Motor Saver SYMCOM'S MOTORSAVER 455 User manual
INPUT
POWER
L1
M1 M2 M3
L2 L3
OL
OL
OL
B
A
C
MAGNETIC
CONTACTOR MOTOR
MS455
THERMOS TAT
OPTIONAL
CONTROL
POWER
24 - 240 VAC
TM
M
MAG.
COIL
HAND STOP
OFF
AU
TO
PILOT
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, 3-phase, 190-480VAC voltage monitor combines line and load-side monitoring to
alert the user of contactor failure. Line-side monitoring 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 is now equipped with an infrared LED to communicate with the
hand-held diagnostic tool—Informer MS Edition—to display trip points, real-time data, and the
last 20 faults and 32 motor starts. Motor run hours, also displayed by the Informer MS, can
now be reset on the 455.
CONNECTIONS
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 contactor) to its corresponding M terminal.
If load-side protection is not desired, connection to the M terminals is not required—the
Model 455 will operate as a line side only voltage monitor in this configuration.
4. Connect the output relay to the circuitry to be controlled. 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.
INSTALLATION INSTRUCTIONS FOR
SYMCOM’S MOTORSAVER®
MODEL 455
2880 North Plaza Drive, Rapid City, South Dakota 57702
(800) 843-8848 ·(605) 348-5580 ·fax (605) 348-5685
www.symcom.com
INPUT
POWER
L1
M1 M2 M3
L2 L3
OL
OL
OL
B
A
C
MAGNETIC
CONTACTOR
MOTOR
MS455
THERMOSTAT
OPTIONAL
CONTROL
POWER
24 - 240 VAC
TM
M
MAG.
COIL
HAND STOP
OFF
AU
TO
PILOT
START
OL
Figure 1. 3-Pole Contactor Wiring Diagram Figure 2. 2-Pole Contactor Wiring Diagram
222 Disk Drive, Rapid City, SD 57701
(800) 843-8848 www.symcom.com
27/06
SETTINGS
1. LINE VOLTAGE ADJUSTMENT:
Rotate the VOLT. ADJ. (VAC) knob to
the nominal 3-phase line voltage
feeding the motor to be protected.
The Model 455 will automatically
sense whether it is connected to a
200V or 400V power system.
2. RESTART DELAY: Rotate the
RESTART (SEC) knob to the desired
position. The restart delay is the time between the MotorSaver seeing acceptable power 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 to 2 seconds.
NOTE: This delay is also the minimum cycle time or rapid-cycle timer for the motor or compressor
when control power is lost such as the operation of the thermostat.
The manual position on the restart adjustment can be used as a manual reset after any fault
condition, or loss of incoming power. To utilize 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 (MAN) 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 desired voltage
unbalance trip level. The NEMA MG1 standard 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 100%
Average
The NEMA MG1 standard also recommends against operating a motor above 5% voltage unbalance
under any circumstances. Therefore, a 5% UB setting is a good place to start, but SymCom
recommends consulting the motor manufacturer 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. Typically, the trip delay is set to
4 seconds, in areas where voltage fluctuations are frequent, the trip delay may need to be set
higher.
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
light will illuminate. If the contacts do not energize and the RUN light does not illuminate, see the
TROUBLESHOOTING section.
RESET RUN HOURS
To reset the run hours, first remove power to the Model 455. