Red ALARM light ON or
Audible Alarm ON indicates
loss of protection. Refer to
the operation manual for
troubleshooting help.
AlarmNeutral
L1 L2 L3
L1 L2 L3
Ground
Green lights ON indicate
power present and protection circuits for each mode
are operating propely.
One or more Green lights
OFF indicates loss of power
or protection. Refer to the
operation manual for
troubleshooting help.
Electrical Panel Extension Hardwired Surge
INTRODUCTION
The PG60-80-100 Series is designed to be installed in very close proximity to the power bus of an electric distribution panel or electric panelboard. It can be used with most panels or panelboards in distribution
today. The PG60-80-100 Series offers peak surge amperage protection
levels of 60 kA to 100 kA per mode. It is designed to be easily mounted
above or below the panelboard. Provisions have been made with a
reversible cover plate to keep the instructions and indicators in a user
friendly position. Standard features include all mode protection, multimode LED indicators that show full protection, diminished protection and
lost protection for all phases. A form C relay for remote alarm indication,
audible trouble alarm with test and silence switch are also standard
equipment.
The system is comprised of three sections; outer housing, cover plate
and inner module. Each section is engineered to make the installer/service technician's task as easy as possible. A description of each section
and the function follows.
Outer Housing - Metal housing measuring 20" wide x 16" high x 6"
deep. The outer housing contains the inner housing. connection lugs for
each phase, neutral and ground, connections for the form C alarm relay
and the audible alarm test and silence switch.
5/8" flange on the forward side of the housing has ten (10) threaded
A
holes that are used to attached the cover plate. Four (4) mounting holes
are located in the back surface of the housing for mounting. It is sug
gested that all four (4) fasteners be used to secure the outer housing.
Cover Plate - Metal plate measuring 19 13/16" wide x 15 13/16" high.
The cover plate contains ten (10) holes located around the edges that
matched the threaded holes in the outer housing and are used to secure
the cover plate to the outer housing. The cover plate is reversible and
has an identification label on both front and reverse sides. The labels
are mirror images of each other and selection of which side to use
depends upon the placement of the outer housing. (This process will be
explained in the installation section that follows.)
Inner Module - Metal box measuring 13 3/16" wide x 9 3/4" high x 4
15/16" deep including the mounting rails that are part of the module.
The inner module is fastened to the outer housing with four (4) bolts
through the mounting rails. Module identification and wiring diagram
labels are attached to the inner module. The inner module contains all
of the surge suppression, noise filtering, fusing, monitoring and reporting
components. Copper bus bars and terminal lugs extend from the inner
module.
NEC Section 285 requires that a SPD have a fault current rating equal
to or greater than the point of installation (switchboard or panelboard).
The PG60-80-100 Series is suitable for use on a circuit capable of delivering not more than 200,000 amperes (120/208-3Y, 120/240-2S,
120/240-3HLD, 277/480-3Y models). 480-3D models are rated at
25,000 amperes. Should you require a 480-3D model with a higher fault
current rating consider Intermatic PG2500/PG3000/PG3500 Series
which are rated at 200 kAIC.
-
INSTALLATION INSTRUCTIONS
and
OPERATIONS MANUAL
Model # PG100 - 208 - 3Y
PEAK SURGE RATING
PG6060 kA per Mode
PG8080 kA per Mode
PG100100 kA per Mode
SUPPLY VOLTAGE AND CONFIGURATION
240-2S120/240 Single Phase
208-3Y120/208 Three Phase Wye
240-3HLD 120/240 Three Phase H. L. Delta
480-3Y277/480 Three Phase Wye
480-3D480 Three Phase Delta
6.0”
20.0”
16.0”
INSTALLATION INSTRUCTIONS and OPERATIONS MANUALPG60-80100 SERIES - V.10-03
WARNING
BUS BARS AND TERMINAL LUGS ARE ENERGIZED
DURING NORMAL OPERATING CONDITIONS. ONLY A
QUALIFIED PERSON SHOULD PERFORM SERVICE.
UNPACKING
Open the carton, remove the PG60 - 100 Series unit and examine the outer housing and cover for shipping damage. If damage is
observed, notify your supplier.
