Contents
Description Page
1.0 Determining Which SPD Device
Has Lost Protection .....................3
2.0 Confirm SPD Replacement Part Number
Before Proceeding ......................3
3.0 SPD Max with Circuit Breaker .............4
4.0 SPD Max with Terminal Block .............7
5.0 Installation of Replacement SPD Module ...11
6.0 Warranty ............................14
Effective October 2014
Instruction Booklet IB158004EN
Eaton SPD Max Series
SPD Replacement
Instruction Manual
2
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
This instruction manual details the field replacement of one or two
Surge Protective Devices within an Eaton SPD Max Series device
when the SPD Max is installed with the door hinge on the left when
facing the device. Follow all Warnings and read this entire manual
before servicing this device.
WARNING
ONLY LICENSED/QUALIFIED ELECTRICIANS MUST COMPLETE ALL
INSTRUCTIONS IN THIS MANUAL IN ACCORDANCE WITH THE NATIONAL
ELECTRIC CODE (NEC), CANADIAN ELECTRIC CODE (CEC), STATE AND
LOCAL CODES, OR OTHER APPLICABLE COUNTRY CODES. ALL APPLICABLE
LOCAL ELECTRICAL CODES SUPERSEDE THESE INSTRUCTIONS. IMPROPER
INSTALLATION COULD CAUSE DEATH, INJURY AND EQUIPMENT DAM-
AGE. FOLLOW ALL WARNINGS AND CAUTIONS. COMPLETELY READ AND
UNDERSTAND THE INFORMATION IN THIS INSTRUCTION MANUAL BEFORE
ATTEMPTING TO INSTALL OR OPERATE THIS EQUIPMENT. IMPROPER
WIRING COULD CAUSE DEATH, INJURY AND/OR EQUIPMENT DAMAGE.
ONLY LICENSED/QUALIFIED ELECTRICIANS WHO ARE TRAINED IN THE
INSTALLATION AND SERVICE OF ELECTRICAL SERVICES ARE TO INSTALL
AND SERVICE THIS EQUIPMENT. HAZARDOUS VOLTAGES ARE PRESENT
INSIDE THE SPD MAX SERIES ENCLOSURE DURING NORMAL OPERATION.
FOLLOW ALL SAFE WORK PRACTICES AND LOCK OUT TAG OUT PROCE-
DURES TO AVOID ELECTRICAL SHOCK AND ARC FLASH.
In the event of a loss of protection, one or more “Replace” red
LED(s) will light on the front display (See Figure 1 showing Phase
B green Protected LED is out and the red Phase B Replace LED
is lit) and, if equipped, an audible alarm will sound. To silence the
alarm, push in Alarm Silence on the front display. The red LED(s) will
remain lit until power is disconnected or the unit has been properly
serviced.
Figure 1. SPD Series Display Located on the Enclosure Lid.
3
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
1.0 Determining Which SPD Device Has Lost
Protection
If the SPD Max Series device has a Catalog number ending in a R,
T, V or X, such as SPMxxxxxxxxR, your device contains one inter-
nally mounted Surge Protective Device (SPD1). Record the Catalog
number of the SPD Max Series device and contact your local Eaton
Distributor to order a replacement SPD or call the Eaton Customer
Support Center at 1-800-809-2772, Option 4, Sub-Option 2 for techni-
cal support.
If the SPD Max Series device has a Catalog number ending in a
S, U, W or Y, such as SPMxxxxxxxxS, your device contains two
internally mounted Surge Protective Devices (SPD1 and SPD2). To
determine which SPD(s) has lost protection open the hinged door of
the SPD Max Series enclosure by loosening, but not removing, the
7 screws holding the metal latches. Carefully open the enclosure
door, but DO NOT OPEN the hinged dead front panels, secured by
four metric TORX
®
head screws, within the enclosure because live
wires are located under the hinged dead front panels. In the center
of the enclosure is the SPD Status indicator (See Figure 2). A red
LED indicates whether SPD1, SPD2 or both SPD1 and SPD2 have
lost protection. Record the Catalog number of the SPD Max Series
device and contact your local Eaton Distributor to order a replace-
ment SPD or call the Eaton Customer Support Center at 1-800-809-
2772, Option 4, Sub-Option 2 for technical support.
Figure 2. SPD Module Status Indicator Located within Enclosure.
2.0 Conrm SPD Replacement Part Number
Before Proceeding
Before proceeding, go to Appendix A and confirm the SPD replace-
ment part number you received matches the SPD Max Catalog Part
Number and SPD replacement part number listed in Appendix A. If
there are any discrepancies contact the Eaton Customer Support
Center at 1-800-809-2772, Option 4, Sub-Option 2.
