 feet in length and using the
CS1-60
CS1-80
CS1-100
CS1-125
CS1-150
CS1-200
CS1-250
CS1-300
CS1

10
If desired, punch holes at this time for the conduit or nipple
or wait until the CS1 is mounted to the building structure.
Punch holes only in the shaded areas as shown in the
following illustrations.
TOP VIEW BOTTOM VIEW
RIGHT VIEW
.75"
3.00"
(FRONT)
(FRONT)
(FRONT)
ALLOWABLE AREA FOR CONDUIT ENTRY
(NON-METALLIC ENCLOSURE)
Conduit Openings
(Non-Metallic Enclosure,
NEMA 4X)
ALLOWABLE AREA FOR CONDUIT ENTRY
(METALLIC ENCLOSURE)
4"
BACK VIEW
LEFT VIEW RIGHT VIEW
TOP VIEW
Conduit Openings
(Metallic Enclosure,
NEMA 4/12)

11
Mount the CS1 to the building structure using
construction methods and hardware appropriate for your site.
Install the conduit and pull the conductors as specified previously
or according to the engineer’s design.
Phases, Neutral* and Ground: Connect the phase, neutral and
ground conductors.
For CS1 series models equipped with an integral disconnect
switch connect the phase conductors to the line-side lugs on the
disconnect and the ground and neutral* conductors to the lugs
labeled “G” and “N” on the internal yellow Integrated
Suppression Bus.
OPENON OFF
N
B
A
G
C
N
B
A
G
C
Mounting
Electrical Connections
Typical Enclosure
Configurations For All TVSS
Series STABILINE®Products
TVSS Series with Metallic Enclosure and Disconnect
TVSS Series with Non-Metallic Enclosure
CS1
CS1
CS1
CS1 Series
CS1 Series

12
For CS1 series models without an integral disconnect
switch, connect the phase conductors to the lugs labeled “A”,
“B”, and “C” on the internal yellow Integrated Suppression Bus
and the ground and neutral* conductors to the lugs labeled
“G” and “N”.
* DELTA-connected CS1 models do not have a neutral
conductor.
Dry Contacts:
options have a dual set of Form “C” dry contacts available for
connection to user-provided remote alarm and monitoring
circuits.
The installer must provide the appropriate raceway and
wiring for this circuit observing the restrictions on conduit
openings illustrated in an earlier section of this manual.
The installer must route the monitoring conductors via the CS1's
door hinge to the blue terminal blocks on the door-mounted cir-
cuit board. Select the appropriate materials and routing to allow
the door to open and close.
The following diagram shows the Form “C” contact
configuration. The annotations on the diagram match the
markings on the blue terminal block.
Your CS1 unit has been carefully tested before leaving
the factory.
If you have questions about Field Startup Testing or would like
to arrange for this service, call Technical Support
at 860.5 .4500, ext. 4755.
Field Testing
Connecting Form C Dry Contacts
NO1 C1 NC1 NO2 C2 NC2
FCC TERMINAL BLOCK
CS1 models equipped with Advanced Monitoring
07
860.507.2025 ext. 70782.

13
• Confirm Pre-Installation Checklist: Confirm that the “Pre-
Installation Checklist” found on page 5 of this manual was com-
pleted correctly before proceeding.
• Battery Installation: Your CS1 unit will be equipped with
a 9-volt battery if you purchased “L3 Advanced” monitoring.
Look at the circuit board behind the door. If there is a 9-volt bat-
tery present it will need to be removed, turned around and rein-
serted into the holder so that the contacts “snap” into place. If the
alarm sounds, press the “ALARM DISABLE” button on the front
of the door. The battery is installed backwards for shipping
purposes.
• Confirm Line Voltage: Measure the line to line voltages
feeding the panelboard and be sure they are within -30% to +10%
of the rated line voltage of the CS1 unit. Use the following
table to determine the range of acceptable voltages for each
model of the CS1 series.
NOTE: The sag counter of the L3 Advanced Monitoring option consid-
ers line voltage deviations below -10% of nominal as sags.
WARNING! Do not apply power if the measured voltage is not within
the range specified for the CS1 model being installed.
➤Apply power to the CS1 by closing the circuit breaker or
switch (if any) feeding the CS1 or closing the integral discon-
nect.
➤If you have L3 Advanced Monitoring option, be sure to re-
enable the alarm by pressing the “ALARM DISABLE” button.
The “ALARM DISABLED” light should not be illuminated and
the alarm should not be audible.
W A R N I N G !
Acceptable Voltage Ranges for All Models
TVSSxx-120/240-2G 240 168 to 264
TVSSxx-120/208-3GY 208 146 to 228
TVSSxx-220/380-3GY 380 266 to 419
TVSSxx-277/480-3GY 480 336 to 528
TVSSxx-347/600-3GY 600 420 to 660
TVSSxx-120/240-3GHD 240 168 to 264
TVSSxx-240-3DG 240 168 to 264
TVSSxx-480-3DG 480 336 to 528
Note: “xx” specifies rating of 60, 80, 100, 125, 150, 200, 250, 300 kA
TVSS NOMINAL L-L -30% TO +10%
MODEL NO. VOLTAGE L-L VOLTAGE
Before Applying Power:
Checklist
CS1-xx
CS1-xx
CS1-xx
CS1-xx
CS1-xx
CS1-xx
CS1-xx
CS1-xx
CS1

