Whole-Home Surge Protector Installation

Purpose

Define the install procedure for a Type 2 (panel-mounted) whole-home surge protector. Required by NEC 230.67 on every residential service replacement since 2020 - and a high-ROI upsell on any panel service call for existing customers. One lightning event prevented makes the entire customer base's surge-protector investment look cheap.

Scope

Applies to:

• Residential 200A or 100A main service panels
• Modular sub-panels feeding sensitive loads (HVAC, well pumps, EV chargers)
• New panel replacements (mandatory per NEC 230.67)

Excludes Type 1 service-entrance devices (utility coordination required) and commercial three-phase systems (separate SOP).

Responsibilities

• Dispatcher confirms panel make/model and available breaker space at booking
• Lead electrician sizes the SPD per the panel rating + customer load profile
• Customer is briefed on the indicator LEDs + the replacement-after-event policy

Procedure

1. Confirm panel make + model. Different brands use different bus configurations; verify the SPD is compatible with the panel.
2. Calculate clamping voltage requirements. Standard residential: 400 V or less let-through at 3 kA test surge. Sensitive electronics households (audiophile, home recording, server): 330 V or less.
3. De-energize the panel. Turn off the main breaker, then the main service disconnect at the meter if accessible. Verify dead at the bus with a non-contact voltage tester + multimeter on a known-live circuit first.
4. Identify the install location. SPDs install closest to the main breaker for maximum effectiveness - top of the panel bus is ideal. Some SPDs install as their own breaker module; others mount externally with a short pigtail.
5. Install per the SPD manufacturer's instructions. For breaker-style: snap into a 2-pole position adjacent to the main. For external mount: secure to the panel exterior, route the pigtail through a knockout, connect to a 2-pole breaker, tie the neutral to the panel ground bus.
6. Keep leads as short as possible. Every inch of lead wire reduces effectiveness - 6" total is the practical maximum.
7. Verify torque on all connections per the panel label specifications.
8. Restore power. Main disconnect first, then panel main. Verify the SPD's indicator LEDs read "Protected" (green on most models).
9. Document the install. Photograph the panel before / after, label the SPD breaker (or external mount) with the install date.
10. Customer briefing. Show the indicator LEDs. Explain that an event-triggered LED color change means the SPD did its job and needs replacement - it's a one-time-use protection device.

Acceptance Criteria

• SPD installed in a 2-pole position closest to the main breaker
• Leads under 6" total length
• Indicator LEDs read "Protected"
• All connections torqued to panel-label spec
• Install date labeled on the SPD or panel deadfront
• Customer signs the field report after a verbal briefing on the LEDs

References

• NEC Article 230.67 (Surge protection on dwelling units)
• NEC Article 285 (Surge Protective Devices)
• Manufacturer install instructions for the specific SPD model
• Manuall internal: Garage Door Panel Replacement