Total Protection Solutions ServiceTrack ST 080 User manual

Surge
Protective
Devices
Installation,
Operation and
Maintenance
Manual
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual
ServiceTrack ST Series:
080, 120, 160, 200, 240,
300 and 400
P.O. Box 3760
Wi ter Park, FL 32790 USA
TEL: [phone]
www.TPSsurge.com
Read entire manual before
attempting installation
CAUTION:

sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual
2
Before Installation
System Configuration Verification
Wiring Connection Diagrams
Upstream Over-Current Protection Device
Con uctor Routing
Con uctor Sizing
Con uit Openings
Mounting
Connection and Wiring Instructions
Phase, Neutral an Groun Connections
Connecting Form C Dry Contacts
Neutral to Groun Filter Jumper
Disconnect Switch Connections
Verification an Power Up
Troubleshooting
Technical Assistance
Returns and Warranty Procedures
Warranty Statement
3 – 7
3
4
5
5
5
5 – 6
7
7 – 9
7
8
9
9
9
10
10
10
11
TABLE OF CONTENTS

1. System Configuration Verification
Confirm that the voltage(s) and service configuration shown on the ServiceTrack ST product label are consistent with the
voltage and service configuration of the facility. A model number is on the right side of the ServiceTrack ST unit. Each model
number corresponds to the configurations printed in the table below:
Example of a SPD model number: TK-ST240-3Y208-FLB1
MODEL NUMBER L-L
VOLTAGE VOLTAGE RANGE VOLTAGE RANGE
TK-STxxx-1P120 108-132 N/A Single-Phase, 120 2-wire+ground
TK-STxxx-1P240 216-264 N/A Single-Phase,
240 2-wire+ground
TK-STxxx-1S240 108-132 216-264 Split-Phase,
120/240 3-wire+ground
TK-STxxx-1S480 216-264 432-528 Split-Phase,
240/480 3-wire+ground
TK-STxxx-3Y208 108-132 187-229 Three-Phase WYE
120/208 4-wire+ground
TK-STxxx-3Y380 198-242 342-418 Three-Phase WYE
220/380
4-wire+ground
230/400 207-253 360-440
TK-STxxx-3Y415 216-264 374-457 Three-Phase WYE
240/415 4-wire+ground
TK-STxxx-3Y480 249-305 432-528 Three-Phase WYE
277/480 4-wire+ground
TK-STxxx-3Y600 312-382 540-660 Three-Phase WYE
347/600 4-wire+ground
TK-STxxx-3D240 120/240 108-132 (A & C P ASES) 216-264 Three-Phase high-leg DELTA
187-229 (B P ASE) 4-wire+ground
TK-STxxx-240NN 216-264 216-264 Three-Phase DELTA
240 3-wire+ground
TK-STxxx-380NN
380 342-418 Three-Phase DELTA
360-440
400 3-wire+ground
415 373-456
TK-STxxx-480NN 432-528 Three-Phase DELTA
480 3-wire+ground
TK-STxxx-600NN 600 540-660 Three-Phase DELTA
3-wire+ground
xxx denotes surge rating per phase (080, 120, 160, 200, 240, 300, or 400)
1Suffixes shown at the end of model number denote available options (-F for enhanced transient filter, -L for component-level fusing, –B for surge counter, –XX for
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual 3
IMPORTANT AFETY IN TRUCTION All work must be performed by licensed and qualified personnel. The electri-
cal system must be properly grounded in accordance with the U. . National Electrical Code, state and local codes or
other applicable codes for this PD to function properly. This device is suitable for installation where the available short
circuit current is 200,000 rms symmetrical amperes at 600VAC or less.
serious personnel injury and/or damage to electrical system. Read the complete installation instructions before
proceeding with installation. Remove all power to the electrical panel before installing or servicing the surge
!
BEFORE INSTALLATION
WARNING: HAZARDOU VOLTAGE PRE ENT Improper installation or misapplication may result in
will not be warranted.
protective device ( PD). Do not install a WYE configured SPD on a DELTA system as failure may result and
L-NNOMINAL CONFIGURATION
L-N / L-G
342-418
360-440
373-456
432-528
540-660
NEMA 4X stainless steel enclosure, and -N for base model available only for 080, 120, 160 models).