Remove the cover plate by removing the ten (10) bolts that secure it and examine the inner housing, bus bars, connecting lugs and
the alarm device for shipping damage. If damage is observed, notify your supplier.
BEFORE INSTALLATION
1. All electrical wiring and connections should be installed by a
qualified electrician. All wiring must comply with the National
Electrical Code (NEC) and local codes.
2. This Surge Protection Device (SPD) incorporates a NEMA 12
enclosure.
3. The installation and operation of any Surge Protection Device
(SPD) requires proper grounding. A properly sized, insulated
grounding conductor is required. The grounding conductor should be
the same wire size (gauge) as the phase and neutral conductors
used for the SPD. Refer to Table 2 for recommendations.
4. The service entrance and panel grounding configurations must
comply with the National Electrical Code and all local codes.
3. Select a location opposite the incoming feed to the panelboard.
The SPD must be mounted in an area that provides sufficient working space around the panelboard and SPD cabinet.
5. The collar and/or conduit used to connect this SPD to the panelboard must be sized correctly for the gauge and length of wire
required. The length of conduit should allow no more than 1/16”
between the edge of the SPD cover plate and the panelboard cover.
TEST and verify system voltage to assure proper selection of
6.
the Surge Protection Device (SPD) in accordance with the wiring diagrams shown below and on the labels located on the inner module.
If the voltage or the number of conductors does not agree with the
information supplied with the Surge Protection Device, contact your
supplier. If you have questions about the proper use of this unit for
your application, contact Intermatic at the numbers listed under
TECHNICAL ASSISTANCE on page 5 of this publication.
PG60 - PG80 - PG100 Series
with cover plate removed. Unit in position
to be installed at the top of panelboard.
FRONT
Wire Pass-through area
Low voltage alarm
contact wiring area
1.980”
INSTALLATION INSTRUCTIONS and OPERATIONS MANUAL2PG60-80-
AC Voltage wiring area
REAR
20.0”
Table 1
9.195”
Wire
Pass-
through
area
3.438”3.438”
5.75”
6.0”
Figure 1
120/240 VAC Single Phase
Line to Line: 240v.; Line to Neutral: 120v.; Line to Ground: 120v.
Figure 2
120/208 VAC Three Phase Wye
Line to Line: 208v.; Line to Neutral: 120v.; Line to Ground: 120v.
Figure 3
120/240 VAC Three Phase
High Leg Delta
PG60-240-2S
PG80-240-2S
PG100-240-2S
N
L2
L1
PG60-208-3Y
PG80-208-3Y
PG100-208-3Y
N
L2
L1
L3
PG60-240-3HLD
PG80-240-3HLD
PG100-240-3HLD
N
L2
L1
L3
G
G
**
Line to Line: 240v.; Line to Neutral: 120v.; Line to Ground: 120v.
** High Line to Neutral: 208v.; High Line to Ground: 208v.
Figure 4
277/480 VAC Three Phase Wye
Line to Line: 480v.; Line to Neutral: 277v.; Line to Ground: 277v.
Figure 5
480 VAC Three Phase Delta
Line to Line: 480v
.; Line to Ground: 480v.
PG60-480-3Y
PG80-480-3Y
PG100-480-3Y
L2
L1
L3
PG60-480-3DLL
PG80-480-3DLL
PG100-480-3DLL
L2
L1
L3
N
G
INSTALLATION (above panelboard)
1. Turn OFF and LOCK the electric power supply to the panelboard.
2. SELECT the location where the Surge Protection Device
(SPD) will be mounted, above or below the electric panel.
Position the SPD adjacent to the electric panel with the bus bars
pointed toward the panel. NOTE: If the SPD is mounted below
the electric panel, the labels on the inner housing will be inverted. Refer to INVERTED INSTALLATION section below for information regarding the inverted installation. Align the SPD to allow
1/16” between the SPD cover plate and the cover of the panelboard. The SPD should be secured to a flat vertical surface that
can support the weight of the device.
3. Temporarily fasten the SPD to the vertical surface and mark
the location where a hole for the collar or conduit will enter.
Refer to Table 1 for acceptable locations on the bottom of the
Outer Housing that can be drilled for wire entry. Note that wiring
G
for the remote monitoring relay enters separate from the AC
power leads. Remove the SPD unit and drill a hole of suf
size to accept the collar or conduit connector. Attach the collar or
connector to the SPD outer cabinet and mount the unit with the
collar or connector inserted into the knockout in the panelboard.