The SPD Max Series device comes equipped with either an installed
30 Amp circuit breaker or a power terminal block. If the SPD Max
Series enclosure has a Catalog number ending with a R, S, V or W,
such as SPMxxxxxxxxR, the enclosure contains one 30 Amp circuit
breaker and the SPD Max can be locked out within the enclosure to
disconnect power to the load side of the breaker where the SPD(s)
are terminated. If an upstream disconnect is available, it should also
be opened. Proceed to 3.0 SPD Max with Circuit Breaker.
If the SPD Max Series enclosure has a Catalog number ending with
a T, U, X or Y, such as SPMxxxxxxxxT, your enclosure contains a
power terminal block and the SPD Max enclosure must be locked
out at the upstream disconnect. Proceed to 4.0 SPD Max with
Terminal Block.
SPD1 Product Label
SPD Module Status
SPD2 Product Label
4
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
3.0 SPD Max with Circuit Breaker
1. Open the hinged door of the SPD Max Series enclosure by loos-
ening, but not removing, the 7 screws holding the metal latches.
2. Carefully open the enclosure door and look at the SPD Status to
determine which SPD(s) needs to be replaced. If the SPD Max
only contains one SPD module there isn’t a SPD Status indicator
module mounted in the center of the dead front panel. A red
LED indicates whether SPD1, SPD2 or SPD1 and SPD2 has lost
protection. DO NOT OPEN the load side hinged dead front
panel located within the enclosure that is secured with two
Torx
®
screws until the circuit breaker within the SPD Max
device has been switched to the OFF position and the locked
out/tagged out procedure has been completed in accordance
with the National Electric Code (NEC), Canadian Electric
Code (CEC), state and local codes, or other applicable coun-
try codes.
3. Disconnect the SPD Status ribbon cable of the specific SPD(s)
which is being replaced by loosening ~½ turn, but not remov-
ing, the Cable Hold Down Bracket(s) screws. Once the screws
have been loosened the bracket(s) can be slid up to gain access
to the ribbon cable connectors(s). Carefully, unplug the ribbon
connector(s) using a pair of long nosed pliers.
4. If the SPD Max has two SPDs mounted within the enclosure
also unplug the SPD Status ribbon cable connector of the SPD to
be replaced (See Figure 3).
Figure 3. SPD Max Device with Circuit Breaker Locked Out.
WARNING
ONLY LICENSED/QUALIFIED ELECTRICIANS WHO ARE TRAINED IN THE
INSTALLATION AND SERVICE OF ELECTRICAL EQUIPMENT ARE TO INSTALL
AND SERVICE THIS EQUIPMENT. HAZARDOUS VOLTAGES ARE PRESENT
INSIDE THE SPD MAX SERIES ENCLOSURE DURING NORMAL OPERATION.
FOLLOW ALL SAFE WORK PRACTICES AND LOCK OUT TAG OUT PROCE-
DURES TO AVOID ELECTRICAL SHOCK AND ARC FLASH.
5. Remove and retain the two Torx
®
screws securing the load side
dead front hinged plate (See Figure 3). If the SPD Max is wired
with the optional Form C for remote monitoring remove the Form
C three pin connector located on the right side of the SPD. If
the SPD Max is equipped with two SPD modules and the Form
C connectors are being used in both modules then both connec-
tors must be removed before the load side Dead-Front can be
lifted. If the Form C option is not connected to field wiring, the
connector(s) do not need to be removed prior to lifting the Dead-
Front panel.
6. Open the load side hinged dead front panel to gain access to the
load side wiring compartment (See Figure 4).
Cable Hold Down
Bracket (Loosen
screws ~1/2 turn)
SPD Status Ribbon Cables
Display Ribbon Cable
Load Side Hinged
Panel Torx
®
screws (2)
5
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
Figure 4. SPD Max Shown with the Load Side Dead Front Panel Open.
Figure 5. Locate the Circuit Breaker Terminals.
CAUTION
BEFORE PROCEEDING VERIFY NO VOLTAGE IS PRESENT ON ANY OF THE
CIRCUIT BREAKER LOAD TERMINALS WITH THE APPROPRIATE METER OR
VOLTAGE INDICATOR VERIFY THAT NO VOLTAGE IS PRESENT IN ANY OF
THE LOAD SIDE WIRING.
7. Caution: Before proceeding verify no voltage is present on
any of the circuit breaker load terminals with the appropriate
meter or voltage indicator verify that no voltage is present in any
of the load side wiring.
8. Then loosen the circuit breaker terminal screws (~ 10 turns) to
remove the phase wires from the circuit breaker.