2. Wiring Connection Diagrams
Figures 1-5 show the electrical relationship between ServiceTrack ST and these five basic service configurations: Single phase,
2 wire; Split phase, 3 wire; Three phase, 4 wire WYE; Three phase, 3 wire DELTA and Three phase, 4 wire high leg DELTA.
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual
4
Fig. 1: Single Phase, 2-Wire Fig. 2: Split Phase, 3-Wire
Fig. 4: 3-Phase, 3-Wire DELTAFig. 3: 3-Phase, 4-Wire WYE
Fig. : 3-Phase, 4-Wire High-Leg DELTA
SPD
SPD
SPD
SPD
SPD
Connections to the SPD are clearly identified. For 80kA
models, connections are made via pigtail leads supplied with
the unit.
For 120kA to 400kA models, connections are made to
terminals inside the SPD enclosure. These terminals are
marked with labels.
For 3 phase units phase A is marked as “P ASE A”, phase B
is marked as “P ASE B” and phase C is marked as “P ASE
C”. For split phase units, the phase connections are marked
“Phase A” and “Phase B”. For single-phase units, the phase
connection is marked “Phase A”. Neutral (if applicable) is
marked as “N” and ground is marked as “GND”.
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 erviceTrack T PD ( ee NEC
Article 250). If the transformer is not accessible, check the main service disconnect/panel for the N-G bond.
Lack of a proper bond will damage ServiceTrack ST and void the warranty.
!

3. Upstream Over-Current Protection Device
• Optional Component-Level Fusing Units: Model Numbers With “-L” Suffix
making them suitable for use in Type 1 and Type 2 SPD applications. These units DO NOT require an upstream
over-current protection device and can be connected to the electrical distribution system bus.
They have built-in over-current fusing rated at 200,000 rms symmetrical ampere at 600VAC
• Standard ServiceTrack ST Units: Model Numbers With “-N” Suffix - Type 2 SPD
(Example model number: TK-ST080-3Y208-NF)
These units MUST be connected to an upstream over-current protective device (circuit breaker, fuse or fused
switch). The ratings for the upstream over-current protective device are as follows:
For 80kA, 120kA and 160kA units:
Class J or equivalent fused disconnect or circuit breaker rated at 60 amperes maximum/
600 volts maximum.
4. Conductor Routing
The factors listed above should be addressed during the design of an installation to reserve a suitable place for ServiceTrack ST
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 appearance purposes because they will severely decrease the effectiveness of ServiceTrack ST.
Braiding or twisting conductors together using tie-wraps or electrical tape increases the protection performance of the device.
One or two twists or braids of all conductors per foot and securely tie-wrap when conductor lengths must exceed 12”.
. Conductor Sizing
Total Protection Solutions recommends installing ServiceTrack ST by using the following conductor size for phase, ground
and neutral connections. Braiding or twisting conductors together using tie-wraps or electrical tape increases the protection
performance of the device. One or two twists or braids of all conductors per foot and securely tie-wrap when conductor lengths
must exceed 12”.
Example of a SPD model number: TK-ST240-3Y208-FL
TK-ST080-xxxxx 80kA/phase1#10 AWG #10 AWG #10 AWG
TK-ST120-xxxxx 120kA/phase 2#6 AWG #6 AWG #10 AWG
TK-ST160-xxxxx 160kA/phase 2#6 AWG #6 AWG #10 AWG
TK-ST200-xxxxx 200kA/phase 2#2 AWG #2 AWG #10 AWG
TK-ST240-xxxxx 240kA/phase2#2 AWG #2 AWG #10 AWG
TK-ST300-xxxxx 300kA/phase2#2 AWG #2 AWG #10 AWG
TK-ST400-xxxxx 400kA/phase2#2 AWG #2 AWG #10 AWG
180kA rated units are shipped with #10AWG leads. Note: Leads should be shortened during installation in order to minimize
conductor length.
2For direct bus connection maximum wire size is recommended. Otherwise match wire size to the rating of the disconnect breaker.
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual 5
PRODUCT LABEL SURGE CURRENT CONDUCTOR SIZE
DESIGNATION CAPABILITY RECOMMENDED MAXIMUM MINIMUM
CAUTION: Do not splice erviceTrack T conductors within the unit’s enclosure or Manufacturer’s warranty
will be void. erviceTrack T’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 bends.
!
(Example model number: TK-ST240-3Y208-FL)
The ServiceTrack ST models ST120 up to and including ST400 are listed as a Type 1 SPD per UL 1449 3rd Edition,
suitable for use in both Type 1 and Type 2 SPD applications. This means that the ServiceTrack ST can be installed
on the line or load side of the main service disconnect. ServiceTrack ST must be connected in parallel to the electrical system.
The ServiceTrack ST models ST120 up to and including ST400 with the "-L" suffix are listed as Type 1 SPDs

sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual
6
FRONT VIEW RIGHT SIDE VIEW
CONDUIT FITTING HOLE
D
H
LEFT SIDE VIEW
M1
M2
C1
C2
C1
C2
C1
C3
TOP VIEW
SURGE RATING H
"A"
"A"
"A"
Ø0.31 (7.9) TYP
OVERALL DIMENSIONS - IN (mm) MOUNTING HOLES
80, 120, 160kA 9.50 (241.3)
W
6.28 (159.5)
D
6.28 (159.5)
M2
4.00 (101.6)
M1
3/4 (19.0)
A
3.00 (76.2)
C3C2
4.00 (101.6)
C1
TRADE SIZE PUNCH LOCATIONS
CONDUIT FITTING
8.75 (222.3)
ENCLOSURE BODYCOVER
4.38 (111.2)
6.00 (152.4)
240, 300, 400kA 8.28 (210.3)11.50 (292.1) 6.28 (159.5) 5.00 (127.0)1.00 (25.4)10.75 (273.1) 4.38 (111.2) 4.00 (101.6)
MOUNTING HOLES
4.00 (101.6)
6.00 (152.4)
10.00 (254.0)
9.50 (241.3)
11.50 (292.1)
15.50 (393.7)
200 to 400kA
80kA
SURGE RATING
12.28 (311.9)
8.28 (210.3) 6.28 (159.5)
6.28 (159.5)
OVERALL DIMENSIONS - IN (mm)
H
6.28 (159.5)
W
6.28 (159.5)
D M1
4.00 (101.6)
PUNCH LOCATIONS
CONDUIT FITTING
5.00 (127.0)
7.00 (177.8)
1.00 (25.4)
10.75 (273.1)
14.75 (374.6)
4.38 (111.2)
4.38 (111.2)
TRADE SIZE
3/4 (19.0)8.75 (222.3)
M2 A
4.38 (111.2)
C1 C2
4.00 (101.6)
6.00 (154.2)
3.00 (76.2)
C3
STANDARD UNITS
OPTIONAL COMPONENT LEVEL FUSING (-L)
120, 160kA
W
Fig. 6 Conduit Openings and
Enc osure/Mounting Dimensions
1.00 (25.4)

6. Conduit Openings
Note the hub supplied with the unit, when properly installed, ensures the enclosure maintains its NEMA 4 rating.
All conduits and fittings must be rated and properly installed such that the final installation maintains a NEMA 4 rating.
Punch holes in locations indicated in Figure 6 for the conduit hub.
7. Mounting
ServiceTrack ST SPD
For convenience all units are shipped with a mounting kit consisting of a hub, chase nipple, offset nipple, lock washers
and wire bushing. Use the construction methods and hardware appropriate for your site. Install the conduit hub and other
supplied hardware. Install conductors according to sections 4, 5 and 6, herein. See Figure 6 for enclosure and mounting
dimensions.*
ServiceTrack ST Disconnect Switch Options
See the ServiceTrack ST Disconnect Switch Installation and Operations Manual for the proper mounting methods.
*Recommen avoi ing wire-pulling lubricant ue to potential for insulation eterioration, especially on such a short, small con uctor installation.
1. Phase, Neutra , and Ground Connections
NOTE: In order to connect the ServiceTrack ST, the cover of the unit must be removed. Use care when removing the cover,
on the backside of the cover) has a cable harness which routes into the enclosure. Additionally there is a ground jumper
between the enclosure and the cover. Units supplied with a surge counter have a harness, which runs from the surge counter
display to a core inside the unit.
Following all applicable National Electrical Code standards as well as state and local codes, connect phase, neutral* and
ground to ServiceTrack ST. If suppressor is being installed on a breaker, installation electrician should install device directly
adjacent to the breaker feeding the device to insure conductor length is kept to a minimum. The 80ka is supplied with #10
AWG conductors permanently attached. hould mounting conditions require extension of the supplied conductor(s), installa-
tion electrician may use a butt-splice or parallel solder with shrink-tube installation. In no event shall the electrician use a
wire nut to make the extension as this will result in loss of suppressor’s performance. Ensure that the conductor lengths are
kept as short and straight as possible. The 120kA to 400kA units come with lugs that can be rotated to face in the direction of
the cable exit by loosening the nut on the input terminal lugs in the SPD. Tighten all lugs to 20in-lb (2.2Nm). On all high-
leg delta systems, the high-leg (color-coded orange according to NEC) must be connected to the Phase B of the SPD.
* The 3-wire plus groun Delta ServiceTrack ST oes not have a neutral con uctor.
CONNECTION AND WIRING INSTRUCTIONS
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual 7
rating of the erviceTrack T unit being installed. Do not splice erviceTrack T conductors within the unit’s
enclosure or Manufacturer’s warranty will be void.
!
The 80kA unit comes with a 3/4” conduit hub. This hub requires a 1- 1/8” diameter hole for proper installation.
Note the hub supplied with the unit, when properly installed, ensures the enclosure maintains its NEMA 4 rating.
The 120kA to 400kA units come with a 1”conduit hub. This hub requires a 1-11/32” diameter hole for proper installation.
CAUTION: Prior to installation ensures the system configuration and voltage are equivalent to the voltage
as there are wires which run from components on the cover to inside the enclosure of the SPD. The monitor board (located
There are no position-oriented components. Unit may be installed in whatever position allows shortest conductor length
to point of termination
Note: Disconnect SPD from electrical system prior to and during any Hipot testing

2. Connecting Form C Dry Contacts
All ServiceTrack ST 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 circuit. The relay contacts are rated
65VDC/150VAC with maximum switching power of 30WDC/60VA AC. See Figure 7 for the form C contact 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.
#18AWG to #20AWG is recommended.
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual
8
COVER REAR VIEW
Fig. 7 Remote Monitoring Termina B ock
Contacts shown in energized norma state.
(No fau t condition)
Insta SPD direct y adjacent to the point of termination to insure conductor ength is as short as possib e
for optimum performance and protection.

3. Neutral to Ground Filter Jumper
All ServiceTrack ST models with enhanced transient filter, “-F” suffix, (which have a neutral connection) come with a green
jumper wire, which loops out of the epoxy and connects the filter from neutral to ground. In certain medical applications or
circuits which employ or contain Ground Fault Circuit Interrupting protection, this Neutral to Ground filter connection
Removal is accomplished by cutting the green jumper wire. Once cut, both ends should be properly separated and insulated
to prevent the ends from making inadvertent electrical contact.
4. Disconnect Switch Connections
See the ServiceTrack ST Disconnect Switch Installation and Operations Manual for the proper connection methods.
. Verification and Power Up
Apply power to ServiceTrack ST by closing the over current protection device or switch feeding the suppressor.
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual 9
For Standard Units
Verify that all “Phase Protection Status” indicating lights are illuminated.
The “Check System” 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 subsequently will illuminate
the “ALARM SILENCED” light. Pressing the “ALARM SILENCE” button
again will enable the alarm.
For Units with Surge Counter Monitoring “-B” Option
The number of surges detected by the SPD is displayed on an eight-digit
LCD display on the front of the ServiceTrack ST 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. 8 Standard Monitoring
Fig. 9 Surge Counter Option
R
Marking Systems, Inc.
4720 Industrial
Rowlett, TX 75088412
972
0791
475
972
0770
x110
P/N
Nameplates
Insulators
Overlays
Prototypes
Labels
www.markingsystems.com
126-0311-005 REV 2
SCALE 1 : 1 IN PDF FILE
WHITE AND PMS 032 RED GRAPHICS ON DARK BLUE MATCH BACKGROUND
DANAHER POWER SOLUTIONS
ON/OFF BACKGROUND IS LIGHT BLUE MATCH
PROOF
LABEL SIZE: 6.28 X 8.28 (.25 RC)
DWG#
DRAWN BY:
DPS311005
SEND ANOTHER PROOF.
GALE ROGERS
SIGNATURE:
FROM:
DATE:
APPROVED WITH CHANGES AS MARKED.
TO:
FAX NO.
This is a black and white proof of your artwork, which shows type style, size and location.
order, in the event differences exist. Material and ink colors will be in accordance with your order.
approval, your order will be printed exactly according to this proof. Approval signifies that this proof
RETURN THIS PROOF PROMPTLY. SHIPMENT OF YOUR ORDER IS BEING DELAYED PENDING ITS RETURN.
copy conforms to this proof.
APPROVED AS IS.
supersedes any documentation supplied with the
Check all data carefully for accuracy. Upon receipt of your
No credit will be given for printed product whose
FAXTEL
R
WARNING: Prior to proceeding, ensure the PD unit is fully disconnected and does not have voltage applied
to its input terminals.
WARNING: It is recommended that the cover of the erviceTrack T 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.
!
!
should be removed to avoid any nuisance tripping the breaker.

