SYMCOM 777-KW/HP-P2, 777-575-KW/HP-P2 Installation Manual

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INSTALLATION INSTRUCTIONS

Rapid City, SD, USA, 01/2010

MODEL 777-KW/HP-P2 777-575-KW/HP-P2

POWER MONITOR

Revision A1

II_777-KW-HP-P2_A1

2880 North Plaza Drive, Rapid City, South Dakota 57702

(800) 843-8848 · (605) 348-5580 · fax (605) 348-5685

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CONNECTIONS .............................................................................................................................3

PROGRAMMING............................................................................................................................7

PROGRAMMABLE PARAMETERS...............................................................................................8

OPERATION.................................................................................................................................11

PROGRAMMING EXAMPLES .....................................................................................................12

SYSTEM DISPLAY.......................................................................................................................13

TROUBLESHOOTING..................................................................................................................14

CLEARING LAST FAULT.............................................................................................................15

TAMPER GUARD.........................................................................................................................15

GROUND FAULT TESTING PROCEDURE.................................................................................16

777-KW/HP-P2 SPECIFICATIONS ..............................................................................................17

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BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION!

FOLLOW NATIONAL, STATE AND LOCAL CODES.

READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION. TION.

WARNING!

Hazardous Voltage. Failure to follow these instructions can result in death,

Power must be disconnected prior to attaching and/or using the battery cable.

Damage to the device or serious injury may occur if the battery programming feature is used while power is applied. Always follow proper safety procedures for removing and securing the

ower source before connecting the battery cable. p

The battery cable cannot be used when power is applied to the device. To program the device when it is powered, the user must utilize a network programming option.

The 777-KW/HP-P2 is a power monitor that is fully programmable for customized protection. The 777-KW/HP-P2 is designed to protect 3-phase systems with operating voltages of 200-480VAC (500-600VAC for the Model 777-575-KW/HP-P2). The output relay is a Form C contact, which can control a contactor or other device within the output relay contact rating. It has advantages over current monitors in low speed motor applications (less than 1800 rpm), lower power applications and in lightly loaded applications.

The 777-P2 can be safely programmed prior to installation by supplying power with a 9V battery. See Figure 4 in the PROGRAMMING section. DO NOT connect the battery to the unit when line voltage is present. The 777-KW/HP-P2 cannot using a 9V battery. For testing purposes, 3-phase power must be used with a minimum voltage of 200VAC (500VAC for the Model 777-575-KW/HP-P2). Follow all safety warnings when dealing with hazardous voltages.

CONNECTIONS

1. Disconnect power and verify line and control power are off.

2. Using the four corner tabs or the DIN rail mount, install the 777-KW/HP-P2 directly above or below the contactor. To mount on a DIN rail, hook the top clips first then apply downward pressure until the lower clips snap onto the rail.

3. a) For amperages from 20-90 amps, insert the motor conductors through the holes marked A, B,

and C. Ensure the motor phase conductors correspond with the round hole designations, i.e. the A phase conductor should go through the round hole marked “A”. See Figure 1 for a typical wiring diagram.

b) For amperages less than 20 amps, loop the motor conductors according to Table 1. Figure 2

shows an example of the looping required for current ranging from 12-20 amps (MULT=2).

serious injury, or equipment damage.

be tested for proper operation or communications

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c) For amperages greater than 90 amps, external CTs (current transformers) are required.

SymCom recommends using CTs with terminal connections for easier installation. All CT secondaries must make five passes through the round holes on the MotorSaver Figure 3 for a typical wiring diagram using external CTs.

NOTE: Pay close attention to the wiring diagrams to eliminate any errors when communicating

power factor information over a network. The L2 phase conductor must pass through the B current measurement hole for proper operation.

4. Connect the 3-phase power from the line side of the contactor to L1, L2, and L3 terminals using 12-18 AWG copper wire. These should be tightened to 7 in.-lbs., max.

5. Connect the control circuit wires to the appropriate terminals. The relay is designed for fail-safe operation; the NO (normally open) contact should be in series with the coil on the contactor for motor control (see Figure 1). For alarm circuits, the NC (normally closed) contact is in series with the alarm circuitry.

