Symcom 460-575 Installation Guide

INSTALLATION INSTRUCTIONS

FOR SYMCOM’S MOTORSAVER



MODEL 460-575

BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION!

FOLLOW NATIONAL, STATE, AND LOCAL CODES!

READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION!

The Model 460-575 MotorSaver is an auto ranging voltage monitor designed
to protect three-phase motors regardless of size. The MotorSaver is used on
475-600 VAC, 50 to 60 Hz motors to protect from damage caused by single
phasing, low voltage, high voltage, phase reversal, and voltage unbalance.

CONNECTIONS

1. Mount the MotorSaver in a convenient location in or near the motor
control panel. If the location is wet or dusty, the MotorSaver should
be mounted in a NEMA 4 or 12 enclosure. The MotorSaver can be
mounted to a back panel using two #6 or #8 x 5/8 screws or can be
snapped onto a DIN rail.

2. Connect L1, L2 and L3 on the MotorSaver’s terminal strip to the LINE SIDE
of the motor starter. (See Figure 1).

3. Connect the output relay to the circuitry to be controlled. For motor control,
connect the normally open contact in series with the magnetic coil of the
motor starter as shown in Figure 1. For alarm operation, connect the
normally closed contact in series with the control circuit as shown in Figure

2.

2880 North Plaza Drive, Rapid City, SD 57702 • [phone]

MODEL 460-575

FIGURE 1: CONTROL WIRING DIAGRAM

LIGHT

MODEL 460-575

FIGURE 2: ALARM WIRING DIAGRAM

10/04 -2-

SETTINGS

MODEL 460

475

500

520 550

575

600

Percent Unbalance =

Maximum Deviation from the Average

Average

x 100

Example: The measured line-to-line voltages are 203, 210, and 212.

Average =

203 + 210 + 212

3

= 208.3

The maximum deviation from the average is the largest difference
between the average voltage (208.3) and any one voltage reading.

208.3 - 203 = 5.3 210 - 208.3 = 1.7 212 - 208.3 = 3.7

The maximum deviation from the average is 5.3.

5.3

208.3

x 100 = 2.5% Unbalance

1. Line voltage adjustment: Rotate the
“VOLTAGE ADJ. (VAC)” to the nominal
three-phase line voltage feeding the motor
to be protected.

2. Restart delay adjustment: Rotate the
“RESTART (SEC)” adjustment to the
desired position. The restart delay is the
time between MotorSaver seeing
acceptable voltage and the MotorSaver
closing its output contacts. For
compressor applications, the restart 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 typically
set between 2 and 10 seconds.

3. Trip delay adjustment: Rotate the “TRIP
DELAY (SEC)” adjustment to the desired
setting. This adjustment does not affect the
trip delay on phasing faults. Typically, the
trip delay adjustment is set between 1 and 5
seconds. In areas where voltage uctuations are frequent, the trip delay
adjustment may be set greater than 10 seconds.

4. Voltage unbalance adjustment: Rotate the “UNBALANCE TRIP (NEMA%)”
adjustment to the desired unbalance trip level. The NEMA MG1 standard
does not recommend operating a motor above 1% voltage unbalance without
derating the motor. The NEMA MG1 standard also recommends against
operating a motor above a 5% voltage unbalance under any circumstances.
SymCom recommends consulting the motor manufacturer for specic
tolerances.

-3- 10/04

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 RESTART delay, the MotorSaver® will
energize its output contacts and the green RUN light will illuminate. If the
contacts do not energize and the RUN light does not illuminate, see the

TROUBLESHOOTING section.

DIAGNOSTIC INDICATOR LIGHTS

RUN

RESTART DELAY

REVERSE PHASE

UNBALANCE / SINGLE PHASE

HIGH / LOW VOLTAGE

CONGRATULATIONS!!

YOU HAVE JUST INSTALLED THE FINEST

MOTOR PROTECTION AVAILABLE!!

10/04 -4-

TROUBLESHOOTING

RED

RED

SYMPTOM

No lights are on.

The unit seems

completely dead.

Red light is

blinking (on initial

power up).

Red light is

blinking (after the

motor has been

previously

running).

Red light is

blinking in this

pattern.

Red light is on

steady.

Green light blinks

and motor is not

running.

Green light is on

steady, but motor

does not start.

