Symcom 455 Installation Guide

INPUT

OL

AUTOPILOT

INSTALLATION INSTRUCTIONS FOR

SYMCOM’S MOT ORSAVER

2880 North Plaza Drive, Rapid City, South Dakota 57702

INPUT

AUTOPILOT

MODEL 455

®

BE SURE POWER IS DISCO NNECTED PRIOR TO INSTALLATION!

FOLLOW NATIONAL, STATE AND LOCAL CODES.

READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION.

The Model 455, 3-pha se, 190-480VAC voltage monitor combines line and load-side monitoring to
alert the user of conta ctor failure. Line-side monitoring will protect the motor from damaging power
conditions including high and low vo ltage, voltage unbalance, single-phasing, phase reversal and
rapid cycling. The Model 455 is now equipped with an infrared LED to communicate with the

hand-held diagnostic tool—Informer MS Edition—to display trip points, real-time data, and the
last 20 faults and 32 motor starts. Motor run hours, also displayed by the Informer MS, can
now be reset on the 455.

CONNECTIONS

1. Mount the MotorSaver® in a conv enient lo cation in or near the motor control panel. If the lo cation is
wet or dusty, it should be mounted in a NEMA 4 or 12 enclosure.

2. Connect L1, L2, and L3 on the MotorSaver® to the LINE SIDE of the motor starter.

3. Connect M1, M2 and M3 to the power lines on the LOAD SID E of the motor starte r.

NOTE: If a 2-pole contactor is use d, jump the hard-wired line from the L side terminal (the wire not
connected through the con ta ctor) to its co rresponding M terminal.

If load-side protection is not desired, connection to the M terminals is not required—the
Model 455 will operate as a line side only voltage monitor in this configuration.

4. Connect the output relay to the circuitry to be controlled. Connect the normally ope n conta ct in
series with the magnetic coil of the motor star ter as shown in Figure 1.

A
B

POWER

C

MAGNETIC

CONTACTOR

OL
OL

MOTOR

OL

A
B

POWER

C

MAGNETIC

CONTACTOR

OL

MOTOR

OL

L1

MS455

M1 M2 M3

CONTROL

POWER

24 - 240 VAC

L2 L3

MAG.

COIL

HAND

THERMOSTAT

OL

OFF

OPTIONAL

TM

STOP

START

M

L1

MS455

M1 M2 M3

CONTROL

POWER

24 - 240 VAC

L2 L3

MAG.

COIL

OL

HAND

OFF

Figure 1. 3-Pole Contactor Wiring Diagram Figure 2. 2-Pole Contactor Wiring Diagram

NOTE: L1 and M1 must be connected to the same supply line as shown. Similarily, L2 and M2, as

well as L3 and M3 must be co nne cted to the same supply lines.

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www.symcom.com

THERMOS TAT

OPTIONAL

TM

START

STOP

M

SETTINGS

1. LINE VOLTAGE ADJUSTMENT:
Rotate the VOLT. ADJ. (VAC) k nob to
the nominal 3-phase line vol tage
feeding the motor to be protected .
The Model 455 w ill automatically
sense whether it is connected to a
200V or 400V power system.

VOLT. ADJ .

(VAC)

208

220

416

440
200
400

190
380

2

UNBALANCE

TRIP (NEMA %)

230

L1 L2 L3

460

190-480 V AC, 3Ø, 50/60 HZ

240
480

8

OVER
VOLT.

SymCom. Inc.

M1 M2 M3

MODEL 455

PHASING

FAULT

RUN

UNDER

VOLT.

PILOT DUTY RATING

480VAAT 240 VAC

2. RESTART D ELAY: Rotate the
RESTART (SEC) knob to the desired
position. The restart delay is the time between the MotorSaver see ing acceptable power and the
MotorSaver closing its output con tacts. For compressor applications, the re start delay should be
set for the approximate time it takes for the head pressure to bleed off of the compressor. For
other applications, the restart delay is typi cally set to 2 se conds.

NOTE: This delay is also the minimum cy cle time or rapid-cycle timer for the motor or comp re ssor
when control power is lost such as the operation of the thermostat.

The manual position on the restart adjustment can be used as a manua l reset after any fault
condition, or loss of incoming power. To util ize this feature, rotate the restart adjustment to “2” to
allow the run light to come on—then rotate the restart delay knob back to the manual (MAN) position.

NOTE: When the manual feature is used , the unit will not have rapid-cycle protection if the control
power is lost (i.e. thermostat control); but will require a manual reset if any fault or loss of in coming
power is experienced.

3. VOLTAGE UNBALAN CE: Rota te the UNBALANCE TRIP (NEMA %) to the desired voltage
unbalance trip level. The NEMA MG1 standard doe s not recommend operating a motor above a
1% voltage unbalance as determined by the following formula without de rating the motor.

% Voltage Unbalance = Maximum Deviation from the Ave rage

x 100%

Average
The NEMA MG1 stan dard also recommends against operating a motor above 5% vol tage unbalance
under any circumstances. Therefore, a 5% UB setting is a good place to start, but SymCom
recommends consulting the motor manufacturer for specific tole rances.

MAN

RESTART

2

IND. CONT. EQ.

DELAY

(SEC)

100

300

302

15

TRIP
(SEC)

784X

LISTED

4. TRIP DELAY AD JUSTMEN T: Rotate the TRIP DELAY knob to the desired set ting. The

adjustment does not affect the trip delay on a single-phasing fault. Typically, the trip delay is set to
4 seconds, in areas where voltage fluctuations are frequent, the trip dela y may need to be set
higher.

POWER-UP

Turn on the 3-phase power to the motor. The MotorSaver’s green RUN light will blink during the
restart delay. After the re start delay, the MotorSaver® will energize its output contacts and the green
light will illuminate. If the contacts do not energize and the RUN light doe s not illuminate, see the
TROUBLESHOOTING section.