Recommended

Full Load Amps

2-2.5 2-10 10 10

2.5-3 2.2-11.1 9 9 3-3.5 2.5-12.5 8 8

3.5-4 2.8-14.3 7 7 4-5 3.3-16.7 6 6 5-6 4-20.1 5 5 6-8 5-25.1 4 4

8-12 6.6-33.5 3 3 12-20 10-50.3 2 2 20-90 20-100 1 1

80-110 80-140 5 100 (100:5) 110-160 120-210 5 150 (150:5) 160-220 160-280 5 200 (200:5) 220-320 240-420 5 300 (300:5) 320-420 320-560 5 400 (400:5) 400-520 400-700 5 500 (500:5) 480-600 480-840 5 600 (600:5) 540-700 560-980 5 700 (700:5) 560-800 640-992/FFF 5 800 (800:5)

OC Range

(Amps)

# of Passes

through each

Window

MULT (CT

Ratio)

Plus. See

Table 1: Wiring Configuration Based on Motor Full Load Amps

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Figure 1: Typical Wiring Diagram

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Figure 2: Looping Example for 12-20A, MULT = 2

Figure 3: Typical Wiring Using External CTs

All CTs must face the same direction, and all CT secondaries must be wired identically, i.e. all X1

terminals enter the main (round) window and return to H1 terminal after exiting the loop conductor window (rectangle). Every CT secondary must make 5 passes through the corresponding main conductor window. SymCom recommends using CTs with terminals to simplify installation.

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PROGRAMMING

To program prior to installation, connect the 9V battery cable to the pins on the left side of the unit (when looking at the display), and then attach a standard 9V battery to the cable. See Figure 4. The 9V battery cable is keyed for proper installation. If the cable is connected improperly, the 777KW/HP-P2 will not power the display. DO NOT connect the battery when line voltage is present. The 777-KW/HP-P2 cannot For testing purposes, 3-phase power must be used with a minimum voltage of 200VAC (500VAC fo r the Model 777-575-KW/HP-P2). Follow all safety warnings when dealing with hazardous voltages.

1. Rotate the MODE SELECT switch to the parameter to be programmed. It is recommended that PWS be programmed first.

2. Press and hold the RESET/PROGRAM button.

3. While holding the RESET/PROGRAM button, rotate the DISPLAY/PROGRAM knob until the proper setting for the parameter that is being programmed is displayed.

4. Release the RESET/PROGRAM button. This stores the new parameter in the nonvolatile memory. If the number changes back to what is was before programming, then the tamper guard is on and will need to be unlocked before programming can be completed (see Tamper Guard).

5. Continue steps 1-4 until all parameters are programmed.

be tested for proper operation or communications using a 9V battery.

Figure 4: Proper Position of the Battery Cable

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PROGRAMMABLE PARAMETERS

The following settings MUST be programmed by the user in order to provide proper protection for the application. Settings vary by situation and application and should be selected and tested for each unique installation. All parameters are actual values except for the VUB and CUB settings; these are programmed as percentages. The range each parameter can be programmed is found in the electrical specifications table. See Programming Example for sample setup instructions. Failure to program all setpoints could result in nuisance tripping or prevent the device from protecting the motor. Always use the proper CTs for the motor full load amperage (FLA).

LV/HV - Low Voltage/High Voltage. The recommended settings for LV (low voltage) and HV (high

VUB - Voltage Unbalance. The NEMA MG1 standard says a motor should not be operated above

MULT - MULT (multiplier) setting is found in Table 1. The MULT setting is determined by the number

OC - Overcurrent. Is typically set to the service factor amperage (SFA) of the motor or 100-135%

NOTE: When using external CTs, do not set OC greater than the thermal rating of the CTs LP - LP (low power) setting is used to shut do wn the motor or pump on an underload condition

NOTE: PWS must be set before setting LP. CUB - Current Unbalance. SymCom recommends contacting the motor manufacturer for a

TC - Trip Class. Determines how quickly the 777-KW/HP-P2 will trip when an overcurrent

While the standard trip classes are 5, 10, 15, 20, and 30, TC can be set from 2–60, with or

voltage) according to the NEMA MG1 standard are ±10% of the motor’s nameplate voltage. Generally, the motor manufacturer should be contacted to verify these limits. High and low voltage trips are based on average voltage measured. Never set LV higher than HV.