LIGHT

PATTERN

N / A

SOLUTION

Measure the three line-to-line voltages. If
any of the voltages are below 350 VAC, the
MotorSaver does not have enough power
to operate its internal electronics. This
may occur on a single-phased system. If
the voltages are correct, call SymCom at
1-800-843-8848 or 1-605-348-5580.

Turn off the three-phase power. Swap any
two leads powering the MotorSaver (L1,
L2, or L3). There is a 50-50 chance of
connecting L1, L2, and L3 correctly the rst
time. Re-apply the three-phase power.

The incoming lines have been reverse
phased. The MotorSaver is preventing
the motor from running backwards. Correct
the phase sequence.

The voltage is unbalanced or
single-phased. Measure the incoming line
voltages and calculate the % unbalance. If
the voltage unbalance does not exceed the
% unbalance reset value, call SymCom at
1-800-843-8848 or 1-605-348-5580.

The voltage is out of tolerance. Measure
the three line-to-line voltages. Calculate
the average of the three voltages. If the
average is 7% above or below the nominal
voltage as selected by the LINE VOLTAGE
ADJUST, the MotorSaver is functioning
properly. If the voltage is within ±7% of the
selected line voltage, call SymCom at
1-800-843-8848 or 1-605-348-5580.

The MotorSaver is in restart delay.

The MotorSaver is in run mode. Ensure
other control devices are allowing the
motor to start. Check control circuit for
loose wires or malfunctioning switches.

Any questions or comments call SymCom at 1-800-843-8848 or

1-605-348-5580

-5- 10/04

SPECIFICATIONS

3 - Phase Line Voltage 475 - 600 VAC

Frequency 50* - 60 Hz

Low Voltage (% of setpoint)

Trip 90% ±1%

Reset 93% ±1%

High Voltage (% of setpoint)

Trip 110% ±1%

Reset 107% ±1%

Voltage Unbalance (NEMA)

Trip 2 - 8% Adjustable

Reset

Trip Setting minus 1% (5 - 8%)

Trip Setting minus 0.5% (2 - 4%)

Trip Delay Time

Low, High, and Unbalanced Voltage 1 - 30 Seconds Adjustable

Single-phasing faults (>25% UB) 1 Second Fixed

Restart Delay Time

After a fault or complete power loss 1 - 500 Seconds Adjustable

Output Contact Rating - SPDT

Pilot Duty 480 VA @ 240 VAC

General Purpose 10 A @ 240 VAC

Power Consumption 6 Watts (maximum)

Weight 14 oz

Enclosure Polycarbonate

Terminal

Torque 6 Inch-Pounds

Wire AWG 12 - 20 AWG

Safety Marks

UL UL508 (File # E68520)

CE IEC 60947-6-2

Standards Passed

Electrostatic Discharge (ESD)

IEC 1000-4-2, Level 3, 6 kv contact,
8 kv air

Radio Frequency Immunity, Radiated 159 MHz, 10 V/m

Fast Transient Burst

IEC 1000-4-4, Level 3, 3.5 kv input
power and controls

*NOTE: 50 Hz will increase all delay timers by 20%

10/04 -6-

Surge

2.350

IEC

ANSI / IEEE

Hi-potential Test

IEC 1000-4-5, Level 3, 4kv line-to-line;
Level 4, 4kv line-to-ground

C62.41 Surge and Ring Wave Compliance
to a level of 6kv line-to-line

Meets UL508 (2 x rated V +1000V for 1
minute)

Environmental

Temperature Range

Ambient Operating: -20° - 70° C (-4° - 158°F)
Ambient Storage: -40° - 80° C (-40° - 176°F)

Class of Protection IP20, NEMA 1 (Finger Safe)

Relative Humidity 10-95%, non-condensing per IEC 68-2-3

DIMENSIONS

SymCom warrants its microcontroller based products against defects in material or workmanship
for a period of ve (5) years* from the date of manufacture. All other products manufactured by
SymCom shall be warranted against defects in material and workmanship for a period of two (2)
years from the date of manufacture. For complete information on warranty, liability, terms, and
conditions, please refer to the SymCom Terms and Conditions of Sale document.

-7- 10/04

Visit our website at www.symcominc.com for our

complete catalog and new product listings!

2880 North Plaza Drive, Rapid City, SD 57702

Phone: [phone] or [phone]

FAX: [phone]