TWL Series Installation Guide

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1 TWL Series Installation Guide Tower Light Controller Protectors Also See TWL Datasheet and Configuration Sheet The TWL Surge Suppressor is probably different than anything you have seen before. You will save substantial installation time & rework by understanding the intent behind its design & installation. Each individual installation is likely to approach a custom installation. There is reasonable chance that a design team configured and ordered the TWL, as well as multiple individual Surge Protective Devices (SPDs). Please take a few moments to understand the TWL s function and the application of each individual SPD. The TWL is a high quality, high energy, surge suppressor hub assembly. Individual SPDs are connected to the TWL. The purpose of the TWL is to provide a common ground reference point for individual SPDs, thus ensuring maximum protection to the tower lighting controller. The TWL also provides the most cost effective ground-level surge protection to uptower lighting equipment. The TWL is designed to use off-the-shelf APT SPDs in a modular manner. Individual SPDs can be replaced, added to, or field retrofit. APT SPDs are extremely robust and readily available in a broad application range. This avoids one-off units, which create cost and availability barriers, and avoids obsolescence issues. Mounting holes for additional SPDs. 4 mounting locations located on opposite side. Cover in place Side view Cover removed For demonstration purposes, the standard TWL pictured above is displayed with one SPDee on left side, AC Power AC XCS inside and with copper ground strap - not included. Thank you for choosing an APT TWL Surge Protective Device (SPD). Proper installation is important to maximize performance. Please follow steps outlined herein. These instructions are not intended to replace national or local codes. Follow all applicable electrical codes to ensure compliance. TWL may include several different voltage SPDs including AC and DC voltages. Incorrect initial installation may result in immediate SPD failure upon start up, not covered by warranty, and/or ineffective surge protection. APT Welcomes Questions & Pre-installation Discussion at or Info@aptsurge.com.

2 WARNING IMPORTANT PLEASE READ WARNING Safety First Hazardous Voltage & Shock Hazard Only qualified licensed electricians should install or service SPDs Hazardous voltages exist within SPDs SPDs should never be installed or serviced when energized Use appropriate safety precautions including Personal Protection Equipment Failure to follow these instructions can result in death, serious injury, and/or equipment damage This manual shall be read in entirety prior to installing Bonding and Grounding Hazard Verify that the neutral conductor in the AC voltage service entrance equipment is bonded to ground in accordance with guidelines established by the National Electric Code (NEC ). This is intended to provide the power system with a defined reference to ground. There may be circumstances where the Authority Having Jurisdiction (AHJ), for example, a DOT, supercedes the NEC and or local codes. We caution that deviations from North American, industry-accepted bonding & grounding and surge suppression techniques may yield undesirable and unexpected results. Verify that the neutral terminal (XO) on the secondary side of distribution transformers are grounded to the system ground in accordance with the NEC and all applicable codes. During installation into an electrical system, the SPD must not be energized until the electrical system is completely installed, inspected and tested. All conductors must be connected and functional including the neutral (if required). The voltage rating of the SPD and system must be verified before energizing the SPD. Failure to follow these guidelines can lead to abnormally high voltages at the SPD. This may cause the SPD to fail. The warranty is voided if the SPD is incorrectly installed and/or if the neutral conductor in the service entrance equipment or downstream of separately derived systems is not bonded to ground in accordance with the NEC. Do Not Hi-Pot Test SPDs Any factory or on-site testing of power distribution equipment that exceeds normal operating voltage such as highpotential insulation testing, or any other tests where the suppression components will be subjected to higher voltage than their rated Maximum Continuous Operating Voltage (MCOV) must be conducted with the SPD disconnected from the power source. The neutral connection at the SPD must also be disconnected prior to performing high-potential testing and then reconnected after test completion. Failure to disconnect SPD and associated components during elevated voltage testing will damage the SPD and will void the warranty. (APT is unaware of any SPD manufacturer that permits Hi-Pot testing of SPDs.)