4. Use the proper gauge wire to connect each of the lugs on
the SPD to the appropriate points on the electric panel. See
able 2 for recommended wire and breaker sizes.
T
icated circuit breaker is optional since the SPD has integral
overcurrent fusing. The SPD can be connected through feedthru lugs on a panelboard.
a breaker or direct tapped for Switchboard installations.
position for the connection that results in the shortest lead
lengths between the SPD and the power bus. Leads should be
kept as short as possible to insure optimum operation. Measure
and cut all leads to proper length. Strip the ends of each lead
9/16" for the SPD terminal lugs and to proper length for the
breaker used. Connect the wire leads to the lugs on the bus
bars of the SPD.
486 torque tightening requirements.
NOTE: For safety, observe proper wire marking
conventions; BLACK for HOT, RED for HOT HIGH
LEG, WHITE for NEUTRAL, GREEN for GROUND.
5. Route the wire lead bundle through the collar or connecter
into the electric panel.
G
6. Connect the GROUND (green) lead to the ground bus in
electric panel.
7. If used, connect the NEUTRAL (white) to the neutral bus in
the electric panel. If installing at a main electrical panel, the neutral and ground leads could terminate at a common bus bar in
the panel.
Connect the phase leads to the appropriate breaker in the
8.
electric panel.
NOTE: For HIGH LEG DEL
high leg is connected to the center bus bar position in
the SPD. (Refer to Figure 3)
Connect wires to the alarm relay leads if used. Alarm wires
9.
should be routed through a hole in the outer housing that is separate from the power leads. If the alarm relay is not used, leave
the wires in the low voltage section, they will have no power and
do not need to be capped. Refer to the alarm wiring drawings
on page 3 or on the wiring label on the inner housing for wire
designation.
The SPD can be connected through
orque the lugs 35 to 50 inch pounds per UL
T
TA, make certain that the
10. CHECK all connections for correct torque.
ficient
Use of a ded
Select a
-
INSTALLATION INSTRUCTIONS and OPERATIONS MANUAL3PG60-80-100 SERIES - V.10-03
Use the following table as a guideline for the PG60, PG80 and PG100 Surge Protection Devices. All models have integral overcurrent fusing and
the use of a dedicated circuit breaker is optional. Lugs accept wire sizes from 10 AWG to 2 AWG. Keep all leads as short and straight as possi-
ble, avoiding sharp 90 degree bends. Increase wire size when lead length is extended.
Table 2
SUGGESTED WIRE and BREAKER SIZES
INVERTED INSTALLATION (under panelboard)
1. Turn OFF and LOCK the electric power supply to the panelboard.
2. SELECT the location where the Surge Protection Device (SPD) will
be mounted below the electric panel. Position the SPD adjacent to the
electric panel with the bus bars pointed toward the panel. NOTE:
labels on the inner housing will be inverted. Align the SPD to allow
1/16” between the SPD cover Plate and the cover of the panelboard.
The SPD should be secured to a flat vertical surface that can support
the weight of the device.
3. Temporarily fasten the SPD to the vertical surface and mark the
location where a hole for the collar or conduit will enter. Refer to Table
1 for acceptable locations on the bottom of the Outer Housing that can
be drilled for wire entry. Note that wiring for the remote monitoring relay
enters separate from the AC power leads. Remove the SPD unit and
drill a hole of sufficient size to accept the collar or conduit connector.
Refer to Table 2 for suggested collar or conduit sizes. Attach the collar
or connector to the SPD outer cabinet and mount the unit with the collar
or connector inserted into the knockout in the panelboard.
Use the proper gauge wire to connect each of the lugs on the SPD
4.
to the appropriate points on the electric panel. See Table 2 for recommended wire and breaker sizes. Use of a dedicated circuit breaker is
optional since the SPD has integral overcurrent fusing. The SPD can
be connected through feed-thru lugs on a panelboard.
connected through a breaker or direct tapped for Switchboard installations. Select a position for the connection that results in the shortest
lead lengths between the SPD and the power bus. Leads should be
kept as short as possible to insure optimum operation. Measure and cut
all leads to proper length. Strip the ends of each lead 9/16" for the SPD
terminal lugs and to proper length for the breaker used. Connect the
wire leads to the lugs on the bus bars of the SPD.
