Total Protection Solutions ServiceTrack 200, ServiceTrack 300, ServiceTrack 400 Operating Instructions Manual
®
Surge
Total Protection
Solutions
Protective
Devices
ServiceTrack Series:
200, 300 and 400
Installation,
Operation and
Maintenance
Manual
SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
TABLE OF CONTENTS
Introduction
Before Installation
System Configuration Verification
Wiring Connection Diagrams
Upstream Over-Current Protection Device
Conductor Routing
Conductor Sizing
Conduit Openings
Mounting
Connection and Wiring Instructions
Phase, Neutral and Ground Connections
Connecting Form C Dry Contacts
Verification and Power Up
Troubleshooting
3
4
4
5
6
6
6
6
7
7
7
8
8-9
9
Module Replacement
Technical Assistance
Returns and Warranty Procedures
Warranty Statement
9
10
10
11
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SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
INTRODUCTION
Today’s sophisticated electronic equipment requires reliable, surge protective devices. By selecting Joslyn®, Total Protection
Solutions
life for your equipment.
The ServiceTrack surge protective device connects to your electrical distribution system to protect sensitive electrical
and electronic equipment against the harmful effects of lightning strikes, induced transients on AC power lines, internally
generated transients and high-frequency noise. ServiceTrack fulfills the single-pulse surge current capacity testing
recommendations per NEMA LS1-1992, paragraphs 2.2.9 and 3.9.
ServiceTrack provides advanced surge protection and filtering technology. Created for optimum reliability and flexibility,
ServiceTrack offers unrivaled protection and features in a modular, building-block design with a choice of four types of
suppression modules: Metal Oxide Varistor (MOV); Silicon Avalanche Diode (SAD); and High-Frequency Filter. This innovative modularity allows simple and quick maintenance procedures should a module need to be replaced. Each suppression and
filter module has an at-a-glance, bicolor status light (green = healthy and red = fault) to confirm the individual elements of
the suppressor system are functioning properly. In addition, each module has a keyed mounting as well as color-coded labels
to ensure correct module replacement:
™
, ServiceTrack™ devices, you have taken a critical step toward decreasing downtime and ensuring longer product
STRIPE COLOR MODULE TYPE
Red 100 kA MOV
Purple 10 kA SAD
Green Filter
ServiceTrack’s unique design provides true, fail-safe protection. An individual thermal cut-off on each MOV and SAD
protects against temporary overvoltage, limited short circuit current conditions and ensures clean end-of-life performance.
MOV module has 20kA backup MOVs to provide continuous protection.
ServiceTrack offers a full range of monitoring options. Choices range from the basic commercial-power and suppressor-status
indicator lights with Form C dry relay contacts, to the full-featured package, featuring audible alarm with disable switch and
surge event counter.
ServiceTrack’s robust NEMA 4/4X enclosure allows installation in outdoor and corrosive environments.
!
▲▲
Improper installation or misapplication may result in 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 suppressor.
All work must be performed 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 suppressor
to function properly. Do not connect ServiceTrack to the line side of the main service breaker or disconnecting means.
Do not install the suppressor where the available short circuit current to ServiceTrack is more than 100,000 RMS
symmetrical amperes at 480VAC.
WARNING: HAZARDOUS VOLTAGES PRESENT
IMPORTANT SAFETY INSTRUCTIONS
SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
3
1. System Configuration Verification:
BEFORE INSTALLATION
1. System Configuration Verification
Confirm that the voltage(s) and service configuration shown on ServiceTrack product label are consistent with the voltage
and service configuration of the facility. A model number is on the label inside ServiceTrack door. Each model number
corresponds to the configurations printed in the table below:
Example of a suppressor model number: TK-SE200-3Y208-A
MODEL NUMBER
TK-SExxx-1P120 102-132 N/A
TK-SExxx-1P240 196-276 N/A
TK-SExxx-1S240 102-132 204-264
TK-SExxx-3Y208 102-132 177-229
TK-SExxx-3Y380 220/380 187-264 323-460
TK-SExxx-3Y480 236-305 408-528
TK-SExxx-3Y600 295-399 510-690
TK-SExxx-3D240 120/240
TK-SExxx-240NN N/A 204-264
NOMINAL L-N L-L
VOLTAGE VOLTAGE RANGE VOLTAGE RANGE
120
240
120/240
120/208
277/480
347/600
(A & C PHASES)
240
102-132
177-229
(B PHASE)
204-264
CONFIGURATION
Single-Phase,
2-wire+ground
Single-Phase,
2-wire+ground
Split-Phase,
3-wire+ground
Three-Phase WYE
4-wire+ground
Three-Phase WYE
4-wire+ground
Three-Phase WYE
4-wire+ground
Three-Phase WYE
4-wire+ground
Three-Phase high-leg DELTA
4-wire+ground
Three-Phase DELTA
3-wire+ground
TK-SExxx-380NN 380 N/A 323-460
TK-SExxx-480NN N/A 408-528
TK-SExxx-600NN 600 N/A 510-690
!
WARNING: Check to ensure that a proper bond is installed between neutral and ground at the transformer
▲▲
480
Three-Phase DELTA
3-wire+ground
Three-Phase DELTA
3-wire+ground
Three-Phase DELTA
3-wire+ground
upstream from all 3-phase WYE, 3-phase high-leg DELTA, or split-phase ServiceTrack device (see 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 and void the warranty.
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SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
2. Wiring Connection Diagrams
Figures 1-5 show the electrical relationship between ServiceTrack 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.
FIG. 1: Single Phase, 2-Wire FIG. 2: Split Phase, 3-Wire
TVSS
TVSS
FIG. 4: 3-Phase, 3-Wire DELTAFIG. 3: 3-Phase, 4-Wire WYE
FIG. 5: 3-Phase, 4-Wire High-Leg DELTA
TVSS
TVSS
TVSS
SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
5
3. Upstream Over-Current Protection Device
ServiceTrack must be connected in parallel with the electrical system. It must be connected to an overcurrent protection
device (circuit breaker or fused switch) rated 200A maximum. If the suppressor is connected to a dedicated overcurrent
protection device, a 60A breaker is recomended (30A minimum, 200A maximum). The advantage of using a dedicated overcurrent protection device for the suppressor (even if the upstream breaker is 200A or less) is that it allows the suppressor to
be de-energized during service without disturbing the electrical service to the rest of the facility.
4. Conductor Routing
!
▲▲
WARNING!ServiceTrack’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.
The factors listed above should be addressed during the design of an installation to reserve a suitable place for ServiceTrack
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.
5. Conductor Sizing
Joslyn recommends installing ServiceTrack by using the following conductor sizes 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
(#2 AWG maximum) where space and bending radii permit.
Example of a suppressor model number: TK-SE200-3Y208
PRODUCT LABEL DESIGNATION SURGE CURRENT CAPABILITY CONDUCTOR SIZE
TK-SE200-xxxxx 200kA/phase #6 AWG
TK-SE300-xxxxx 300kA/phase #4 AWG
TK-SE400-xxxxx 400kA/phase #2 AWG
6. Conduit Openings
If desired, punch holes at this time for the conduit or nipple or wait until ServiceTrack is properly mounted. Punch holes
only in the shaded areas as shown in the following illustrations:
Fig. 6 Conduit Openings
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SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
7. Mounting
4 PLCS.
Mount ServiceTrack using construction methods and hardware appropriate for your site. Install the conduit and pull the
conductors as specified above or according to the engineer’s design.