3 Table of Contents PRE-INSTALLATION & PLANNING...1 INSTALLATION...2 Step 1 - Verify that all correct components are in hand:... 2 Step 2 - Identify appropriate mounting location for TWL (See Figure 1)... 3 Step 3 - Mount TWL to Wall... 3 Step 4 - Connect 4 copper ground strap to TWL (Figure 2)... 3 Step 5 - Run wire bundles into TWL, MARKING ALL conductors... 3 Step 6 - Connect individual SPDs... 3 PHOTOCELL SPD (FIGURES 3,4 & 5)...5 INDIVIDUAL LIGHT SPD(S) (FIGURE 6)...7 AC POWER SPD (FIGURE 7)...8 Step 7 Double check work Label conductors & SPDs - Energize Tower Light Controller... 9 ADVANCED TOPICS...9 REMOTE SPD DIAGNOSTIC INDICATION...9 FIGURES FIGURE 1: You will Need Sufficient Space on Wall for TWL & SPDs...2 FIGURE 2: Ground Strap Attachment...4 FIGURE 3: Photocell SPD Mounting Location...5 FIGURE 4: Standard Photocell SPD Installation...6 FIGURE 5: Optional SPD Installation...6 FIGURE 6: Individual Light SPDs...7 FIGURE 7: AC Power SPD...8 FIGURE 8: Bonding Multiple TWLs Together...9 Questions?? Need Assistance?? Contact APT at or Info@aptsurge.com.

4 INSTALLATION PRE-PLANNING OVERVIEW: This Surge Suppressor is probably different than anything you have seen before. You will save substantial installation time & rework by understanding the intent behind its design and installation. Need to meet all applicable Codes and Regulations Intended for indoor use If outdoor, the TWL assembly can be mounted in an appropriate weather-resistant enclosure with appropriate weathertight sealing apparatus. Intended to be a central grounding hub for multiple individual SPDs There will be multiple conduits and wiring to and from the TWL Need appropriate wall space. There will probably be multiple SPDs attached to the side of the TWL do not try to cram into too small of space Need appropriate path to ground grid or ground intended to use 4 copper ground strap to connect to existing grounding grid. This path needs to be straight line, not bends or kinks. TWL was intended for wires to enter one side of the TWL and exit the opposite side: AC Power Intended to come from upstream service entrance SPD, enter the TWL, connect to TWL-housed AC power SPD, and conductors exit TWL to the Tower Light Controller. Photocell Intended for lead from photocell to enter the DIN Rail mounted SPD, which is a series SPD. The load travels through this SPD, which is different than the other SPDs, which are parallel-connected. The lead from the SPD goes to the Tower Light Controller. (This SPD is directional. If the Unprotected and Protected ends are miss-connected, the SPD will provide decreased surge protection. Direction is important!) Uptower loads: Leads are intended to enter the TWL at the bottom, connect to appropriate SPDs within the TWL, then the leads exit at the top of the TWL to Uptower. There may be more than one way to do this. TWL includes many knockouts for customized appropriate installation. Commingling lower and higher voltage lines Follow all applicable Codes Following may be useful: NEC 300.3(C) Conductors of Different Systems. (1) 600 Volts, Nominal, or Less. Conductors of circuits rated 600 volts, nominal, or less, ac circuits, and DC circuits shall be permitted to occupy the same equipment wiring enclosure, cable, or raceway. All conductors shall have an insulation rating equal to at least the maximum circuit voltage applied to any conductor within the enclosure, cable, or raceway. NEC Lightning Conductors. Where practicable, a separation of at least 1.8 m (6ft) shall be maintained between communication wires and cables on buildings and lightning conductors. NEC Communication Conductor Separation from Other Conductors Page 1