50 inch pounds per UL
For safety
NOTE:
BLACK for HOT
GREEN for GROUND.
5. Route the wire lead bundle through the collar or connecter into the
electric panel.
6. Connect the GROUND (green) lead to the ground bus in electric
panel.
7. If used, connect the NEUTRAL (white) to the neutral bus in the
electric panel. If installing at a main electrical panel, the neutral and
ground leads could terminate at a common bus bar in the panel.
8. Connect the phase leads to the appropriate breaker in the electric
panel.
NOTE: For HIGH LEG DELTA, make certain that the high leg is connected to the center bus bar position in the SPD. (Refer to Figure
3)
Connect wires to the alarm relay leads if used.
9.
be routed through a hole in the outer housing that is separate from the
power leads. If the alarm relay is not used, leave the wires in the low
voltage section, they will have no power and do not need to be capped.
Refer to the alarm wiring drawings on page 3 or on the wiring label on
the inner housing for wire designation.
486 torque tightening requirements.
, observe proper wire marking conventions;
, RED for HOT HIGH LEG, WHITE for NEUTRAL,
The SPD can be
orque the lugs 35 to
T
Alarm wires should
10. CHECK all connections for correct torque.
INSTALLATION INSTRUCTIONS and OPERATIONS MANUAL4PG60-80-100 SERIES - V.10-03
ALARM RELAY CONNECTIONS
The
Brown - c
Normal operating condition - relay energized
Brown - c
Alarm condition - relay not
energized
Figure 6
ALARM RELA
Relay:Single pole double throw.
Power Rating:
Operation:Energized during normal conditions.
ALARM CONDITIONS
Alarm sounding and relay in "alarm state"
1.
will reverse state upon the loss of one or more protection com
ponents.
2.
by qualified personnel. Remove the ten (10) bolts holding the
cover plate in place.
3. Move the Alarm Switch to the SILENCE position. The local
audible alarm should silence but the alarm relay output should
remain in the alarm condition until the unit is returned to normal
operating condition.
4.
minal lugs. CAUTION: LINE VOLTAGE MAY BE PRESENTAT
THE
5. Turn the breaker OFF and then ON to reset the SPD.
6. If the alarm condition will not clear upon reset and the line
voltages are present and are of the correct value, contact
Intermatic TECHNICAL ASSISTANCE at the number given on
page 5 of this publication.
Alarm not sounding but relay in "alarm state"
1.
alarm will not sound under the following conditions:
2.
tion. If all of the Line indicator lights are ON and the
cator light is OFF
remote monitoring system.
Y SPECIFICATIONS
120 VAC - 500 mA
24 VAC - 1 A.
De-energized during alarm conditions or loss
of power.
The audible alarm will sound and the alarm relay output
The following steps should be performed only
CAUTION:
erify that the proper voltage is present at each of the ter-
V
TERMINAL LUGS.
The alarm relay output will change state but the audible
a) Loss of power to the PG Series unit.
b) The circuit breaker in the electric panel that is feeding
the SPD is turned to the OFF position or tripped.
c) A fault exists in the remote monitor system.
Check for PROTECTION ST
TUS indicator light illumina
A
, consult directions for trouble shooting the
Violet - n/c
Orange - n/o
Violet - n/c
Orange - n/o
Alarm indi
-
-
-
ALARM
OPERATION
PROTECTIO
N MODES
CAUTION; HIGH V
OLT
AGE INSIDE
SEVICE BY QUALIFIED
PERSONN
EL ONL
Y
Red ALARM
light ON or
Audible Alarm
ON indicates
loss of protection. Refe
r to
the operatio
n manual for
troubleshoo
ting help.
Alarm
Neutral
L1
L2
L3
L1
L2
L3
Ground
Green lights ON indicat
e
power prese
nt and protec-
tion circuits for each mo
de
are operating propely
.
One or more
Green lights
OFF indicates loss of
power
or protection. Refer to th
e
operation manual for troubleshoo
ting help.