Circuit
Breaker
Terminals
6
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
9. Carefully remove the neutral connection on the SPD (Wye and
High Leg Delta models only) and ground ring terminal attached to
the SPD (See Figure 6) and retain the hardware (screws and flat
washers) for installation of the replacement SPD module.
Figure 6. Neutral and Ground Connection Locations.
10. Carefully remove the four mounting screws from the SPD and
retain for installing the replacement SPD module (See Figure 7).
Then slowly remove the SPD from the SPD Max enclosure.
Figure 7. Location of Four SPD Mounting Screws.
11. Remove the Cable Hold Down Bracket including hardware (screw
and flat washer) and retain for installation of the replacement
SPD module (See Figure 7).
12. Proceed to 5.0 Installation of Replacement SPD Module.
Neutral Connection
Ground Connection
Cable Hold Down Bracket
and Hardware (Screws
and Flat Washers)
7
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
4.0 SPD Max with Terminal Block
If the SPD Max Series enclosure has a Catalog number ending with
a T, U, X or Y, such as SPMxxxxxxxxT, the enclosure contains a power
terminal block and the SPD Max enclosure must be locked out and
tagged out at the upstream disconnect or Source Power from the
unit. Before proceeding, verify and record which Surge Protective
Device within the SPD Max Series enclosure, SPD1, SPD2 or SPD1
and SPD2 are to be replaced before turning power off to the SPD
Max Series enclosure at the upstream disconnect or Source Power
(Refer to the section “Determining which SPD device has lost pro-
tection”, if necessary). Once this has been recorded, Lock Out and
Tag Out power to the SPD Max enclosure in accordance with
the National Electric Code (NEC), Canadian Electric Code (CEC),
state and local codes, or other applicable country codes.
1. Open the hinged door of the SPD Max Series enclosure by loos-
ening, but not removing, the 7 screws holding the metal latches.
Carefully open the hinged door (See Figure 8).
2. Disconnect the SPD Status ribbon cable of the specific SPD(s)
which is being replaced by loosening ~ 1/2 turn, but not remov-
ing, the two Cable Hold Down Bracket(s) screws(See Figure 8).
Figure 8. SPD Max with Two SPDs Installed, Terminal Block Option.
Cable Hold Down
Bracket (Loosen
screws ~1/2 turn)
SPD Status Ribbon Cables
Display Ribbon Cable
Load Side Hinged
Panel Torx
®
screws (2)
8
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
3. Once the screws have been loosened the bracket(s) can be
slid up so you can disconnect the ribbon cable connectors(s).
Carefully, unplug the ribbon connector(s) using a pair of long
nosed pliers.
4. If the SPD Max has two SPDs mounted within the enclosure
also unplug the SPD Status ribbon cable connector of the SPD to
be replaced (See Figure 9).
WARNING
ONLY LICENSED/QUALIFIED ELECTRICIANS WHO ARE TRAINED IN THE
INSTALLATION AND SERVICE OF ELECTRICAL EQUIPMENT ARE TO INSTALL
AND SERVICE THIS EQUIPMENT. HAZARDOUS VOLTAGES ARE PRESENT
INSIDE THE SPD MAX SERIES ENCLOSURE DURING NORMAL OPERATION.
FOLLOW ALL SAFE WORK PRACTICES AND LOCK OUT TAG OUT PROCE-
DURES TO AVOID ELECTRICAL SHOCK AND ARC FLASH.
5. Remove and retain the two Torx
®
screws securing the load side
dead front hinged plate (See Figure 8). If the SPD Max is wired
with the optional Form C for remote monitoring remove the Form
C three pin connector located on the right side of the SPD mod-
ule. If the SPD Max is equipped with two SPD modules and the
Form C connectors are being used in both modules then both
connectors must be removed before the load side Dead-Front
can be lifted. If the Form C option is not wired, the connector(s)
do not need to be removed prior to lifting the Dead-Front panel.
6. Open the load side hinged dead front panel to gain access to the
load side wiring compartment (See Figure 10).
Figure 9. Ribbon Cables Disconnected from SPD1.
Figure 10. Torx
®
Screws Removed with Hinged Dead Front Panel Open
Display Ribbon Cable
Load Side Hinged
Panel Torx
®
Screws
SPD Status Cable
9
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
Figure 11. Location of Terminal Block and Terminal Block Screws.
7. Caution: Before proceeding verify no voltage is present on
the terminal block load terminals with the appropriate meter
or voltage indicator verify that no voltage is present in any of the
load side wiring.