RESET RUN HOURS

To reset the run hours, first remove power to the Model 455 . Make a note of each of the adjustable
settings. Turn all of the setpoint knobs to the minimum po sition, i.e., VOLT. ADJ. and RESTART
fully counter-clockwise; UNBALANCE TRIP AND TRIP DELAY fully clockwise . Apply power
momentarily, then remove power again to readju st each setting back to the noted/de sired level.
Reapply power.

2

7/06

TROUBLESHOOTING

SYMPTOM SOLUTION

The RUN light does not blink
on initial power-up and all
three fault lights are on.

No LEDs are lit—the unit
seems completely dead.

PHASING FAULT light is
blinking on initial power-up.

PHASING FAULT light is
blinking after the motor has
previously been running.

The PHASING FAULT light
is on and the unit will not
reset even though the
RESTART DELAY is not in
the manual (MAN) position.

The UNDERVOLT. or
OVERVOLT light is on

The RUN LIGHT blinks, the
motor starts momentarily but
quickly turns off with the
PHASING FAULT light on.

Check the RESTART DELAY knob. If it is set to the manual (MAN)
position, the Model 455 is in manual reset mode. Turn the
RESTART DELAY to “2” fo r several seconds until the output
contacts close.
Measure the three line-to-line voltages. If any of the voltages are
below 150VAC, the Model 455 doe s not have enough power to
operate its internal electronics. This may occur on a single-phased
system. If the voltages are corre ct, call SymCom at [phone].
Turn off the 3-phase power. Swap any two lea ds powering the
Model 455: L1, L2, or L3. There is a 50:50 chance of correctly
connecting leads the first time. Re-apply 3-phase power.

The incoming lines have been reverse -phased. Swap and two
incoming power lines to the magnetic contactor.

Measure incoming lines for correct voltage. If the voltage s do not
exceed the NEMA unbalance setting, a sing le-phasing condition
has occurred on the load side o f the contactor. Check the contacts
on the magnetic contactor. If the contacts appear in good condition,
check the wiring to M1, M2 and M3. Power must be removed and
re-applied to clear this fault condition. If the conta cts and wiring are
good, call SymCom at [phone].
Measure the three line-to-line voltages and calculate the av erage.
If the average is outside ±7% of the nominal voltage as set by
VOLT. ADJ., the MotorSaver®is functioning properly. If the voltage
is within the reset w indow, call SymCom at [phone].
Check the contactor to ensure the con tacts and motor wiring are in
good condition. Power must be removed and re-applied to clear this
fault condition.
If the problem persists, call SymCom at [phone].

INDICATOR LIGHTS

LED INDICATOR CONDITION

UNDERVOLTAGE ON

OVERVOLTAGE ON

PHASING FAULT ON

PHASING FAULT BLI NKING Incoming power is reverse-phased.
UNDERVOLTAGE, OVERVOLTAGE AND

PHASING FAULT LIGHTS ON
RUN LIGHT ON Output contact is energized.
RUN LIGHT BLINKING The MotorSaver®is timing through the re start delay.

Voltage is less than 93% of nominal voltage as set by
the VOLT. ADJ. knob

Voltage is greater than 107% of nominal voltage as
set by VOLT. ADJ.

Voltage unbalance is greater than the setting of
UNBALANCE TRIP or a single-phasing fault has
occurred. If single-phasing has occurred on the load
side of the contactor, power must be remo ved and re­applied to the MotorSaver®.

Unit has been powered up in the manual restart
position.

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7/06

MODEL 455 SPECIFICATIONS

3-Phase Line Voltage
Frequency

Low Voltage (% of setpoint)

Trip
Reset

High Voltage (%of setpoint)

Trip
Reset

Voltage Unbalance (NEMA)

Trip
Reset

Trip Delay Time

Low and High Voltage,
and Voltage Unbalance

Single-Phasing Faults

Restart Delay Time

After a fault or power loss

Output Contact Rating – SPDT

Pilot Duty
General Purpose

Standards Passed

Electrostatic Discharge (ESD)
Radio Frequency Immunity (RFI)

Fast Transients

Repeat Accuracy P rotection

Fixed Condition s

Power Consumption

Weight
Terminal

Torque

Operating Temperature
Safety Marks

UL

*50Hz will increase all delay timers by 20%

190–480VAC (nominal)
475–600VAC (Model 455-575)
50*/60Hz

90%
93%

110%
107%

2–8%

4.5%

2–30 seconds (adjustable)
2 seconds (fixed)

Manual, 2–300 seconds (adjustable)

480VA @ 240VAC
10A @ 240VAC

IEC 61000-4-2, Level 3, 6kV contact, 8kV air
IEC 61000-4-2, Level 3, 10V/m
IEC 61000-4-4, Level 3, 4kV input power

2kV inputs/outputs

±0.1%
6 Watts (max.)
14 oz.

7 in.-lbs. (max.)

-40° to 70°C (-40° to 158°F)

UL508 (File #E68520)

QUESTIONS OR COMMENTS?

PLEASE CALL SYMCOM AT [phone] OR [phone]

SymCom, Inc. warrants its micro controller-based products against defects in material or
workmanship for a period of five (5 ) years from the date of manufacture. All other products
manufactured by SymCom shall be warran ted against defects in material or workmanship for a
period of two (2) years fro m the date of manufacture. For com ple te information on warranty, liability,
terms, and conditions, please refer to the SymCom Terms and Conditions of Sale document.

2880 North Plaza Drive, Rapid City, South Dakota 57702

[phone]· [phone] · fax [phone]

4

www.symcom.com

7/06