5 INSTALLATION 1. Verify that all correct components are in hand: TWL: This is effectively an assembly that SPDs attach to in a modular format. AC voltage SPD: Verify correct voltage and number of phases. This will mount perpendicular over the top of the two DIN Rails. It is raised on stand offs so that wiring can pass underneath it. We recommend that this SPD be installed last so it remains out of your way. Photocell SPD: Verify correct voltage. This will mount on a DIN Rail inside the TWL. Individual Light SPDs: Use a voltmeter to check all voltages to ensure correct SPDs. Verify correct voltage. Be aware that some strobe lights are DC voltage. Connecting the wrong SPDs to wrong voltages will fail SPDs at startup. Not included with TWL or SPDs: Conduit, fittings, wire, hardware, etc. 4 copper ground strap & ground connections Mounting hardware Labeling equipment 2. Identify appropriate mounting location for TWL (See Figure 1) Figure 1 You will Need Sufficient Space on Wall for TWL & SPDs Photocell Conductor AC Power (Now Surge Protected) Wire Bundle Going Up-tower (Now Surge Protected) Photocell Conductor (Now Surge Protected) TOWER LIGHT CONTROLLER TWL & SPDs AC POWER SERVICE ENTRANCE Unprotected Wire Bundle Going Up-tower AC Power Existing Copper Strap Ground Grid YOU WILL NEED SUFFICIENT SPACE FOR GROUND STRAP 4 Copper Strap Connection to Ground Page 2

6 Presumed indoor use: If outdoor, need appropriately sized outdoor rated enclosure to house TWL and all SPDs. Anticipate wiring and conduit into and out of TWL AC Power Intended to come from upstream service entrance SPD, enter TWL hub, connect to TWL-housed AC power SPD, and conductors exit TWL to Tower Light Controller. Photocell Intended for lead from photocell to enter Unprotected side of DIN Rail mounted SPD. This is a series SPD. The load travels through this SPD, which is different than the other SPDs, which are parallel-connected. This SPD is directional. If the Unprotected and Protected ends are miss-connected, the SPD will provide decreased surge protection. Direction is important! Uptower loads: Leads are intended to enter the TWL at the bottom, connect to appropriate SPDs within the TWL, then the leads exit at the top of the TWL to uptower. Other orientations are possible depending on situation. For example, the TWL can be mounted sideways if required. The proposed APT SPDs are not direction or orientation sensitive. Anticipate ground conductor path to ground grid or ground. Intended to use 4 copper ground strap to connect to existing grounding grid. This path needs to be straight, no bends or kinks. It is physically possible to use large gauge ground wires. However, traditional round wire has much more inductance than flat strap. This hurts performance in surge & lightning protection scenarios. Given a choice, using round wire would be a mistake. If round wire is unavoidable, we recommend multiple, exactly-parallel ground wires of equal length to minimize inductive losses. 3. Mount TWL to Wall Consider mounting the 4 copper ground strap to an appropriate location on the backside of the TWL before mounting the TWL to the wall. This may be easier, see #4 below. Mount TWL to wall using the four attachment holes on the aluminum baseplate. Use appropriate attachment hardware (not included). Ensure that 4 copper ground strap is installed and robustly connected to ground system. Failure to provide reliable ground will defeat the purpose of the TWL and associated SPDs. 4. Connect 4 copper ground strap to TWL (Figure 2) Four sets of predrilled holes are provided; one on each side of the TWL. This maximizes effectiveness, eases installation, and also allows bonding to other equipment if desired. If required, these can be used to bond two TWL s side by side. The 4 copper ground strap is intended for installation directly under the aluminum backplane with robust bolts (included). The aluminum backplane is tin-plated to prevent dissimilar metal cathodic interaction (prevent corrosion). The backplane is elevated approximately 7/8 to provide working access. Torque connections to 7 lb-ft. Ensure that ground strap is not ripped or torn during installation. 5. Run wire bundles into TWL, MARKING ALL conductors Use appropriate care to separate wires into separate conduit(s). Use appropriate conduit and connectors to the TWL. It may be appropriate to provide separate conduit(s) for AC power and/or the photocell (if equipped). 6. Connect individual SPDs We suggest installing SPDs in the following order: 1. Photocell do this first to get it out of the way 2. Individual light SPD(s) (there may be several) 3. AC power SPD do this last because it will cover the work area making work on other units more difficult Page 3

7 Figure 2 Ground Strap Attachment Bolt holes for installers' ease of installation. Use appropriate pair of bolts. 1 3/4" Typical 4" copper clad strap mounts under the aluminum backplane. (Aluminum backplane is tin-plated for dissimilar metal reasons and corrosion resistance) (1/2" / 13 x 1" Bolts - Qty 2) Questions?? Need Assistance?? Contact APT at or Info@aptsurge.com. Page 4

