SymCom MOTORSAVER 455-480R Installation Instructions Manual

INPUT

POWER

L1

M1 M2 M3

L2 L3

OL
OL
OL

B

A

C

MAGNETIC

CONTACTOR

MOTOR

MS455-480R

THERMOS TAT

OPTIONAL

CONTROL

POWER

24 - 240 VAC

TM

M

MAG.

COIL

HAND

STOP

OFF

AUTOP

ILOT

START

OL

BE

SURE

POWER IS DISCONNECTED PRIOR TO INSTALLATION!

FOLLOW NATIONAL, STATE AND LOCAL CODES.

READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION.

The Model

455

-480R, 3-phase voltage monito r combines line and load-side monitoring to alert the
user of contactor failure. Line-side monito ring will protect the motor from damaging power conditions
including high and low voltage, voltage unbalance, single-phasing, phase reversal and rapid cycling.
The Model 455-480R has a high voltage relay to handle up to 600V control voltage and is now
equip

ped

with an infrared LED to communicate with the hand-held diagnostic tool, the Informer MS

Ed

ition, t

o display trip points, real-time data, and the last 20 faults and 32 motor starts.

CON

NECTION

S

1.

Mount

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

location 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 SIDE of the motor starter.
NOTE: If a 2-pole contactor is used, jump the hard-wired line from the L side terminal (the wire

not connected through the con tactor) to its co rresponding M terminal.

If load-side protection is not desired, connection to the M terminals is not required—the
Model 455-480R will operate as a line-side only voltage monitor in this configuration.

4. Connect the output relay to the circuitry to be controlle d . Connect the normally open contact

in series with the magnetic coil of the motor starter as shown in Figure 1.

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 connected to the same supply lines.

INST

A

LLATION INSTRUCTIONS FOR

SYMCOM’

S

MOTORSAVER

®

MODEL 455-480R

INPUT

POWER

L1

M1 M2 M3

L2 L3

OL

OL
OL

B

A

C

MAGNETI

C

C

ONTACTOR

MOTOR

MS455-480R

THERMOSTAT

OPTIONAL

CONTROL

POWER

24 - 240 VAC

TM

M

MAG.

COIL

HAND

STOP

OFF

AUTOPILOT

START

OL

Fi

gure

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

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SETTI

NGS

1. LINE

VOLTAGE

ADJUSTMENT: Rotate the

VOLT. ADJ. (VAC) knob to the
nominal 3-phase line voltage
feeding the motor to be protected.

2. RESTART DELAY: Rotate the RESTART (SEC) knob to the desired positio n. The restart
delay is the time between the Moto rSaver seeing acceptable power and the MotorSaver
closing its output contacts. For compressor applications, the restart delay should be set fo r
the approximate time it takes for the head pressure to bleed off of the compressor. For o the r
applica tions, the restart delay is typically set to 2 se conds.
NOTE: This delay is also the minimum cycle time or rapid-cy cle time r for the motor or
compresso r when control power is lost such a s the operation of the thermostat.

The manual position (MAN) on the restart adjustment can be used as a manual reset after
any fault condition, or loss of incoming power. To utili ze 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 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 incoming power is experienced.

3. VOLTAGE UNBALANCE: Rotate the UNBALANCE TRIP (NEMA %) to the desi red voltage
unbalance trip level. The NEMA MG1 standa rd does not recommend operating a motor
above a 1% voltage unbalance as determined by the following formula without derating the
motor.

% Voltage Unbalance = Maximum Deviation from the Average

x 1

00%

Average

The NEMA MG1 stan dard also recommends against operating a motor above 5% voltage
unbalance under any circumstan ce s. Therefo re, a 5% UB se tting is a good place to start, but
SymCom recommends con sulting the motor manufacture r for specific tolerances.

4. TRIP DELAY ADJUSTMENT: Rotate the TRIP DELAY knob to the desired setting. The
adjustment does not affect the trip delay on a single-phasing fault. Typi call y , the trip delay is
set to 4 seconds, in areas where voltage fluctuations are freq uent, the trip delay may need to
be set higher.

POWER-UP

Tur

n 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 light will illuminate. If the contacts do not energi ze and the RUN light doe s not
illuminate , see the TROUBLESHOOTING section .

L1

L2 L3

380-480 VAC, 3Ø, 50/60 HZ

MODEL 455-480R

OVER
VO LT.

PHASING

FAULT

UNDER

VOLT .

PILOTDUTY RATING

470 VAAT 600VAC

RUN

V OLT

. ADJ.