Example: Nameplate voltage = 230 V

LV = 90% x 230=207 V HV = 110% x 230 = 253 V

a 1% voltage unbalance without derating the motor. Most utility supplied power sources have a difficult time sustaining a 1% VUB. The motor manufacturer should be consulted for an exact VUB setting. Setting VUB to 999 will disable voltage unbalance protection, but will not disable voltage single-phase protection. Voltage unbalance is calculated as follows:

%Voltage Unbalance = [(Maximum deviation from the average)/Average] x 100% Example: Measured line-line voltages = 203, 210, and 212. The average =

(203+210+212)/3 = 208.3. The maximum deviation from the average is the greatest difference between the average voltage (208.3) and any one voltage reading: 212-

208.3 = 3.7, 210-208.3 = 1.7 and 208.3-203 = 5.3. The maximum deviation from the average is 5.3, thus voltage unbalance = 5.3/208.3 x 100= 2.5%.

of passes of the motor leads or the size of external CTs and the full load amps of the motor the unit will be monitoring. MULT sets the trip point range for overcurrent and ground fault current faults. Set MULT first, then set OC and GF.

of motor full-load amps (FLA), which are determined by the motor manufacturer. If any one leg exceeds the OC setting, the 777-KW/HP-P2 will trip according to the Trip Class (TC) settings.

(that is based on power instead of solely on current). LP can be set in either kilowatts (kW) or horsepower (hp) as determined by the PWS setting. Setting LP to 0 disables the underload trip feature.

specific setting. Current unbalance is calculated the same way voltage unbalance is calculated (see formula above). Setting CUB to 999 will disable current unbalance and current single-phase protection.

(overload) condition is detected. TC is a dual-function setting—both a thermal trip class (NEMA standard) and a linear trip delay (in seconds) can be set.

without jam protection. The trip class setpoint is the time in seconds that the device will take to trip when any phase current is greater than or equal to 600% of the OC setpoint. These

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additional “non-standard” trip classes allow the unit to follow a trip curve in-between the

RD1 - Restart Delay One. Rapid-cycle timer, in seconds (default). The purpose of this timer is to

RD2 - Restart Delay Two. Referred to as a motor cool-down timer, in minutes (default). RD2 is

RD3 - Restart Delay Three. This timer, in minutes (default), only initiates after a low power trip

The Automatic Dry-Well Recovery Calculator allows the 777-KW/HP-P2 to automatically

#RU/ADDR - Restart Attempts (Underload/Address. The #RU/ADDR is a dual-function setting. #RU

“standard” trip class curves shown in Figure 5. Trip classes 2–60 can be set from approximately the 7 o’clock to 10 o’clock position with the

DISPLAY/PROGRAM knob. Trip classes J02–J60, which include jam protection, can be set from approximately the 10 o’clock to 1 o’clock position. This additional jam protection feature, when enabled, is initiated 1 minute after the motor starts and provides a 2-second trip delay for motors exceeding 400% of the OC setting.

The linear overcurrent trip delay can be set from approximately the 1 o’clock to 5 o’clock position from 0–60 seconds (L00–L60) or to “oFF.” If TC is set to L00, the 777-KW/HP-P2 will trip off within 1 second after motor current reaches the OC setpoint. If both trip class and linear trip delay settings are programmed, the 777-KW/HP-P2 will follow the faster trip time. For example, TC is set to J15 and L20, and the amperage is 200% of the OC setting. Following the trip class 15 curve, the 777-KW/HP-P2 will trip off in approximately 100 seconds. Thus the 777-KW/HP-P2 will follow the linear trip delay setting, because it is faster, and will trip off in 20 seconds.

The motor manufacturer should be contacted for an exact TC setting. Table 3 describes the trip classes, and Figure 5 shows the trip class curves.

provide protection against short cycling and to allow adequate cool down time between motor starts. This timer is initiated when power is first applied to the unit. If no voltage fault conditions exists, the output relay will energize (the NO will close and the NC will open) as soon as RD1 timer expires. In most cases, this is set to 20-30 seconds. This should provide adequate protection for successive power outages or short cycling caused by other motor controls. This timer is also initiated when motor current goes to zero. Setting RD1 to zero will turn off this feature and ensure that when an alarm circuit is used, an alarm will sound only when there is a fault or power to the unit is lost.

used to restart the motor after a trip due to a current unbalance, current single-phasing, or an overcurrent condition. A setting of 5-10 minutes will give most motors adequate time to cool down after an overcurrent condition. The motor manufacturer should be contacted for an exact value.

and is referred to as a dry-well recovery timer in pumping applications. This is set according to the time it takes for the well to recharge after pumping dry. This setting varies widely by application and there is no typical setting. RD3 can be set from 2-500 minutes or to A to enable the automatic Dry-Well Recovery Calculator.

select a restart delay based on the run time of the last run cycle before tripping on a low power fault. Table 2 shows the next restart delay vs. run time. In general, a longer run time produces a shorter restart delay. This feature allows the 777-KW/HP-P2 to optimize running and rest times automatically.