8 PHOTOCELL SPD (FIGURE 3, 4 & 5) Identify an appropriate mounting location for the photocell SPD We suggest the less-populated area of DIN Rail opposite the intended connection of the AC voltage SPD (because there will be more space) (Figure 3) Identify the SPD s Unprotected and Protected ends. This SPD is directional. The Unprotected side needs to be wired to the photocell. The Protected side needs to be wired to the tower light controller. Reversal will result in ineffective surge protection. (Figure 4) Also see Alternate Installation below. Note that this is a series, in-line connected SPD. The signal goes through the SPD. Connection of this SPD will not consume any of the existing feed-through terminal blocks. Mount the SPD on the DIN Rail Connect Unprotected side of SPD to photocell in appropriate conduit Connect Protected side of SPD to tower light controller in appropriate conduit Make sure SPD is properly secured to DIN Rail as that connection is the ground path for this SPD. A secondary ground connection may be added from the SPD s ground terminal to the aluminum backplane. Alternate Installation (Figure 5): The APT SPD includes surge protection for two (2) different sets of conductors. If you only have one (1) set of conductors, the SPD can be wired in a manner that provides redundant or cascade protection through the second surge suppression path. (There is a remote possibility that the impedance of the second suppression path can interfere with the signal. If this occurs, revert to standard installation above.) APT DIN rail SPDs are actually two separate SPD circuits in the same package. Rather than use one circuit and abandon the other circuit, you can use both of them in a cascade manner. This provides redundancy at no extra cost surge goes through the two suppression circuits within the one SPD. (This is usually a good idea for any circuit!) There is an Unprotected side and a Protected side. (The Unprotected side has the ground lug) 1.) Wire from the Photocell into either Unprotected side, 2.) Loop from one Protected side to the other Protected side, 3.) Wire to the tower light controller from the other Unprotected side. Note schematic on SPD Do Not reverse the Unprotected & Protected sides or you will hurt performance. Figure 3 Photocell SPD Mounting Location Photocell SPD can be mounted on any open DIN rail area Page 5

9 Figure 4 Standard Photocell SPD Installation Protected Side Protected side towards tower light controller TOWER LIGHT CONTROLLER SPD has a Protected and an Unprotected side. Unprotected side should be towards photocell. Protected side should be towards tower light controller. Unprotected side towards photocell PHOTOCELL Figure 5 Optional Photocell SPD Installation TOWER LIGHT CONTROLLER (The orientation of the unit pictured above is upside down) PHOTOCELL To Tower Light Controller From Photocell Loop on Protected side, not Unprotected side "Protected" side The unprotected side has the ground lug Note Schematic on side Page 6

10 INDIVIDUAL LIGHT SPD(S) (FIGURE 6) Identify an appropriate mounting location for each SPD. Notice that there are four pre-drilled holes for APT SPDee s on an upper row. (We recommend using upper row first.) There are also multiple knockouts on a bottom row. Consider proximity to existing DIN rail connectors. Read SPD installation manual. Mount SPD to TWL. Notice orientation of LED indicator. Rotate SPD such that LED is visible from front. Connect SPD AC-Hot or DC-Positive to terminal block as shown in Figure 6. Torque: 7 lb-in Connect SPD AC-Neutral or DC-Negative to terminal block as shown in Figure 6. Torque: 7 lb-in Note that both of these are fed through connectors. The load goes in and out of the terminal. The SPD is connected electrically in parallel, not in series. Connect SPD Ground to terminal block as shown in Figure 6. Torque: 7 lb-in Configure SPD leads as short and straight as possible. Do Not coil excess leads. Do Not create sharp kinks. Long leads & sharp bends seriously hurt performance!! Repeat for appropriate number of SPDs Figure 6 Individual Light SPDs Terminal Blocks without connections Empty sets of terminal blocks (One set per SPD) Try to use closest set of terminals to SPD to keep leads short SPD connected Leads from SPD to back side of terminal block Two Ground Terminals are interconnected via grounded DIN rail - Connect lead from controller to one terminal - Connect lead to uptower load to the other terminal Each gray terminal block has three terminals: Two terminals are visible on this side - one from controller (input) - one to loads on tower (output) Leads from controller into terminal block Conductors will go under the AC Power SPD (If installed last, this SPD will not be in the way) Leads from terminal block to loads up tower One terminal on the back side (not visible in this photo) for connecting the SPD Page 7