Your ServiceTrack ST system does not require scheduled maintenance. The unit’s heavy-duty construction is designed to pro-
vide 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 :00 p.m. (EST) at 800-647-1911
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual
10
TROUBLESHOOTING
One or more phase protection status indicating lights
are off, check system indicating light is on and form C
alarm contacts have changed state
Verify that the input power feeding ServiceTrack ST is
energized using a voltage tester. If power is present,
contact factory for assistance:
800-647-1911.
INDICATION PROCEDURE
INFORMATION EXAMPLE
Model Number TK-ST240-3Y208-FL
Serial Number
Date of Purchase
Sales Order Number 15478
Description of Failure “Check System” indicating light illuminated
Desired Action Replace
TECHNICAL ASSISTANCE
RETURNS AND WARRANTY PROCEDURES
15478-0111-001
January 2, 2011 (1st week)
ServiceTrack ST products are warranted for a period of 30 years from date of purchase. In the event that any module or sub-
assembly within the SPD fails to perform as specified during the warranty period, call our Technical Support at 800-647-1911
to obtain a Return Material Authorization number. We will ship a replacement for the defective parts free of charge
(installation labor and site preparation excluded). Return the defective parts within 30 days of receiving the replacement
unit as soon as it is removed from the electrical system and in no event later than one week following the date of receipt
of the replacement unit.Failure to return the defective parts will result in billing for the replacement parts. To help expedite the
return procedures, please have the following information at hand when you contact Total Protection Solutions:

During the applicable warranty period, any Total Protection Solutions®surge protector device which fails due to defect in
materials, workmanship, or any transient surge event to include lightning, shall be repaired or replaced at the expense of the
manufacturer.
Prior to shipment of any suspect or known defective product a Return Material Authorization (RMA) number must be
obtained. An official RMA number and shipping instructions can be obtained from the distributor where the product was
originally purchased. Distributors can obtain the official RMA number by contacting the Total Protection Solutions Customer
Service Department at 800-647-1911. Products arriving without an official RMA number will not be accepted and will be
returned freight collect to the original point of shipment.
Products being returned with an official RMA number should be shipped by prepaid freight to the nominated point of return
as shown on the RMA documentation.
Total Protection Solutions shall have no liability under this warranty for problems or defects directly or indirectly caused by
misuse of the Product, alteration of the Product (including removal of any warning labels), accidents, improper installation,
application, operation or improper repair of the Product.
T IS WARRANTY REPRESENTS T E ENTIRE WARRANTY OF TOTAL PROTECTION SOLUTIONS. ALL OT ER
WARRANTIES EXPRESS OR IMPLIED, ORAL OR WRITTEN, INCLUDING, BUT NOT LIMITED TO, T E WARRANTIES OF
MERC ANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EREBY DISCLAIMED. T E LIABILITY OF TOTAL
PROTECTION SOLUTIONS, AT ITS SOLE OPTION, UNDER T IS WARRANTY IS EXPRESSLY LIMITED TO T E REPLACE-
MENT OR REPAIR OF T E DEFECTIVE PART T EREOF. IN NO EVENT S ALL TOTAL PROTECTION SOLUTIONS BE
LIABLE OR RESPONSIBLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND OR C ARACTER,
NOR S ALL ITS LIABILITY EVER EXCEED T E PURC ASE PRICE PAID FOR SUC DEFECTIVE PRODUCT.
This warranty is not transferable and may only be enforced by the original purchaser. Claims under this warranty must be
submitted to Total Protection Solutions within thirty (30) days of discovery of any suspected product defect.
Warranty Period
ServiceTrack®ST 30 years
sERVICEtRaCk st®InstallatIon, opERatIon and MaIntEnanCE Manual 11
TPS WARRANTY STATEMENT
30 YEAR
W A R R A N T Y
W A R R A N T Y
30 YEAR
F R E E 
REPLACEMENT

30 YEAR
WARRANTY
WARRANTY
30 YEAR
F R E E 
REPLACEMENT
®
by
®
P.O. Box 3760
Wi ter Park, FL 32790 USA
www.TPSsurge.com
1.800.647.1911
©2011 TOTAL PROTEC CCCTION SOLUTIONS, LLC CCC PRINTED IN U.S.A. ALL RIGHTS RESERVED. PN 750-0092-001 REV 7 3.9.11
C