14
Depending on which monitoring option your CS1 series
STABILINE surge suppression system came with you can verify
proper operation of the unit as follows:
➤If your TVSS has Base Monitoring (see picture):Verify that the
green indicating lights are illuminated. Three-phase units have
three (3) green indicating lights labeled “A”, “B”, and “C”. Split-
phase units should only have lights “A” and “C” illuminated.
➤If your TVSS has L1 Standard Monitoring (see picture):Verify that
only the green indicating lights are illuminated and that there are
no red lights illuminated. Green lights indicate a normal condition
for each phase. Red lights indicate a fault condition. Three-phase
units have three indicating lights labeled “A”, “B”, and “C”. Split-
phase units should only have lights “A” and “C” illuminated.
The L1 Standard Monitoring option is equipped with two sets
of Form “C” contacts. The relay containing the contacts is in the
“alarm condition” when the power is off to the unit, when the unit
is encountering loss of power to one or more phases, or the CS1
is encountering more than 50% loss of capacity due to internal
fuse operation. Test the operation of the Form “C” contacts by
de-energizing the CS1 and checking the state of the contacts
with a continuity tester or observing the effect of the contacts on
the user-provided remote alarm circuits.
Verify Proper Operation
®
with Base Monitoring.
®
with L1 Primary Monitoring.
CS1 Series STABILINE
CS1 Series STABILINE
CS1
CS1
®

15
➤If your TVSS has L3 Advanced Monitoring (see picture):Verify
that the green indicating lights are illuminated and that the red
“fault” lights are off. Three-phase units have three (3) green indi-
cating lights labeled “A”, “B”, and “C”. Split-phase units should
only have lights “A” and “C” illuminated.
The L3 Advanced Monitoring option contains an audible alarm
that should not operate under normal conditions. The alarm can
be tested by pressing the “ALARM TEST” button on the front of
the door. The “LOW BATTERY” light should not be illuminated.
If it is, change the 9-volt battery on the circuit board behind the
door.
The L3 Advanced Monitoring option is equipped with two
sets of Form “C” contacts. The relay containing the contacts is in
the “alarm condition” when the power is off to the unit, when the
unit is encountering loss of power to one or more phases, or the
internal fuse operation. Test the operation of the Form “C” con-
tacts by de-energizing the CS1 and checking the state of the
contacts with a continuity tester or observing the effect of the
contacts on the user-provided remote alarm circuits.
The L3 Advanced Monitoring option has the same
features as the L1 Advanced Monitoring plus these additional
features:
• Audible Alarm
• RMS Voltage readout
• % Protection Available
• Swell Counter
• Surge Counter
• Sag Counter
• Outage Counter
®
with L3 Advanced Monitoring.
CS1 Series STABILINE
CS1 is encountering more than 50% loss of capacity due to
CS1

16
Your CS1 series STABILINE®surge suppression
system does not require periodic maintenance. The unit’s heavy-
duty design should preclude the need for any repairs; however,
the following indications and procedures may be appropriate:
Contact Technical Support
Monday through Friday, 8:00 a.m. to 5:00 p.m. (EST):
800.787.3532 or 860.507.2025, ext. 70782
INDICATION PROCEDURE
One or more phase
indicator lights are off.
unit or Advanced Monitoring
indicates less than 50% avail-
able capacity.
1. Check that the external power source supplying
power to unit is energized.
2. Check that the circuit breaker or switch
(if appropriate) feeding the CS1 is turned “on.”
3. Check the cables connecting the door-mounted
devices to the suppression module.
4. If all of above are O.K., contact factory.
Contact factory.
Troubleshooting
Installation Assistance
CS1 advanced hand-held test