ALARMOPERATION
PROTECTION MODES
CAUTION; HIGH VOLTAGE INSIDE
SEVICE BY QUALIFIED PERSONNEL ONLY
Red ALARM light ON or Audible Alarm ON indicates loss of protection. Refer to the operation manual for troubleshooting help.
AlarmNeutral
L1L2L3
L1L2L3
Ground
Green lights ON indicate power present and protec- tion circuits for each mode are operating propely. One or more Green lights OFF indicates loss of power or protection. Refer to the operation manual for troubleshooting help.
FINAL CHECKOUT PROCEDURE
1. CHECK all connections for correct location and torque.
Make sure that the electrical panel and the SPD are clear of all tools, metal parts and personnel.
2.
urn power ON to the electrical panel.
T
3.
4. Place Alarm Switch in the NORMAL position.
5. Turn the power ON to the SPD.
Check all PROTECTION ST
6.
PROTECTION MODE indicators ON.
ALARM indicator OFF.
Check output continuity for the
7.
(a) Common to Normally Open = greater than 10 M ohms, (b) Common to Normally Closed = 0 ohms.
Alarm should be silent.
Audible
The
8.
9. Place Alarm Switch in SILENCE position: Audible alarm should sound. Return Alarm Switch to normal position.
10. Place Alarm Switch in TEST position. Audible alarm should sound, the Red Alarm Indicator LED should be ON and the alarm relay
outputs should reverse state. Return the switch to the NORMAL position.
OPERATION
1. The ALARM SWITCH should be in the NORMAL position for standard operating conditions.
The COVER PLATE must be in position with all bolts secured to prevent access by unauthorized personnel.
2.
The PROTECTION MODE indicator lights should be ON.
3.
The ALARM indicator light should be OFF.
4.
Periodic functional checks of the system as required by local codes or procedures are conducted by performing steps 9 and 10 of
5.
COVER PLA
The cover plate has labels on the front and back.
One side has the labels positioned for use when
the SPD is located at the top of the electrical
panel. The second side of the cover plate is used
when the SPD is positioned at the bottom of the
electric panel. MAKE SURE THAT THE PROPER
SIDE IS PLACED FOR
LIGHTS ARE VISIBLE.
SPD mounted above the Panelboard
1.
housing so that the mounting holes align with the
threaded holes and the indicator light positions in the
label align with the indicator lights in the inner mod
ule.
NOTE: In this application, the label with the LED indi
cators will be at the top of the cover plate.
SPD mounted under the Panelboard
1. Position the cover plate on the face of the outer
housing so that the mounting holes align with the
threaded holes and the indicator light positions in the
label align with the indicator lights in the inner mod
ule.
NOTE: In this application, the label with the LED indicators will be at the bottom of the cover plate.
TECHNICAL ASSISTANCE
For application or technical assistance contact
Intermatic at 1-800-391-4555 or on the web at
www
CHECKOUT
the FINAL
TE INSTALLA
Position the cover plate on the face of the outer
.intermatic.com.
TUS Line indicator lights for proper illumination.
A
Alarm Relay if used.
PROCEDURE.
TION
WARD AND ALL INDICATOR
-
-
-
Main breaker
Wire pass-
through areas
TYPICAL INSTALLATIONS
Neutral bus
Alarm relay
wiring area
circuit breaker
Ground bus
Alarm relay
wiring area
Neutral bus
Main breaker
Figure 6
ire pass-
W
through areas
INSTALLATION INSTRUCTIONS and OPERATIONS MANUAL5PG60-80-100 SERIES - V.10-03
ALARM
OPERATION
PROTECTIO
N MODES
CAUTION; HIGH V
OLT
AGE INSIDE
SEVICE BY QUALIFIED
PERSONN
EL ONL
Y
Red ALARM
light ON or
Audible Alarm
ON indicates
loss of protection. Refe
r to
the operatio
n manual for
troubleshoo
ting help.
Alarm
Neutral
L1
L2
L3
L1
L2
L3
Ground
Green lights ON indicat
e
power prese
nt and protec-
tion circuits for each mo
de
are operating propely
.
One or more
Green lights
OFF indicates loss of
power
or protection. Refer to th
e
operation manual for troubleshoo
ting help.
ALARMOPERATION
PROTECTION MODES
CAUTION; HIGH VOLTAGE INSIDE
SEVICE BY QUALIFIED PERSONNEL ONLY
Red ALARM light ON or Audible Alarm ON indicates loss of protection. Refer to the operation manual for troubleshooting help.
AlarmNeutral
L1L2L3
L1L2L3
Ground
Green lights ON indicate power present and protec- tion circuits for each mode are operating propely. One or more Green lights OFF indicates loss of power or protection. Refer to the operation manual for troubleshooting help.
TEN YEAR LIMITED PRODUCT WARRANTY
Intermatic PG60-80-100 Series SURGE PROTECTION DEVICES
For
(1) What Is Covered By This Limited Warranty
Repair or Replacement of Product
Intermatic Incorporated ("Intermatic") warrants to the original purchaser only
PG60-240-3HLD, PG60-480-3Y
PG100-240-2S, PG100-208-3Y
(each a "Product") shall be free from defects in material or workmanship for a period of ten years (120 months) from date of pur
chase or 126 months from date of manufacture. If the purchaser discovers a defect in material or workmanship, the purchaser must
promptly submit a warranty claim. Upon a determination by Intermatic that the Product is defective, Intermatic shall correct any
defect in material or workmanship by, at Intermatic's option, either repairing or replacing the defective Product. Any repair, including
both parts and labor, shall be at Intermatic's expense. The foregoing remedies are the purchaser's exclusive remedies for a breach
.
of warranty
For purposes of this Limited Warranty, a Power Transient shall mean over-voltage resulting from momentary voltage spikes or
surges on an AC power line of magnitude that the Product, according to its specifications, is designed to stop before such spikes or
surges affect downstream equipment.
The Product must be installed in the appropriate application in complete accordance with the installation instructions. All building
wiring and other connections to the Product must conform to all applicable national, state and local electrical codes; the Product
must not be opened, modified, exposed to extreme heat or cold, submerged or subjected to abnormal use or service. All products
must be used in accordance with the instructions provided with the Product and the purchaser shall be solely responsible for selecting a Product model with specifications appropriate for the equipment to be protected. Intermatic shall determine, in its sole discretion, whether any Product returned by a purchaser has been used in accordance with its instructions, is an appropriate model for the
purchaser's use thereof, and whether the Product is defective.
(2) What Is Not Covered By This Warranty
Intermatic does not warrant (a) defects in the Product or damage to any equipment caused by the failure to properly install the
Product; (b) damage caused by use of the Product for purposes other than those for which it was designed; (c) damage caused by
disaster such as fire, flood and wind; (d) damage caused by unauthorized attachments or modification of the Product; (e) damage to
the Product occurring during shipment; (f) damage caused by electrical disturbances exceeding published product specifications or
(g) damage to the Product caused by any other abuse or misuse by the purchaser.
(3) Disclaimer of Warranty
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER EXPRESSED WARRANTIES. TO THE EXTENT ALLOWED BY
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN
ANY
,
W
LA
TO THE DURATION OF THIS LIMITED WARRANTY.
TION
DURA
Limitation of Remedies
(4)
IN NO CASE SHALL
UPON BREACH OF WARRANTY, BREACH OF CONTRACT, NEGLIGENCE, STRICT TORT, OR ANY OTHER LEGAL THEORY.
SUCH EXCLUDED DAMAGES INCLUDE, BUT ARE NOT LIMITED TO, DAMAGE TO SOFTWARE, LOSS OF DATA, LOSS OF
PROFITS, LOSS OF SA
AL, COST OF
OF CAPIT
PARTIES INCLUDING CUSTOMERS, DAMAGE TO PROPERTYAND PERSONAL INJURY. SOME STATES DO NOT ALLOW
LIMITS ON W
THIS PARAGRAPH AND IN PARAGRAPH (3) MAY NOT APPLY.
(5)
No action arising out of any claimed breach of warranty may be brought more than one year after the cause of action has occurred.
(6)
Unless modified in writing signed by both parties, this agreement is understood to be the complete and exclusive agreement
between the parties, suspending all prior agreements, oral or written, and all other communications between the parties relating to
the subject matter of this aggreement. No employee of Intermatic or any other partyis authorized to make any warranty in addition to
those made in this aggreement.