ENCLOSURE SIZE
Inches 13.69H 12.40W 7.94D
Centimeters 34.77H 31.50W 20.17D
Fig.7 Enclosure Dimensions
12.40
10.00
12.75
Ø0.31
4 PLCS
7.94
13.6912.40
0.34
CONNECTION AND WIRING INSTRUCTIONS
1. Phase, Neutral, and Ground Connections
Phase, Neutral* and Ground: Following all applicable National Electrical Code standards as well as state and local codes,
connect the phase, neutral* and ground conductors to ServiceTrack’s lugs. Ensure that the conductor lengths are kept as
short and straight as possible. The lugs can be rotated to face in the direction of the cable exit by loosening the nut on the
input terminal lugs in the suppressor. Tighten all lugs to 20 in-lb (2.2 Nm). On all high-leg delta systems the high-leg (colorcoded orange according to NEC) conductor must be connected to the Phase B terminal of the suppressor.
*DELTA-connected ServiceTrack does not have a neutral conductor.
SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
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2. Connecting Form C Dry Contacts
All ServiceTrack units come standard with two sets of Form “C” relay dry contacts for the suppressor status and one set of
Form “C” relay dry contacts for the commercial-power status. These contacts are for connection to a user-provided remote
alarm and monitoring circuits. The relay contacts are rated 110V DC/125V AC with maximum switching power of 30W
DC/62.5VA AC.
Fig. 8 Remote Monitoring Terminal Block
(contacts shown during normal
conditions with power energized)
Figure 8 shows the state of these dry contacts in normal energized conditions. When all suppression and filter modules are
functional and power is present to all phases, terminals “1 and 2” and “4 and 5” are an open circuit while terminals “2 and 3”
and “5 and 6” are a closed circuit. The contacts change state when one or more modules have failed.
Similarily, when input power is present in all phases, terminal “7 and 8” are an open circuit and terminals “8 and 9” are a
closed circuit. The contacts change state when the unit is encountering loss of power to one or more phases (less than 50%
of nominal voltage for duration of 10 cycles).
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 open and close properly.
Tighten screws on terminals to 4.5 in-lbs (0.5 Nm). See Fig. 9 for the Form “C” contact configuration. The annotations on
the diagram match the markings on the terminal block.
3. Verification and Power Up
Apply power to ServiceTrack by closing the circuit breaker or molded-case switch feeding the suppressor.
Fig. 9 Standard Monitoring
For Standard Units
Verify that all indicating lights, “COMMERCIAL-POWER STATUS” and
“MODULE STATUS”, are illuminated.
Fig. 10 Audible Alarm Option
LINE 1
STATUS: POWER PRESENT WHEN LIGHTS ARE ON
ON/OFF
MODULE STATUS
ALARM SILENCE
GREEN:
All Protection Online
RED:
Reduced Protection Online
(Consult Operation Manual)
ALARM SILENCED
For Units with Audible Alarm Monitoring Option
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.
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SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Fig. 11 Counter Option
PHASE B
MODULE STATUS
GREEN:
All Protection Online
RED:
Reduced Protection Online
(Consult Operation Manual)
PHASE C
ALARM SILENCED
For Units with Surge Counter Monitoring Option
The number of surges detected by the suppressor is displayed on
PHASE A
STATUS: POWER PRESENT WHEN LIGHTS ARE ON
ON/OFF
ALARM SILENCE
an eight-digit LCD display on the front of the ServiceTrack door.
SURGE COUNT
TROUBLESHOOTING
Your ServiceTrack system does not require scheduled maintenance. The unit’s heavy-duty construction is designed to provide
years of uninterrupted service.
INDICATION PROCEDURE
One or more commercial-power status indicating
lights are off
The upstream circuit breaker is tripped
and cannot be reset
“MODULE STATUS” indicating light on ServiceTrack
door is illuminated RED
MODULE REPLACEMENT
1. A bicolor (green/red) indicating light is available on the
side of each module to help you visually identify the failed
module(s). Carefully open the ServiceTrack door while the
power is still applied to the suppressor and visually identify
the module(s) with a side-mounted RED indicating light.
WARNING! HAZARDOUS VOLTAGES ARE PRESENT
WITHIN THE SUPPRESSOR ENCLOSURE. USE
EXTREME CAUTION WHEN PERFORMING THIS TASK.