11 AC POWER SPD (FIGURE 7) We suggest installing this last because it mounts over the top of other wiring & circuitry. Identify the mounting standoffs. The XCS SPD will mount onto those standoffs. Identify the terminal blocks for AC Power SPD. These are immediately adjacent to the SPDs mounting location, and include one extra terminal for a 120/240V application. (The other pre-configured terminals assume one hot and one neutral. AC power presumes two hots and one neutral.) There may be an existing SPD at the electrical service entrance, grounded at that point. The TWL SPD serves as a redundant, cascaded SPD, grounded in the TWL at the same point as the other tower light SPDs. Do not eliminate the TWL AC power SPD under the presumption that the service entrance SPD provides protection. Read SPD installation manual. Mount SPD such that conductors to terminal blocks are shortest. Inches matter - do not run the conductors across the TWL to the opposite set of DIN rail connectors. Bolt down SPD to standoffs. Connect SPD AC-Hot(s) to terminal block as shown in Figure 7. Torque: 7 lb-in Connect SPD AC-Neutral to terminal block as shown in Figure 7. Torque: 7 lb-in Note that both of these are feed-through connectors. The load goes in and out of the terminal. The SPD is connected electrically in parallel, not in series. Connect SPD Ground to terminal block as shown in Figure 7. Torque: 7 lb-in Configure SPD leads as short and straight as possible. Do Not coil excess leads. Do Not create sharp kinks. Figure 7 AC Power SPD Incoming Power APT XCS-family SPD (120/240V split phase in this example) Leads from terminal block to tower light controller AC power input Leads from SPD to back side of terminal block SPD Mounting Standoffs Two Ground Terminals are interconnected because they are both grounded to the DIN rail G into one terminal block from service entrance or AC power panel SPD connects to load conductors via feed-through terminal blocks Leads into terminal blocks from service entrance or AC power panel L1 & L2 into terminal block from service entrance or AC power panel L1 & L2 out of terminal block to tower light controller AC power input N into terminal block from service entrance or AC power panel N out of terminal block to tower light controller AC power input G out of other terminal block to tower light controller AC power input (Both Ground terminal blocks are connected together and grounded to DIN Rail) Page 8

12 7. Double check work Label conductors & SPDs - Energize Tower Light Controller Double check work confirm that correct SPDs are installed to correct circuits. If in doubt please contact APT Tech Support at (800) Double check torque to 7 lb-in. Double check that ground terminals are tight to DIN Rail Upon verification that SPDs are installed correctly, Label each wire bundle for ease of future service, and label each SPD Energize circuits Individual SPD LED indicators should illuminate correctly. Install TWL cover. Advanced Topics: Two TWLs side by side, or one above or below the other. (Figure 8): Mount appropriately. Ensure solid ground connection between two TWLs via 4 copper ground strap. Figure 8 Bonding Multiple TWLs Together 4" copper ground strap interconnects two TWLs To Ground Remote SPD Diagnostic Indication: Most APT SPDs are available with optional Dry Contacts for remote monitoring purposes. These indicate A-OK/Good or Failed status. See individual SPD datasheets for more information. SPDs must be ordered with this option and cannot be field retro-fit. When equipped, the SPD includes additional Form C Dry Contact wires. These wires may be connected to additional feedthrough terminal blocks for remote connection elsewhere. Questions?? Need Assistance?? Contact APT at or Info@aptsurge.com. Advanced Protection Technologies th Street North Clearwater, Florida (800) (727) Fax (727) info@apttvss.com European Authorized Representative Obelis s.a. Boulevard Général Wahis Brussels, BELGIUM Tel: +(32) Fax: +(32) mail@obelis.net #8615 UL is a registered trademark of Underwriters Laboratories, NEC and National Electrical Code are registered trademarks of National Fire Protection Association, C , C , C , C are registered trademarks of IEEE. Page 9

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