Run Time

> 1Hr 6 10 30 min.- 59.99 min. 15 4 15 min.- 29.99 min. 30 2 < 15 min. 60 1

TABLE 2: Automatic Dry-Well Recovery Timer

settings are displayed and selected by turning the DISPLAY/PROGRAM dial from approximately the 7 o’clock to 12 o’clock position. ADDR settings are displayed and selected by turning the DISPLAY/PROGRAM dial from approximately the 12 o’clock to 5 o’clock position.

Next Restart

Delay (minutes) Starts/Hr

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#RU is the number of restarts the 777-KW/HP-P2 will attempt after a low power fault before the unit locks out and requires a manual reset. #RU can be set to 0, 1, 2, 3, 4, or A. This counter is cleared one minute after restarting if the 777-KW/HP-P2 does not trip again on

#RF/COM - Restart Attempts (other faults)/ Communications Settings. The #RF settings are

If #RF is set to “0”, the 777-KW/HP-P2 will require manual resetting after all current

If #RF is set to “A”, the 777-KW/HP-P2 will always restart automatically after current

If #RF is set to “ocA”, the 777-KW/HP-P2 will always restart automatically after current

COM determines the baud rate, even/odd parity, and stop bit. COM can bet set to C00-

PWS - Power Scale. The range setting for the LP setting. Settings 1-4 will allow the LP setting to

GF - Ground Fault. The maximum allowable current that can flow to ground before the 777-

low power. If #RU is set to “0”, the 777-KW/HP-P2 will require manual resetting after all low power

faults. If #RU is set to “A”, the 777-KW/HP-P2 will always automatically restart after low power faults, once the RD3 timer expires.

ADDR is the RS-485 address of the 777-KW/HP-P2 and is only used when communicating with any external communication device. The address can be set from A01–A99.

displayed and selected by turning the DISPLAY/PROGRAM dial from approximately the 7 o’clock to 12 o’clock position. COM settings are displayed and selected by turning the DISPLAY/PROGRAM dial from approximately the 12 o’clock to 5 o’clock position.

#RF is the number of restarts the 777-KW/HP-P2 will attempt after current unbalance or current single-phase faults before the unit locks out and requires a manual reset. This counter will be cleared one minute after start-up if the unit does not trip again for the same fault condition. Available settings are 0, 1, 2, 3, 4 and A, or to include overcurrent faults, #RF can be set to oc1, oc2, oc3, oc4 or ocA.

unbalance, current single-phase and overcurrent faults. unbalance and current single-phase faults, once the RD2 timer expires. Overcurrent faults

will require a manual reset. unbalance, current single-phase and overcurrent faults, once the RD2 timer expires.

C07. C00 and C04 are duplicates provided for backward compatibility.

• C00 = 9600 baud, No parity, and 1 stop bit

• C01 = 9600 baud, Odd parity, and 1 stop bit

• C02 = 9600 baud, No parity, and 1 stop bit

• C03 = 9600 baud, Even parity, and 1 stop bit

• C04 = 19200 baud, No parity, and 1 stop bit

• C05 = 19200 baud, Odd parity, and 1 stop bit

• C06 = 19200 baud, No parity, and 1 stop bit

• C07 = 19200 baud, Even parity, and 1 stop bit

display in kW. Settings 5-8 will allow the LP setting to display in hp.

PWS Setting LP Range

1 0.01 - 0.99 kW 2 1.00 - 9.95 kW 3 10.0 - 99.5 kW 4 100 - 650 kW 5 0.01 - 1.30 hp 6 1.34 - 13.3 hp 7 13.4 - 133.0 hp 8 134 - 871 hp

KW/HP-P2 de-energizes its relay. This is a residual, class II ground fault system and should not be used for personnel safety. A typical setting for GF is 10-20% of motor FLA (in amps). GF may be set to oFF if this feature is not desired. The GF test procedure in this installation instruction manual must be conducted before the device is brought online.