(VA C)

416 440

400 460
380

480

UNBALANCE

TRIP

(NEM A %)

8

2

M 1 M 2 M3

SymCom. Inc.

300

100

2

MAN

RESTART

(SEC)

302

15

TRIP

DELAY

(SEC)

IND. CONT

. EQ.

LISTED

784X

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TROUB

L

ESHOOTING

SYM

PTOM SOLUT

ION

The RUN

li

ght does not blink
on initial power-up and all
three fault lights are on.

Check the RESTART DELAY. If it is set to the manual position
(MAN), the Model 455 is in manual reset mode. Turn the RESTART
DELAY out of MAN until the output contacts close.

N

o

LEDs are lit—the unit

seems completely dead.

Measure the three line-to-line voltages. If any of the voltages is less
than 305VAC, the MotorSaver® does not have enough power to
operate its internal electronics. This may occur on a single-phased
system.

PHASING FAULT l

ight is

bl

inking on initial power-up.

Turn off the 3-phase power. Swap any two leads powering the
Model 455: L1, L2, or L3. There is a 50:50 chance of co rrectly
connecting the leads the first time. Re-apply power.

PHASING FAULT l

ight is

bl

inking after the motor has

previously been running.

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

The PHAS

ING

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

Measure incoming lines for correct voltage. If the voltage s do not
exceed the NEMA unbalance setting, a single-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 an d
re-applied to clear this fault condition. If the contacts and wiring are
good, call SymCom at [phone].

The UNDERVO

LT.

or

OVERVOLT. light is on

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
±7% of the nominal voltage, call Sym Com at [phone].

The RUN

LI

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

Check the contactor to ensure the contacts 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].

I

ND

ICATOR LIGHTS

LED

IND

ICATOR CONDITION

UNDERVOLTAGE

ON

Vo

ltage is less than 93% of nominal voltage as set

by the VOLT. ADJ. knob

OVERVOLTAGE

ON

V

oltage is greater than 107% of nominal voltage as

set by VOLT. ADJ.

PHASING

FAUL

T ON

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 removed and
re-applied to the MotorSaver®.

PHASI

NG

FAULT BLINKING Incoming power is reverse-phased.

UNDERVOL

TAGE,

OVERVOLTAGE

AND PHASING FAULT LIGHTS ON

Unit has been powered up in the manual restart
position.

RUN LIGHT

ON Output c

ontact is energized.

RUN

LI

GHT BLINKING The MotorSaver®is timing through the restart delay.

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*50H

z will increase all delay timers by 20%

SymCom, Inc. warrants its microcontroller-ba sed products against defects in material or
workmanship f

or a period of five (5) year s from the date of manufacture. All other products

manuf

actured by SymCom shall be warranted against defects in material or workmanship for a

peri

od of two (2) years from the date of manufacture. For com ple te information on warranty, liability,

ter

ms, and conditions, please refer to the SymCom Terms and Conditions of Sale document.

MODEL 455-48

0R SPECIFICATIONS

3-Phase

Line Voltage

380–480VAC

Frequency

50*/

60Hz

Low Voltage (%

of setpoint)

Trip

90% ±

1%

Res

et

93% ±1%

High

Voltage (% of setpoint)

Trip

110%

±1%

Res

et

107% ±1%

Voltage

Unbalance (NEMA)

Trip

2–8%

(adjustable)

Res

et

Trip setting minus 1%

Trip Delay

Time

Low and high voltage,

and voltage unbalance

2–30 seconds (adjustable)

Single-pha

sing faults

2 seconds (fixed)

Rest

art Delay Time

Afte

r a fault or power loss

Manual, 2–300 seconds (adjustable)

Output

Contact Rating – SPDT

Pilot duty

470VA @

600VAC

Standards

Passed

Ele

ctrostatic Discharge (ESD)

IEC 61000-4-2, Level 3, 6kV con ta ct, 8kV air

R

adio Frequency Immunity (RFI)

IEC 61000-4-2, Level 3, 10V/m

Fa

st transients

IEC 61000-4-4, Level 3, 4kV input power
2kV inputs/outputs

Repeat

Accuracy Protection

Fixed

conditions

±0.1%

Powe

r Consumption

6 Watts (max.)

Weight

14 oz.

Terminal

To

rque

7 in.-lbs. (max.)

Operating

Temperature

-40° to 70°C (-40° to 158°F)

Safety

Marks

UL

UL508 (Fi

le #E68520)

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