Installation, Operation and Maintenance Instructions

INTRODUCTION

Congratulations on joining the extensive list of satisfied Current Technology customers. Since our inception in 1971, we have installed thousands of suppression filter systems to protect critical loads in a wide variety of industries.

The success of our products is a result of more than two decades of focused lab and field research resulting in a unique and exclusive approach to mitigation of power anomalies. Our patented suppression filter systems provide all modes of bi-directional surge suppression and line noise filtering with a revolutionary engineering design called seamless technology .

Taking a unique and superior approach to the suppression and filtering of power anomalies, seamless technology utilizes the individual performance capabilities of four major components — selenium cells, carbon thin film high energy capacitors, metal oxide varistors (MOVs), and synergistic component geometry — to deliver “seamless” power without damaging surges, flicker or HF noise.

Only Current Technology combines the components of seamless technology for an orchestrated effect. Much like an orchestra, all parts work together to produce results vastly superior to the efforts of one or two components.

To maximize performance from your Current Technology suppression filter system, strategic location is as important as correct wiring methods. Proper physical location enables the BPA to enhance important transient and noise protection.

The BPA suppression filter system should be installed as close to the protected loads as possible; wire lengths and wiring bends should be minimized. This positioning maximizes both surge suppression and filtering, while providing optimal protection for the protected loads. Please contact our engineering department or your sales representative for additional information.

Today’s sophisticated electronic systems require the best power conditioning possible. By selecting Current Technology products, you have taken a critical step toward decreasing downtime and ensuring longer product life for your equipment. We look forward to fulfilling your suppression filter system needs.

INSTALLATION

THE FOLLOWING IS INTENDED FOR QUALIFIED ELECTRICAL PERSONNEL ONLY.

READ COMPLETE INSTALLATION INSTRUCTIONS BEFORE BEGINNING INSTALLATION. CALL CURRENT TECHNOLOGY WITH ANY QUESTIONS.

IT IS THE FINAL RESPONSIBILITY OF THE INSTALLING ELECTRICIAN TO ENSURE THAT ALL LOCAL CODES AND OTHER APPLICABLE SAFETY/ENVIRONMENTAL CONDITIONS ARE MET.

Enclosure/Environment: The standard enclosure for the CURRENT TECHNOLOGY BPA suppression filter system is a NEMA Type 4/12. Unit should be installed in a safe, protected area with ambient temperature between -40oC to +60oC (-40oF to +140oF). Humidity should be 5-95% non-condensing relative humidity.

1. Verify Voltages: Ensure that ALL voltages are correct and verify the type of power distribution configuration used (i.e. 3 Phase 120/208 grounded WYE) before installing the BPA. See Table 1 for nominal voltages and voltage configurations for each model. Product model number is found on the product label inside front door.

WARRANTY VOID IF CONNECTED TO IMPROPER VOLTAGE OR IF THE NEUTRAL GROUND BOND IS NOT CORRECTLY INSTALLED. CHECK SOURCE VOLTAGES BEFORE CONTINUING. CHECK NEUTRAL BOND AT DISTRIBUTION TRANSFORMER PROVIDING POWER TO PROTECTED LOADS AND NEUTRAL BOND AT SERVICE ENTRANCE TO VERIFY Xo BOND CONNECTION INTEGRITY. CAUTION !

Units designed for power distribution systems utilizing a ground MUST NOT be installed on ungrounded distribution systems. Refer to Table 1 for configuration and nominal voltages for each model. For “high-leg” Delta model BPA120/240-3GHD, the “high-leg” MUST be connected to Phase B (middle phase lug).

2. CONDUIT ENTRANCE The following information details conduit mounting for both surface and flush mount units.

Punch conduit holes for conduit connectors in gray shaded areas shown in Figure 1 so external wiring will not interfere with internal components nor require excessively sharp bends. Conduit fitting should be located near upper right of enclosure to allow easy connection to input lugs.

NOTE: Larger wire sizes may require side conduit entrance in order to meet wire bending requirements.

Figure 1.

CONDUIT ENTRANCE LOCATION

3. MOUNTING The following instructions are for mounting unit in/on wall. Mount unit securely and rigidly to building surface or structural member using 4 mounting holes provided on back of unit before electrical connection. Attach conduit and pull wire as necessary. Refer to Figure 3 below for mounting hole dimensions and spacings.

NOTE: BPA should be located as close to the protected loads as physically possible to minimize wire lengths.

Figure 3.

MOUNTING TEMPLATE DRAWING

4. Install wiring as detailed below:

A unit with standard integral fused disconnect may be installed per the NEC Tap Rules (Article 240) with #8 AWG COPPER conductors, or via a three-pole 15 Amp breaker with #8 AWG COPPER conductors for three phase units and a two-pole 15 Amp breaker for single phase units. A unit with optional fuse block or no fusing should be installed via a three-pole 15 Amp breaker for three-phase units or a two-pole 15 Amp breaker for two phase units with #8 AWG COPPER conductors.

Neutral and Ground conductors should be at least 100% of Phase conductor ampacity.

1) Wire should be appropriately stripped for inserting into lugs.

2) Connect the three phase conductors into the incoming lugs of the disconnect switch, fuse block, or terminal block with Phase A connected to lug labeled L1, Phase B connected to lug labeled L2, and Phase C connected to lug labeled L3. See Figure 4.

3) Lugs should be appropriately tightened.

For single phase installations, Phase B/Lug L2 is not used.

FOR DISTRIBUTION SYSTEMS WITH A GROUND AND/OR NEUTRAL CONDUCTOR, SEE BELOW

NEUTRAL INSTALLATION: Connect neutral tap conductor to lug marked “NEUTRAL TERMINAL LUG” as called out in Figure 4.

GROUND INSTALLATION: Connect ground tap conductor to green lug mounted in top center of enclosure labeled “SAFETY GROUND TERMINAL” and the copper lug mounted on the top left side of the unit’s “MERF” labeled “TRANSIENT GROUND” as called out in FIGURE 3. The ground tap conductor should be tapped from the grounding plane derived from the service entrance connection.

Figure 4.

INSTALLATION DETAIL DRAWING

(UNIT PICTURED WITH INTEGRAL FUSED DISCONNECT SWITCH)

WIRING THE OPTIONAL FORM “C” DRY CONTACTS

For wiring of the form “C” dry contacts, identify the three output terminals located on the dry contact circuit board: common, normally open and normally closed labeled C, NO and NC accordingly. For normally closed operation, connect the normally closed terminal and common terminal to the monitoring indicator. For normally open operation, connect the normally open terminal and common terminal to the monitoring indicator. When the status of the unit’s fuses/suppression elements changes, the NC and NO outputs reverse their status while the NC opens and the NO closes. Form “C” dry contacts are rated for 0.5 amps at 120 volts.

5. Before energizing unit, check ALL electrical connections, both field installed and factory connected, for solid connection.

6. DO NOT APPLY POWER UNTIL ALL OF THE FOLLOWING ELECTRICAL FIELD CHECKS HAVE BEEN COMPLETED.

Before applying power to the unit, check off the following electrical field tests. All voltages should be measured with a TRUE RMS voltmeter (i.e., Fluke 87):

o Line-to-Line voltage does not exceed +10% of the rated nominal voltage for the unit. The unit’s rated nominal voltage can be found on the label inside the unit door or in Table 1 located on the last page of this document.

o Line-to-Neutral voltage does not exceed +10% of the rated nominal voltage for the unit. The unit’s rated nominal voltage can be found on the label inside the unit door or in Table 1.

o Line-to-Ground voltage does not exceed +10% of the rated voltage for the unit as called out in Table 1.

o Neutral-to-Ground voltage does not exceed the rated voltage for the unit as called out in Table 1.

CAUTION !

VOLTAGE READINGS OTHER THAN THOSE LISTED AS ACCEPTABLE ABOVE WILL DAMAGE THE UNIT AND VOID THE WARRANTY. IF YOU HAVE QUESTIONS REGARDING VOLTAGES OR WIRING, PLEASE CALL CURRENT TECHNOLOGY.

7. FINAL INSTRUCTIONS:

If all voltages are within tolerance, close and screw down door, then apply external power to the unit by engaging external breaker. For units with integral fused disconnect switch, turn integral fused disconnect ON. After power is applied the indicator lights will illuminate.

OPERATIONS

1. The BPA is now operational. Current Technology suppression filter systems are designed to operate indefinitely without any component failures or routine parts replacement.

2. To disengage unit and remove protection from the electrical system, either turn off external power by disengaging the circuit breaker feeding power to the unit; or, for units with integral fused disconnect switch, turn switch to OFF position.