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OPERATION

The relay operation of the Model 777-KW/HP-P2 is designed to be fail-safe. This means when the voltage is within the programmed limits, the relay will energize—the NO contact will close and the NC contact will open. When the unit loses power or senses a fault condition, the relay will deenergize and contacts will return to their original state. Once the unit has been installed and programmed, the unit is ready to operate. Turn MODE SELECT to the RUN position. The display will show “run” alternating with a number (the number displayed will be the number corresponding to where the DISPLAY/PROGRAM knob is pointed). It will do this for the restart delay time programmed into RD1. Once the timer expires, the relay will energize—the NO contact will close and the NC contact will open. If something other than this is displayed, see the troubleshooting section for more information. If MODE SELECT is taken out of RUN, the 777-KW/HP-P2’s relay will

e-energize. d

Trip Class Application Description

15 Specialized applications

Small fractional horsepower motors where acceleration times are almost instantaneous or where extremely quick trip times are required

(Fast Trip) Hermetic refrigerant motors, compressors, submersible pumps and general-purpose motors that reach rated speed in less than 4 seconds

Non-Standard

J Prefix

(Jam

Protection)

Trip Classes

10000

1000

100

Trip Time (Seconds)

(Standard Trip) Most NEMA-rated general-purpose motors will be protected by this setting

(Slow Trip) Motors with long acceleration times (>10 seconds) or high inertia loads

Programming any of the trip classes with the J prefix will enable jam protection. This additional protection is enabled 1 minute after the motor starts and provides a 2 second trip time for motors exceeding 400% of the OC setting

Trip time in seconds when any phase current is 600% of OC. Time is approximately 90% of the TC setting

Table 3: Trip Class Descriptions

Class 30 Class 20

Class 15 Class 10

Class 5

0 100 200 300 400 500 600 700 800 900 1000

% of OC Setting

Figure 5: Overload Trip Curves

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PROGRAMMING EXAMPLE

Motor to be protected: 3-phase, 460 Volt, 20hp / 15KW submersible pump with a full load amperage rating of 26.9A and maximum service factor amps of 30.3A. Use the following calculations and reasoning to determine the appropriate settings for this application.

LV- 460 x 0.90 = 414 HV- 460 x 1.10 = 506 VUB- Motor manufacturer suggests 3 MULT- From Table 1 = 1 OC- Service Factor Amperage = 30.3 LP- Normal pumping operation reads 15kW

Pump with a momentarily restricted flow (deadhead) reads 10.5kW; therefore set LP

slightly above that point; LP = 11.5kW CUB- Motor manufacturer suggests 6 TC- Submersible pump motor, TC = 10. No linear trip delay is desired, TC also = oFF. RD1- To protect the pump for accidental rapid cycling, RD1 = 20 seconds. RD2- Because the motor may be hot from running in an unbalance or single-phase condition, a

motor cool-down time of 10 minutes, RD2 = 10, should be appropriate. RD3- Set to 50 minutes. Testing shows that the well will recharge in 50 minutes. #RU- Because an underload (low power) would signal a deadhead or dry-well situation, #RU

should be set to 3 for this application. #RF- Because an overload (overcurrent) fault signals a serious problem in this application (e.g.,

worn bearings), "oc" should not be included in the #RF setting so that a manual reset after

an overload fault is required. A #RF=1 will give the system 1 chance to recover from an

unbalance or single-phasing problem before manual reset is required. PWS- The name plate rating for this pump is 15kW, therefore PWS = 3 (10.0-99.5kW) GF- A ground fault setting of 15% of full load amps will be a significant indicator that the motor

should be evaluated for repair or replacement. Therefore, GF = 26.9A x .15 = 4. Note: Since no network communications are connected to this unit, there are no setting changes

needed for ADDR or COM.

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SYSTEM DISPLAY

On power up, the 777-KW/HP-P2 will show the current software revision. For example if the software revision is 33.04, the 777-KW/HP-P2 will show 033 followed by 004.

