Symcom 777-KW/HP, 777-LR-KW/HP, 777-575-KW/HP, 777-HVR-LR-KW/HP, 777-HVR-KW/HP Installation Guide

ALLATION INSTRUCTIONS FOR

MODELS 777-KW/HP

INST

, 777-LR-KW/HP,777-575-KW/HP,

777-HVR-LR-KW/HP, 777-HVR-KW/HP

POWER MONITOR/MOTOR PROTECTION RELAY

BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION!

FOLLOW NATIONAL, STATE AND LOCAL CODES!

READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION.

The Model 777-KW/HP is a solid-state power monitor/motor protection relay. It is fully-programmable
for customized protection. It is designed to protect three phase systems operating on voltages from
190 to 480 VAC (500-600VAC for 777-575-KW/HP). The output relay is a Form C contact, which can
control a contactor or other device within the output relay contact rating. The unit can be programmed
prior to installation by applying 120VAC to terminals ‘L1’ and ‘L2’ (except 777-575-KW/HP and
777-HVR-KW/HP). The unit can NOT be tested for proper operation using this voltage. For testing
purposes, three phase power needs to be used with a minimum voltage of 190VAC
(450VAC for 777-575-KW/HPand 777-HVR-KW/HP).

CONNECTIONS

1. Disconnect power and verify power is off.

2. Using the four corner tabs or the DIN rail mount, mount the 777 directly above or below the
contactor. To use the DIN rail mount, hook the top clip first then apply downward pressure
until the lower clip ‘clicks’ onto the rail.

3. A) For amperage ranging from 25-90 amps (2-9 Amps -LR types), insert the motor
conductors through the holes marked ‘A’, ‘B’, and ‘C’. Make certain that the conductor through
each hole corresponds to the right motor conductor, i.e. the ‘A’ phase conductor should go through
the ‘A’round hole. See Figure 1 for a typical wiring diagram.
B) For amperage less than 25 amps, loop the motor conductors according to Table 1.
Figure 3 shows an example of the looping required for current ranging from 8.1 to 12 amps (MULT=3).
C) For amperage greater than 90 amps, external CT’s (current transformers) are required.
SymCom recommends CT’s with terminals be used for ease of installation. All CTsecondaries
must make five passes through the round holes on the PumpSaver. See Figure 2 for a typical
wiring diagram using external CT’s.
NOTE: Pay close attention to this diagram to eliminate any power factor errors that will create
errors in the horsepower measurements.

4. Connect the three phase power from the line side of the contactor to ‘L1’, ‘L2’, and ‘L3’ terminals
using 12-18AWG copper wire (See Figure 1). Figure 1 is drawn for a power system wired in
“ABC” phase sequence. For power systems with “ACB” phase sequence, switch L1 and L3

input.

connections on 777-KW

5. Connect the control circuit wires to the appropriate terminals. The relay is a fail safe design
so the ‘NO’ contact should be in series with the coil on the contactor for motor control
(see Figure 1). For alarm circuits, the ‘NC’ contact is in series with the alarm circuitry.

Visit our website at www

/HP

.symcominc

.com for our

complete catalog and new product listings!

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

L1 L2 L3 NO C NC

MODEL 777-KW/HP

OVERLOAD RELAY 20-90A

RESET/

PROGRAM

RD3

#RF

VUB

OC

#RU/ADDR

MULT

RD2 PWS

HV

LPS

RD1

CUB

GF
LV

TC

RUN

DISPLAY / PROGRAM

MODE SELECT

SUITABLE 10 KA RMS, 600 VAC MAX

SYMCOM INC. 800-243-8848 RAPID CITY

, SD

®

IND. CONT. EQ.

LISTED

784X

LR46510

L3-

L1

L

E

+

O

V

HP

T

L1-

L2

L2-

L3

N

T

C

E

B

A

C

KW

A

G

R

R

W

R

E

P

O

U

Model

Full Load Amps

# of Loops

# of Conductors

through A, B and C

MULT to Program

(CT Ratio)

777-XXX-LR-KW/HP

777-KW/HP

777-HVR-KW/HP

777-575-KW/HP

External CTs required.
See wiring diagram for
external CTs.

able 1: Wiring Configuration Based on Motor Full Load Amps

T

1 - 2
2 - 9

2 - 2.5

2.5 - 3
3 - 3.5

3.5 - 4
4 - 5
5 - 6
6 - 8

8 - 12
12 - 25
25 - 90

80 - 110
110 - 160
160 - 220
220 - 320
320 - 420
400 - 520
480 - 600
560 - 800

1
0

9
8
7
6
5
4
3
2
1
0
4
4
4
4
4
4
4
4

2
1

10

9
8
7
6
5
4
3
2
1
5
5
5
5
5
5
5
5

2
1

10

9
8
7
6
5
4
3
2

1
100 (100:5)
150 (150:5)
200 (200:5)
300 (300:5)
400 (400:5)
500 (500:5)
600 (600:5)
800 (800:5)

Figure 1: Typical Wiring Diagram for FLAof 26-90 (“ABC” phase sequence*)

- 2 -

*For input power configuration of “ACB” phase sequence, invert the L1 and L3 terminals on the 777-KW/HP

02/04

.

