Symcom 460-MR Installation Guide

INSTALLATION INSTRUCTIONS FOR

SYMCOM’S MOTORSAVER

MODEL 460-MR

®

BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION!

FOLLOW NATIONAL, STATE AND LOCAL CODES.

READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION.

The Model 460-MR MotorSaver® is an auto-ranging voltage monitor designed to protect 3-phase
motors regardless of size. The MotorSaver
from damage caused by single-phasing, low voltage, high voltage, phase reversal, and voltage
unbalance. The Model 460-MR features an optional manual reset mode. In addition, when the
MotorSaver
displayed until the unit is manually reset, even if power is removed and reapplied.

CONNECTIONS

1. Mount the MotorSaver® in a convenient location in or near the motor control panel. If the

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

3. Connect the output relay to the circuitry to be controlled. For motor control, connect the

4. The Model 460-MR is shipped with a jumper across the two manual reset pins (see Fig. 3). This

®

is in the manual reset mode and a fault condition occurs, the fault code will be

location is wet or dusty, the MotorSaver
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.

(see Figure 1).

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 in
Figure 2.

will allow the MotorSaver

®

to operate in automatic reset mode. To operate the MotorSaver® in
manual reset mode, the jumper must be removed and replaced with an NO (normally open)
pushbutton switch. A pre-assembled connector and 12” cable are shipped with each
MotorSaver

®

(pushbutton not included). The connector must be plugged into the MotorSaver®

with the locking tabs facing downward.

®

is used on 190-480VAC, 50/60 Hz motors to protect

®

should be mounted in a NEMA 4 or 12 enclosure. The

2880 North Plaza Drive, Rapid City, SD 57702

[phone] · [phone]

www.symcominc.com

Figure 1. Control Wiring Diagram

Figure 2. Alarm Wiring Diagram

Figure 3. Manual Reset Connections

2

7/05

SETTINGS

1. Line voltage adjustment: Rotate the VOLTAGE ADJ.
(VAC) to the nominal 3-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 the MotorSaver
and the MotorSaver
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.

NOTE: The restart delay adjustment is inoperative
when configured for manual reset.

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 fluctuations 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 specific
tolerances.

Percent Unbalance = Maximum deviation from the average

Average

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

Average = 203 + 210 + 212

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

®

closing its output contacts. For

3

208.3 - 203 = 5.3 210 - 208.3 = 1.7 212 - 208.3 = 3.7
The maximum deviation from the average is 5.3.

®

seeing acceptable voltage

= 208.3

x 100 = 2.5% unbalance

5.3

208.3

x 100%

3

7/05

MANUAL RESET SWITCH OPERATION

The MotorSaver® always requires a manual reset after a power loss when operated in manual reset
mode. If no faults are currently detected, and no faults were detected before power was removed,
both lights will flash in unison until the reset button is pressed. When a fault is detected, the
MotorSaver

®

will flash the fault code until the fault condition clears and the reset button is pressed. If
the fault clears but the reset button has not been pressed, the MotorSaver
fault. If power is lost before the MotorSaver
to flash the corresponding fault code once power is reapplied. This allows for identification of the last
fault even after power conditions have returned to normal. As soon as the reset button is pressed,
the MotorSaver

®

will resume normal operation.

NOTE: If the jumper is left in place, or the manual reset button is pressed when the 460-MR is
powered-up, it will operate in automatic reset mode. If an automatic restart would be a hazard
to equipment or personnel, use the manual reset mode.

POWER-UP

Automatic Reset Mode: With the jumper in place, or the manual reset button pressed, apply 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 illuminate. If the contacts do not energize and the RUN light does not illuminate, see the
TROUBLESHOOTING section.

Manual Reset Mode: With the jumper removed and the manual reset button released, apply 3­phase power to the motor. The MotorSaver’s green and red lights will blink in unison until the
manual reset button is pressed – then the contacts will energize and the RUN light will illuminate.

NOTE: Upon power up, if a light pattern other than the red and green lights blinking in unison
is displayed (while in manual reset mode), the Model 460-MR is in a fault condition or was in
a fault condition before it lost power. The fault code will be displayed until the unit is
manually reset.

®

®

is reset, it will remember the previous fault and continue

®

will energize its output contacts and the green RUN light

will continue flashing the

DIAGNOSTIC INDICATOR LIGHTS

RUN GREEN

RESTART DELAY

GREEN

REVERSE PHASE

UNBALANCE / SINGLE PHASE

HIGH / LOW VOLTAGE RED

MANUAL RESET REQUIRED

GREEN & RED

4

RED

RED

7/05

TROUBLESHOOTING

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

previously been running)

Red light is blinking in

this pattern

Red light is on steady

LIGHT

PATTERN

N/A

RED

RED

RED

RED

SOLUTION

Measure the three line-to-line voltages. If any
of the voltages are below 150VAC, the
MotorSaver
operate its internal electronics. If the voltages
are correct, call SymCom at [phone] or
[phone].

Turn off the 3-phase power. Swap any two
leads powering the MotorSaver
There is a 50-50 chance of connecting L1, L2
and L3 correctly the first time. Reapply 3-phase
power.

The incoming lines have been reverse-phased.
The MotorSaver
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 [phone] or
[phone].

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
voltage is within ±7% of the selected line
voltage, call SymCom at [phone] or
[phone].

®

does not have enough power to

®

(L1, L2, or L3)

®

is preventing the motor from

®

is functioning properly. If the

Green light blinks and

motor is not running

Green light is on steady,

but motor does not start

Green and red lights

blink in unison and
motor does not run

GREEN

GREEN

GREEN & RED

The MotorSaver
delay – this occurs only when the manual reset

®

is timing through the restart

jumper is in place.

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.

The MotorSaver

®

is waiting for a manual reset.

5

7/05

MOTORSAVER® 460-MR SPECIFICATIONS

3-Phase Line Voltage
475-600VAC (optional)
95-120VAC (optional)
Frequency
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 Delay Time (automatic restart mode only)

Low, High and unbalanced voltage 1-30 seconds adjustable

Single-phasing faults (>25% UB) 1 second fixed

Restart Delay Time
After a fault or power loss 1-500 seconds adjustable
Output Contact Rating – SPDT

Pilot Duty 480VA @ 240VAC
General Purpose 10A @ 240VAC

Power Consumption
Weight
Enclosure
Terminal

Torque 6 in.-lbs.
Wire AWG 12-20 AWG
Safety Marks
UL UL508 (File #E68520)
CE IEC 60947-6-2
Standards Passed

Electrostatic Discharge (ESD)

Radio Frequency Immunity,
Radiated

Fast Transient Burst

Surge

IEC

ANSI/IEEE

Hi-Potential Test

Environmental

Temperature Range
Class of Protection IP20, NEMA 1 (Finger Safe)
Relative Humidity 10-95%, non-condensing per IEC 68-2-3

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

190-480VAC

50*/60Hz

Trip setting minus 1% (5-8%)
Trip setting minus 0.5% (2-4%)

6 Watts
14 oz.
Polycarbonate

IEC 100-4-2, Level 3, 6kV contact,
8kV air

159 MHz, 10V/m

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

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 +1000 V for 1 minute)

Ambient Operating: -20° to 70°C (-4° to 158°F)

6

7/05

DIMENSIONS

SymCom, Inc. warrants its microcontroller-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 warranted against defects in material or 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

7/05

Visit our website at www.symcominc.com for our

complete catalog and product listings!

2880 North Plaza Drive, Rapid City, SD 57702

[phone] · [phone]

www.symcominc.com

8

7/05