3. Should verification and test of unit operation be necessary, the integral test connector installed in each Current Technology unit allows connection of Current Technology’s portable DTS-2 Diagnostic Test Set to test component and total unit function. See Maintenance Section and DTS-2 product literature for further information.

MAINTENANCE

The BPA suppression filter system does not require periodic maintenance. The unit’s heavy-duty design should preclude the need for any repairs; however, the following indicators may signal the need for fuse or indicator light replacement and/or unit testing:

UNITS WITH INTEGRAL FUSED DISCONNECT OR FUSE BLOCK

INDICATION	PROCEDURE
One or more phase indicator lights are off.	1. Check that the external power source supplying power to unit is energized. 2. Check that the integral fused disconnect switch is turned on. 3. Check that fuses are installed and operational. 4. Check connector connecting indicator lights to light board. 5. If all of above are O.K., indicator light board requires replacement. Contact factory. 6. If internal fuse or external breaker are faulty/tripped, use DTS-2 portable diagnostic test set to verify unit integrity before fuse replacement and/or breaker reclosing.
Portable Diagnostic Test Set (Current Technology Model DTS-2) Indications	Refer to Diagnostic Test Set Manual for procedures and explanations.

FUSES: The suggested fuses for use with the integral fused disconnect are 15A 200,000 AIC class CC-type fuses.

UNITS WITHOUT INTEGRAL FUSED DISCONNECT

INDICATION	PROCEDURE
One or more phase indicator lights are off.	1. Check that the circuit breaker/external disconnect switch supplying power to unit is energized. 2. Check connector connecting indicator lights to light board. 3. If all of above are O.K., indicator light board requires replacement. Contact factory. 4. If external disconnect switch fuses or external breaker are faulty/tripped, use DTS-2 portable diagnostic test set to verify unit integrity before fuse replacement and/or breaker reclosing.
Portable Diagnostic Test Set (Current Technology Model DTS-2) Indications	Refer to Diagnostic Test Set Manual for procedures and explanations.

TABLE 1: NOMINAL VOLTAGES

MODEL3	VOLTAGE	CONFIGURATION	NOMINAL VOLTAGES (L – L1L – N1L – G1N – G)
BPA 120/240-2G-DF	120/240	GROUNDED NEUTRAL	240	120	120	0 – 2
BPA 120/208-3GY-DF	120/208	GROUNDED WYE	208	120	120
BPA 220/380-3GY-DF	220/380	GROUNDED WYE	380	220	220
BPA 277/480-3GY-DF	277/480	GROUNDED WYE	480	277	277
BPA 347/600-3GY-DF	347/600	GROUNDED WYE	600	347	347
BPA 120/240-3GHD-DF	120/240 X 208	GROUNDED NEUTRAL “HIGH-LEG”  DELTA	240	A&C: 120 B: 208	A&C: 120 B
BPA 240-3GCD-DF	240	GROUNDED CORNER DELTA	240		0/2402
BPA 240-3UD-DF	240	UNGROUNDED DELTA	240
BPA 480-3GCD-DF	480	GROUNDED CORNER DELTA	480		0/4802
BPA 480-3UD-DF	480	UNGROUNDED DELTA	480
BPA 575-3GCD-DF	575	GROUNDED CORNER DELTA	575		0/5752
BPA 575-3UD-DF	575	UNGROUNDED DELTA	575
BPA 600-3GCD-DF	600	GROUNDED CORNER DELTA	600		0/6002
BPA 600-3UD-DF	600	UNGROUNDED DELTA	600

1NOTE: All line voltages may be +/- 10%.

2NOTE: For Delta systems, phase-to-ground voltages is either: 1) The rated phase-to-phase voltage or 2) Zero (0) for the “grounded” phase.

3NOTE: DF suffix on the model number designates unit with integral fused disconnect switch. Nominal voltage ratings remain the same with or without integral fused disconnect.

4NOTE: Neutral-Ground voltages will vary per installation.

WARRANTY

The Warranty Card must be completely filled out and returned in order to allow product updates and information to be provided to the customer. Current Technology’s five year limited warranty begins when the owner takes possession of the facility.

LEGAL NOTICE

Current Technology products are protected by patents which may be issued after the publication of this document as well as by one or more of the following patents: 5,023,746; 4,835,650; 4,675,538; 4,675.772; 5,191,502; 4,860,502; 4,127,888; 5,146,357; 4,794,490; 5,257,157. All rights reserved. Current Technology will enforce and protect its patent rights as provided by Section 35 USC and a $500,000 litigation protection insurance policy.