8. Then loosen the terminal block screws (~6 turns) and remove the
phase wires from the terminal block
9. Carefully remove neutral connection on the SPD (Wye and High
Leg Delta models only) and ground ring terminal attached to the
SPD and retain the hardware (screws and flat washers) for instal-
lation of the replacement SPD module.
Figure 12. Location of Ground and Neutral Connections.
Terminal
Block
Screws
Neutral Connection
Ground Connection
10
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
Figure 13. Remove Four Mounting Screws.
10. Carefully remove the four screws securing the SPD module to
the enclosure base (See Figure 13).
11. Remove the SPD module and retain screws for installing the
replacement SPD module.
12. Remove the Cable Hold Down Bracket and it’s hardware (screw
and flat washer) for installation on the replacement SPD module
(See Figure 13).
13. Proceed to 5.0 Installation of Replacement SPD Module.
SPD Cable Hold Down
Bracket and Hardware
Screws and Flat Washers)
11
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
5.0 Installation of Replacement SPD Module
CAUTION
TO ACHIEVE THE BEST VPR PERFORMANCE, THE REPLACEMENT SPD
MODULE’S PHASE WIRES SHOULD BE TRIMMED TO THE LENGTHS SPECI-
FIED IN TABLE 1.
The replacement SPD phase wires are stenciled with the appropriate
phase markings and should be cut to the lengths shown in Table 1.
Table 1. Replacement SPD Module Phase Wire Lengths
SPD # Phase A Phase B Phase C
SPD1 7.5” 8.5” 9.5”
SPD2 9.5” 8.5” 7.5”
Figure 14. Circuit Breaker Version with Typical Wire Connections – Load Side.
1. After cutting the phase wires to the proper length, strip off ½” of
wire insulation in preparation for installing the supplied ferrules.
2. Install the supplied ferrules to the phase wires prior to installa-
tion of the replacement SPD module into the SPD Max device.
At least one crimp is recommended on the ferrule to hold it in
place during installation.
3. Install Cable Hold Down Bracket removed from the original
SPD module using the original hardware. Position the washer
between the replacement SPD module and the bracket and
secure with screws.
4. Install the replacement SPD module into the SPD Max and
re-install the original four mounting screws to secure the SPD
module to the enclosure. (Assemble Tip: When installing SPD
Replacement modules that are less than 200kA, install the two
bottom mounting screws first, before mounting the two top
mounting screws.)
5. Re-attach the neutral (wye and high leg delta only) and ground
ring terminal(s) and tighten to 35 Lb-In.
6. Install the phase wires with ferrules to the load side of the circuit
breaker (Figure 14) or terminal block (Figure 15) and tighten to 35
Lb-In. Each phase wire is marked with the specific phase desig-
nation in white ink and should correspond to the phase markings
labeled under the circuit breaker or terminal block. Verify con-
nections are tight by lightly pulling on the phase wires to confirm
that they are secure in the terminals.
Phase A
Phase B
Phase C
12
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
Figure 15. Terminal Block Version with Typical Wire Connections – Load Side.
7. Close the load side hinged dead front panel and tighten the two
Tor x
®
screws to 10 Lb-In (See Figure 3 or 8).
8. Reattach the Form C connection (if equipped) for remote com-
munication.
9. Reattach all ribbon cable connectors that were disconnected ear-
lier. Slide the Hold Down Bracket(s) back into place and tighten
screws to 5 Lb-in (See Figure 3 or 8).
10. Circuit Breaker Models: Follow Lock Out Tag Out procedures
prior to re-applying power to the circuit breaker within the SPD
Max device.
11. Terminal Block Models: Follow Lock Out Tag Out procedures
before removing the lock at the upstream disconnect device and
re-applying power.
12. With power restored verify the SPD Max is operating properly by
observing the LED(s) as described below for specific model con-
figurations.
a. Models with suffix S, U, W and Y contain two SPD mod-
ules. Verify that neither LED is lit on the Status Indicator
located on the interior dead-front panel and the green LEDs
are lit on the external SPD Display mounted on the hinged
door. If there are any red LEDs lit disconnect power, Lock
Out Tag Out the SPD Max and verify installation procedures.
If red LEDs are lit after re-applying power call the Eaton
Customer Support Center at 1-800-809-2772, Option 4, Sub-
Option 2 for technical support.
b. Models with suffix R, T, V and X contain one SPD module.
Verify the green LEDs are lit on the external SPD Display
mounted on the hinged door. If there are any red LEDs lit
disconnect power, Lock Out Tag Out the SPD Max and verify
installation procedures. If there are any red LEDs lit after
re-applying power call the Eaton Customer Support Center at
1-800-809-2772, Option 4, Sub-Option 2 for technical support.