2. Remove input power to ServiceTrack by disconnecting
the upstream overcurrent protection device. Verify that
the circuits are de-energized by using a voltage tester.
The indicating lights on the suppressor should not be
illuminated at this time.
Verify that the input power feeding ServiceTrack is
energized using a voltage tester
Contact factory for assistance.
800-647-1911
One or more suppression/filter modules may have
failed and need to be replaced. Follow the module
replacement procedures below.
Fig. 12 Module Replacement
3. Using a standard flat-head screwdriver remove the hex
bolts (Part A), lock washers (Part B) and flat washers (Part
C) on the top module(s). You may need to remove the power
terminal lugs (Part D) before removing the bolts holding
the modules.
4. Slide the failed module(s) out.
Note: There are small interconnect pins (Part E) between
modules. The pins are used to monitor the status of each
module. If the pins are not properly re-installed in next
step, indicating lights on the side of the modules will not
illuminate.
SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
9
TECHNICAL ASSISTANCE
Our staff is ready to support you and answer any questions.
Monday through Friday, 8:00 a.m. to 5:00 p.m. (EST) 800-647-1911.
RETURNS AND WARRANTY PROCEDURES
ServiceTrack products are warranted for a period of 30 years from date of shipment. In the event that any module or subassembly within the suppressor fails to perform as specified during the warranty period, call our Technical Support at 800647-1911 to obtain a Return Material Authorization number. We will immediately ship a replacement for the defective parts
free of charge (installation labor and site preparations excluded). Return the defective parts to Joslyn 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 information at hand when you contact Joslyn:
INFORMATION EXAMPLE
Model Number TK-SE200-3Y208-B
Serial Number 23114-0341-001
Date of Purchase October 17, 2003 (41st week)
Sales Order Number 23114
Description of Failure Cannot silence the audible alarm
Desired Action from Joslyn Repair and return
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SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
WARRANTY STATEMENT
30 YEAR
WARRANTY
WARRANTY
30 YEAR
FREE
REPLACEMENT
During the applicable warranty period, any Total Protection Solutions™surge protective device which fails due to defect in
materials, workmanship, or any electrical anomaly, including lightning, shall be repaired or replaced at Joslyn’s discretion
without charge. In the event of a return, the device must be shipped FOB Joslyn place of business within the applicable
warranty period. The applicable warranty period for this Joslyn surge protection device is outlined below in the Warranty
Period section. The warranty period for any repaired devices or replacement devices will be only the remaining portion of
the original limited warranty.
A Return Material Authorization (RMA) number must be obtained from the Company’s Customer Service department before
returning any Products.
The Company 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.
THIS WARRANTY REPRESENTS THE ENTIRE WARRANTY OF THE COMPANY. 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 THE COMPANY, AT ITS SOLE OPTION, UNDER THIS WARRANTY IS EXPRESSLY LIMITED TO THE
REPLACEMENT OR REPAIR OF THE DEFECTIVE PART THEREOF. IN NO EVENT SHALL THE COMPANY BE LIABLE OR
RESPONSIBLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND OR CHARACTER, NOR
SHALL ITS LIABILITY EVER EXCEED THE PURCHASE PRICE PAID TO JOSLYN FOR SUCH DEFECTIVE PRODUCT.
This warranty is not transferable and may only be enforced by the original purchaser. Claims under this warranty must be
submitted to Joslyn within thirty (30) days of discovery of any suspected product defect.
Warranty Period
ServiceTrack
™
30 Years from original date of purchase
SERVICETRACK™INSTALLATION, OPERATION AND MAINTENANCE MANUAL
11
®
30 YEAR
WARRANTY
WARRANTY
30 YEAR
FREE
REPLACEMENT
5900 Eastport Boulevard Richmond, VA 23231-4453 USA
TEL: 800.647.1911
©2003 PRINTED IN U.S.A. ALL RIGHTS RESERVED. PN 750-0090-001 500/6.17.04/ J-2801
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