L1

L2 L3 NO C NC

MODEL 777-KW/HP

OVERLOAD RELAY 20-90A

RESET/

PROGRAM

DISPLAY / PROGRAM

MODE SELECT

SUITABLE 10 KA

RMS, 600 VAC MAX

SYMCOM INC. 800-243-8848 RAPID CITY, SD

®

IND. CONT. EQ.

LISTED

784X

LR46510

/HP.

RD3

#RF

VUB

OC

#RU/ADDR

MULT

RD2 PWS

HV

LPS

RD1
CUB

GF
LV

TC

RUN

L3-

L1

L

E

+

O

V

HP

T

L1-L

2

L2-

L3

N

T

C

E

B

A

C

KW

A

G

R

R

W

R

E

P

O

U

Figure 2: Typical Wiring Diagram Using External CTs.

L1 L2 L3 NO C NC

MODEL 777-KW/HP

OVERLOAD RELAY 20-90A

RESET/

PROGRAM

DISPLAY / PROGRAM

MODE SELECT

SUITABLE 10 KA RMS, 600 VAC MAX

SYMCOM INC. 800-243-8848 RAPID CITY, SD

®

IND. CONT. EQ.

LISTED

784X

LR46510

RD3

#RF

VUB

OC

#RU/AD

DR

MUL

T

RD2 PWS

HV

LPS

RD1
CUB

GF
LV

TC

RUN

L3-L

1

L

E

+

O

V

HP

T

L1-

L2

L2-L

3

N

T

C

E

B

A

C

KW

A

G

R

R

W

R

E

P

O

U

Figure 3:

Looping Example Showing Three Conductors (MUL

(No other necessary connections are shown.)

- 3 -

T=3 from T

able 1)

02/04

PROGRAMMABLE PARAMETERS

The programmable parameters are the parameters which the user MUST program to provide the correct
protection for the application.

All parameters are actual values except for the “VUB” and the “CUB” settings.
These are programmed as percentages. The range these parameters can be programmed to is found on
the electrical specifications on page 11. See page 7 for programming examples.

LV/HV - The recommended settings for LV (low-voltage) and HV (high-voltage) according to the NEMA

MG1 standard are ±10% of the motors nameplate voltage. For other settings the motor
manufacturer should be contacted. Example: The motor nameplate voltage is 230 volts. If we
take 90% and 110% of 230 we get 0.9 x 230= 207 volts for the LV setting and 230 x 1.1= 253
volts for the HV setting. These parameters are based on the average voltage going to the motor.

VUB - VUB (voltage unbalance) is factory set at 6%. The NEMA MG1 standard says a motor should not

be operated above 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. A setting of 999 for VUB will disable the VUB protection and
SP (single phase protection).

The VUB is calculated as follows:
%VUB = [(Maximum deviation from the average)/Average] x 100%

Example:Measured line-line voltages = 203, 210, and 212, so the average = (203+210+212)/3 = 208.3,

the maximum deviation from the average is the biggest 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,
therefore the maximum deviation from the average is 5.3. The VUB is then = 5.3/208.3 x 100= 2.5%

MULT - MULT (multiplier) setting is found from table 1. The MULT setting is determined by the current the

unit will be monitoring. This allows the unit to display the correct current. Changing this setting will
also change the “OC”, and “GF” set points.

OC - OC (overcurrent) is usually set at the service factor amperage (typically 100-115% of motor FLA)

of the motor, which is determined by the motor manufacturer. If any one leg of current exceeds the
oc setting, the unit will follow its overload trip curve. (see Figure 4).

LP- LP (low power setting) is used to shut down the motor or pump on an underload condition.

Setting LP to 0 disables the underload trip feature. LP is set in either kilowatts (KW) or
horsepower (HP) depending on the PWS setting. NOTE: PWS must be set before setting LP.

HP- HP (high power setting) is used to shut down the motor or pump on an overpower condition.

The High Power trip uses the underload trip delay and dry well recovery timer (RD3) to delay trips
and restarts. The HP and underload trip delay settings can only be adjusted from the SymCom
Solutions software or another software utility that can send Modbus write commands.
The 777-KW/HP is shipped from the factory with this feature disabled.

CUB - CUB (current unbalance) is factory set to 7%. SymCom recommends the motor manufacturer be

contacted for an exact setting. The CUB is calculated the same way the VUB is determined above.
The CUB protection can be disabled by programming a 999 in this setting. This will disable current
unbalance protection and current single phasing protection.

TC - TC (trip class) is the parameter used to determine when the unit will trip when an overload

condition is detected. For standard motors, the

able 2 and Figure 4 show the range of TC settings and

should be contacted for exact

TC settings.

T

TC is typically set at 20.

The motor manufacturer

trip times.

02/04

- 4 -