The output display can show one of the following parameters when MODE SELECT is in RUN: L1L2, L2-L3, and L3-L1 line voltage; %VUB; A, B, and C phase current; %CUB; measured GF current, KW, HP. The display is used for programming the operating parameters of the device and also identifies what caused the unit to de-energize its relay or what is keeping the unit from energizing its relay, and under normal operating conditions, what the last fault was. The last fault can be displayed by pressing and holding the RESET/PROGRAM button while MODE SELECT is in RUN. When the unit trips off or is holding the motor off, the current fault condition will be shown in the display without pressing the button (CAUTION: pressing the reset button at this time will reset the unit). Table 4 lists the fault codes the unit could display.

Displayed

Message

oc Tripped on overcurrent SP

ub uc Tripped on undercurrent CF

GrF Tripped on ground fault

HI A high voltage condition exists (won’t allow motor to start)

Lo A low voltage condition exists (won’t allow motor to start)

rP Incoming phases have been reversed, the motor may run backwards if started

oFF A stop command was issued from a remote source HPr Tripped on high power

LPr Tripped on low power

CLo Tripped on low control voltage

clr No previous faults

Pro Shown when programming using the battery in the RUN position

FFF Displayed value is greater than 999 (can be due to incorrect MULT s etting)

Meaning

Tripped on current single-phasing or unit won’t start because the voltage is single-phased

Tripped on current unbalance or unit won’t start because the voltage is unbalanced

Tripped on contactor failure (due to faulty contacts or connections on the load side)

Table 4: Fault Codes

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TROUBLESHOOTING

The 777-KW/HP-P2 will display a fault code alternating with a number or with “run” when it has tripped. If the unit is showing a fault code alternating with “run,” it is timing down the restart delay. If the fault code is alternating with a number (voltage reading or zero), the unit will not allow the motor to start because there is a problem with the incoming voltage. If the display is showing just a fault code, the unit is in a manual reset mode. This could be because the number of restarts (#RF, #RU) has expired or is not allowed. If the display reads “oFF,” a stop command was issued through the communications network or a remote monitor.

PROBLEM SOLUTION

The unit will not start. Display alternates “rP” with the DISPLAY/PROGRAM parameter value.

The unit will not start. Display alternates “SP”, “ub”, “HI”, or “Lo” with the DISPLAY/ PROGRAM parameter value.

Display alternates “SP”, “ub”, or “oc” with “run.”

Display alternates “uc” with “run.”

Display is showing a solid “SP”, “ub”, or “oc.”

Display is showing a solid “uc.”

Display is showing a solid “CF.”

Display is showing a solid “GrF.”

Display alternates “LPr” with “RUN”

The voltage inputs are reverse-phased. If this is the initial start-up, swap any two of the leads connected to L1, L2, or L3 on the 777KW/HP-P2 to correct the problem. If the unit has been previously running, the power system has been reverse-phased. Check the

hase sequence of the incoming power lines. p

Note: L1 must be tapped from conductor Phase A, L2 from B, and L3 from C for correct power factor measurements on remote communications. The incoming voltage is not within the limits programmed in the VUB, HV, and LV settings. Turn the DISPLAY / PROGRAM knob to read each incoming line voltage value. Correct the incoming power problem and check programmed limits by turning the MODE SELECT knob. Compare incoming values for HV, LV, and VUB to setpoints to verify they are correct. The unit has tripped on the fault shown on the display and is timing down RD2 before restarting. No further action is required.

The unit has tripped on undercurrent and is counting down RD3 before restarting. If undercurrent is not a normal condition for this installation, check for broken shafts, broken belts, etc. The unit has tripped on the fault shown and a manual reset is required because of the programmed setting in #RF. Check the system for problems that would produce the single-phase, overcurrent or current unbalance fault, such as a jam. The unit has tripped on undercurrent and a manual reset is required because of the setting in #RU. Check the system for problems that would produce a loss of load such as a broken belt or a lack of liquid to pump. The unit has tripped on current single-phasing, but was not singlephased by the incoming voltage. Check for damaged contacts or loose or corroded wiring connections. A ground fault current greater than the programmed GF value has been detected. Check the motor for insulation breakdown. A manual reset is required to clear this message. Press the RESET button to perform a manual reset. The unit has tripped on low power (LPr) and is timing down RD3 before restarting. If LPr is not a normal condition for this installation, check for loss of liquid, closed valves, broken belts, etc.