17
The CS1 series STABILINE Surge Suppression System
should provide years of uninterrupted service.
With several levels of monitoring available, the user should
be able to verify the normal operation of the CS1 and confirm
that it is connected correctly to the power system.
Superior Electric does recommend two periodic tests in
order to:
• Verify that the unit is able to clamp surges to an acceptable level
• Verify that the unit has acceptable surge handling capacity
These tests should be coordinated with scheduled mainte-
nance events in your facility. They can be performed in house
with the aid of the CS1 hand-held test unit or requested as a ser-
vice from Superior Electric or an authorized service representa-
tive.
The CS1 series STABILINE Surge Suppression System is
available with the following options:
• L1 Standard Monitoring
• L3 Advanced Monitoring
• Integral Disconnect Switch
• CS1 hand-held test unit
The CS1 is warranted to be defect-free and performance-
guaranteed for seven years.
Size and Weight:
ENCLOSURE SIZE/WEIGHT ENCLOSURE SIZE/WEIGHT
MODEL NON-METALLIC ENCLOSURE METAL ENCLOSURE
(with integral disconnect switch)
19.5”H x 17.5”W x 9.5”D / 57 lbs
17.5”H x 15.5”W x 7.0”D / 40 lbs
15.5”H x 13.5”W x 7.0”D / 28 lbs
28”H x 16”W x 9.5”D / 91 lbs
20”H x 16”W x 9.5”D / 59 lbs
16”H x 16”W x 9.5”D / 45 lbs
Specifications
Options
Seven-Year Limited Warranty
Operation / Maintenance
CS1-200-300
CS1-100-150
CS1-60-80
®
®

18
Single-Pulse Surge Ratings: The following single-pulse surge rat-
ings are measured and presented in accordance with NEMA LS1-
1992 and can be verified with independent laboratory test reports:
*CS1-250: 250 kA, all modes
*CS1-300: 300 kA, all modes
*In compliance with NEMA LS1-1992, CS1 series STABILINE suppression fil-
ter systems are single pulse surge current tested in all modes at rated currents of
the product by an industry-recognized independent test laboratory. Single pulse
surge current capacities of 200,000 amps or less are established by single-unit
testing of all components or sub-assemblies within each mode. Due to present
industry test equipment limitations, single pulse surge current capacities over
200,000 amps are established via testing of individual components or sub-assem-
blies within a mode. Per ANSI/IEEE C62.41-1991 and ANSI/IEEE C62.45-1992,
capacity tested per mode utilizing a 1.2 x 50 μsec 20KV open circuit voltage, 8 x
20 μsec 10 kA short circuit current Category C3 bi-wave at one minute intervals
without suffering either performance degradation or more than 10% deviation of
clamping voltage at a specified surge current.
Repetitive Surge Rating: The repetitive surge current capacities
were achieved in all modes utilizing a 1.2 x 50 μsec,
20 kV open circuit voltage, 8 x 20 μsec, 10 kA short-circuit
current Category C3 bi-wave at one minute intervals without per-
formance degradation of more than 10% deviation of
clamping voltage.
REPETITIVE SURGE CURRENT CAPACITY PER MODE
IMPULSES
> 3,500
> 4,000
> 4,500
> 5,000
> 5,500
> 6,500
> 7,000
> 7,500
MODEL
CS1-60: 60 kA, all modes
CS1-80: 80 kA, all modes
CS1-100: 100 kA, all modes
CS1-125: 125 kA, all modes
CS1-150: 150 kA, all modes
CS1-200: 200 kA, all modes
CS1 series STABILINE suppression filter systems are repetitive surge current
CS1-60
CS1-80
CS1-100
CS1-125
CS1-150
CS1-200
CS1-250
CS1-300
®
®

19
Operating Frequency: 47 to 63 Hertz
Noise Attenuation:The following EMI-RFI noise rejection, or
attenuation values, for CS1 units are in compliance with test
and evaluation procedures outlined in NEMA LS1 –1992, para-
graphs 2.2.11 and 3.11:
Note: Standardized insertion loss data obtained utilizing MIL-STD-220A 50 ohm
insertion loss methodology. Noise source path = 100’ to model maximum average
circuit distance, filter connection distance = 6”.
The following standards and listings apply to the CS1 series
STABILINE models:
ANSI/IEEE C62.41 – 1991 and C62.45 – 1992
ANSI/IEEE C62.1 and C62.11
Canadian Standards (cUL)
FIPS PUB 94
NEMA LS1-1992 Guidelines
NFPA (NEC), 75 and 78
UL 1449 2nd Edition, 1283, 489, 198, 248-1
Standards and Listings
ATTENUATION FREQUENCY
EMI-RFI FILTER ATTENUATION (dB)
PRODUCT
TVSS 60, 80
TVSS 100, 125, 150
TVSS 200, 250, 300
100 KHz 1MHz 10MHz 100MHz
50 dB 37 dB 38 dB 53 dB
44 dB 33 dB 36 dB 53 dB
41 dB 31 dB 35 dB 53 dB
CS1-
CS1-
CS1-
®