13. Close the hinged door and secure the seven latches over the
door and re-tighten the screws to 35 Lb-in..
14. The Eaton SPD Max is now protecting critical electrical and elec-
tronic equipment from damage by voltage transients and surges.
Phase A
Phase B
Phase C
13
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
Table 2. Appendix A. SPD Max Series Replacement SPD Catalog Part Numbers.
SPM Max
kA Rating
SPD Max Catalog Number
(xxxx = Voltage code)
Replacement SPD
Catalog Number
Suffix (R, T, V, X)
Replacement SPD
Catalog Number
Suffix (S, U, W, Y)
100kA SPM100xxxx1(R, T, V, X) SPD100xxxx1J-ND
SPM100xxxx2(R, T, V, X) SPD100xxxx2J-ND
SPM100xxxx3(R, T, V, X) SPD100xxxx3J-ND
120kA SPM120xxxx1(R, T, V, X) SPD120xxxx1J-ND
SPM120xxxx2(R, T, V, X) SPD120xxxx2J-ND
SPM120xxxx3(R, T, V, X) SPD120xxxx3J-ND
160kA SPM160xxxx1(R, T, V, X) SPD160xxxx1J-ND
SPM160xxxx2(R, T, V, X) SPD160xxxx2J-ND
SPM160xxxx3(R, T, V, X) SPD160xxxx3J-ND
200kA SPM200xxxx1(R, T, V, X) SPD200xxxx1J-ND
SPM200xxxx2(R, T, V, X) SPD200xxxx2J-ND
SPM200xxxx3(R, T, V, X) SPD200xxxx3J-ND
SPM200xxxx1(S, U, W, Y) SPD100xxxx1J-ND
SPM200xxxx2(S, U, W, Y) SPD100xxxx2J-ND
SPM200xxxx3(S, U, W, Y) SPD100xxxx3J-ND
250kA SPM250xxxx1(R, T, V, X) SPD250xxxx1J-ND
SPM250xxxx2(R, T, V, X) SPD250xxxx2J-ND
SPM250xxxx3(R, T, V, X) SPD250xxxx3J-ND
300kA SPM300xxxx1(R, T, V, X) SPD300xxxx1J-ND
SPM300xxxx2(R, T, V, X) SPD300xxxx2J-ND
SPM300xxxx3(R, T, V, X) SPD300xxxx3J-ND
320kA SPM320xxxx1(S, U, W, Y) SPD160xxxx1J-ND
SPM320xxxx2(S, U, W, Y) SPD160xxxx2J-ND
SPM320xxxx3(S, U, W, Y) SPD160xxxx3J-ND
400kA SPM400xxxx1(R, T, V, X) SPD400xxxx1J-ND
SPM400xxxx2(R, T, V, X) SPD400xxxx2J-ND
SPM400xxxx3(R, T, V, X) SPD400xxxx3J-ND
SPM400xxxx1(S, U, W, Y) SPD200xxxx1J-ND
SPM400xxxx2(S, U, W, Y) SPD200xxxx2J-ND
SPM400xxxx3(S, U, W, Y) SPD200xxxx3J-ND
500kA SPM500xxxx1(S, U, W, Y) SPD250xxxx1J-ND
SPM500xxxx2(S, U, W, Y) SPD250xxxx2J-ND
SPM500xxxx3(S, U, W, Y) SPD250xxxx3J-ND
600kA SPM600xxxx1(S, U, W, Y) SPD300xxxx1J-ND
SPM600xxxx2(S, U, W, Y) SPD300xxxx2J-ND
SPM600xxxx3(S, U, W, Y) SPD300xxxx3J-ND
800kA SPM800xxxx1(S, U, W, Y) SPD400xxxx1J-ND
SPM800xxxx2(S, U, W, Y) SPD400xxxx2J-ND
SPM800xxxx3(S, U, W, Y) SPD400xxxx3J-ND
14
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
6.0 Warranty
Installation of replacement SPD module(s) does not extend the
original manufacturer’s warranty period. Refer to the SPD MAX
instruction booklet, IB158002EN, for complete warranty informa-
tion. A copy of IB158002EN can be downloaded from the Eaton
website at www.eaton.com/spd
15
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
EATON www.eaton.com
Notes:
Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com
© 2014 Eaton
All Rights Reserved
Printed in USA
Publication No. IB158004EN / TBG 001163
October 2014
Eaton is a registered trademark.
All other trademarks are property
of their respective owners.
Instruction Booklet IB158004EN
Effective October 2014
Eaton SPD Max Series
SPD Replacement
Instruction Manual
/