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PROBLEM SOLUTION

Display is showing a solid “LPr”

Display alternates “HPr” 2 with “RUN”

Display is showing solid

“HPr” Display alternates “CLo” 2

with “RUN” Display is showing solid

“CLo”

CLEARING LAST FAULT

The last fault stored can be cleared on the 777-KW/HP-P2 by following these steps:

1. Rotate the MODE SELECT switch to GF.

2. Press and hold the RESET/PROGRAM button. Adjust the DISPLAY/PROGRAM knob until “cLr”

appears on the display. Release the RESET/PROGRAM button.

To verify the last fault was cleared, place the MODE SELECT switch in the RUN position. Then press and hold the RESET/PROGRAM button; “cLr” should be on the display.

TAMPER GUARD

The 777-KW/HP-P2 setpoints can be locked to protect against unauthorized program changes.

1. Rotate the MODE SELECT switch to GF.

2. Press and hold the RESET button. Adjust the DISPLAY/PROGRAM knob until “Loc” appears on

the display.

3. Release the RESET button.

4. Turn MODE SELECT switch to RUN. The program is now locked, but all settings can be viewed. The unit can be unlocked by following

the same steps except adjust the DISPLAY/PROGRAM knob to “unL” in step 2.

The unit has tripped on low power and a manual reset is required because of the setting in #RU. Check the system for problems that would produce a loss of load like a broken belt or a pump is out of liquid. Press the RESET button to perform a manual reset. The unit has tripped on high power and is timing down RD2. Check for a high power condition.

The unit has tripped on high power and requires a manual reset because of the setting in #RF. Press the RESET button to perform a manual reset. The unit has tripped on low control voltage (CLo) and is timing down RD2 before restarting.

The unit has tripped on low control voltage and a manual reset is required because of the setting in #RF. Verify system voltage is correct. Press the RESET button to perform a manual reset.

uc, HPr, and CLo are enabled only from a network master via a communications module.

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GROUND FAULT TESTING PROCEDURE

A ground fault test must be performed before installing the 777-KW/HP-P2 as required by

L1053 and NEC, ANSI/NFPA 70. U

1. Disconnect power.

2. Hook up the three line voltages to L1, L2, and L3 as required by the installation instructions.

3. Program the desired parameters into the unit. For test purposes, set MULT to 1 and GF to the

minimum allowed setting.

4. Construct the circuit, using an AC power supply. This circuit simulates a ground fault condition by

generating a current in one of the phases. Alternate test circuits may be used. The only requirement is the current through the current transformer must be between 115% and 150% of the GF setting and pass through only one CT window.

5. The values of V and R will be determined by the current required to generate a GF trip condition:

I = Vrms/R, where I = 115% of GF setting.

6. Place the unit in the RUN position, apply 3-phase power and allow the NO contact to close.

7. Energize the test circuit by pushing and holding the test pushbutton until the unit trips (within 8.5

seconds). The display should show “GrF” and the NO contacts should be open. Release the NO pushbutton.

8. The results of the test are to be recorded on the test form provided below. The form should be

kept by those in charge of the building’s electrical installation in order to be available to the authority having jurisdiction.

9. Confirm programmed parameters and proceed with installation instructions.

-----------------------------------------------------

GROUND FAULT TEST RESULTS*

Date Performed by Results Location

*A copy of this form should be retained by the building’s electrical foreman.

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777-KW/HP-P2 SPECIFICATIONS

Functional Specifications Programmable Operating Points

LV- Low Voltage Threshold 170–524V (450–649)* HV- High Voltage Threshold 172–528V (451–660V)* VUB- Voltage Unbalance Threshold 2-25% or 999 (disable) MULT- # of Conductors or CT Ratio (XXX:5) 1–10, 100, 150, 200, 300, 400, 500, 600, 700, 800 OC- Overcurrent Threshold ** (20–100A) ÷ MULT or 80–140% of CT Primary PWS- Power Scale 1 = 0.01–0.99kW 5 = 0.01–1.32hp

LP – Low Power** 0.01-650kW or 0.01-871hp or 0 (off); LP setting is

CUB- Current Unbalance Threshold 2–50% or 999 (disable) TC- Overcurrent Trip Class

2-60, J2-J60, L00-L60, oFF

RD1- Rapid Cycle Timer 0-999 seconds RD2- Restart Delay After All Faults Except

Undercurrent (motor cool-down timer)

RD3- Restart Delay After Undercurrent (dry-well

recovery timer) #RU- Number of Restarts After Undercurrent 0, 1, 2, 3, 4, A (Automatic) ADDR- RS485 Address A01–A99 #RF-Number of Restarts After All Faults Except

Undercurrent

COM- Communication setting C00-C07 UCTD- Undercurrent Trip Delay *** 5 seconds (default) GF- Ground Fault Current Threshold** (3-20A) ÷ MULT or 12-40% of CT Primary or oFF Trip Times Ground Fault Trip Time Trip time

101%-200% of Setpoint 8 seconds ±1 second 201%-300% of Setpoint 4 seconds ±1 second 301%-400% of Setpoint 3 seconds ±1 second 401% or Greater 2 seconds ±1 second

Current Unbalance Trip Times

% Over Setpoint

0% 1% 2% 3% 4% 5% 6% 11%

15% Input Characteristics Input Voltage (3-phase) 200–480VAC (Model 777-KW/HP-P2)

Frequency 50/60 Hz Motor Full Load Amp Range 3-phase, (looped conductors required) 2–20A 3-phase (direct) 20–90A

2 = 1.00–9.95kW 6 = 1.34–13.3hp 3 = 10.0–99.5kW 7 = 13.4–133hp 4 = 100–650kW 8 = 134–871hp

dependent upon PWS setting. PWS setting must be programmed prior to programming LP setting.

2–500 minutes

2–500 minutes, A (Automatic)

0, 1, oc1, 2, oc2, 3, oc3, 4, oc4, A, ocA (Automatic)

Trip time 30 seconds 15 seconds 10 seconds

7.5 seconds 6 seconds 5 seconds 4 seconds 3 seconds 2 seconds

500–600VAC (Model 777-575-KW/HP-P2)

If a “J” is included in the trip class (TC) setting, jam protection is enabled.

If "oc" is displayed in the #RF setting, overcurrent and high power will be included as an automatic restart after

RD2 expires. Otherwise, a manual reset is required after an OC and HPr fault.

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3-phase (external CTs required) 80–800A Output Characteristics Output Contact Rating SPDT (Form C) Pilot duty rating: 480VA @ 240VAC, B300

Expected Life Mechanical 1 x 106 operations Electrical 1 x 105 operations at rated load General Characteristics Environmental

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

Pollution Degree 3 Class of Protection IP20 (Finger Safe) Relative Humidity 10-95%, non-condensing per IEC 68-2-3

Accuracy at 25°C (77°F)

Voltage ±1% Current ±3% (<100A direct) Timing ±0.5 second Ground Fault ±15% (< 100A)

Repeatability

Voltage ±0.5% of nominal voltage

Current ±1% (<100A direct) Maximum Input Power 10 W Safety Marks

UL UL508, UL1053

CE IEC 60947-1, IEC 60947-5-1 Standards Passed

Electrostatic Discharge (ESD)

Radio Frequency Immunity (RFI), Conducted

Radio Frequency Immunity (RFI), Radiated

Fast Transient Burst IEC 61000-4-4, Level 3, 3.5kV input power Surge

IEC 61000-4-5 Level 3, 2kV line-to-line; Level 4, 4kV line-to-

ANSI/IEEE C62.41 Surge and Ring Wave Compliance to a level of 6kV

Hi-potential Test Meets UL508 (2 x rated V +1000V for 1 minute)

Vibration IEC 68-2-6, 10-55Hz, 1mm peak-to-peak, 2 hours, 3 axis

Shock IEC 68-2-27, 30g, 3 axis, 11ms duration, half-sine pulse Mechanical

Dimensions 3.0" H x 3.6" W x 5.1" D

Terminal Torque 7 in.-lbs.

Enclosure Material Polycarbonate

Weight 1.2 lbs Maximum Conductor Size Through 777-KW/HP-P2 0.65" with insulation

NOTE: The 777-KW/HP-P2 can be programmed prior to installation by connecting a 9V battery. Disconnect power prior to using the battery cable and follow all safety warnings. *575 Volt Model ** Do not program the unit above the thermal rating for the CTs. *** Network programmable feature. See the Programming Guide.

General purpose: 10A @ 240VAC

Ambient Storage: -40° to 80°C (-40° to 176°F)

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

ground

line-to-line

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NOTES

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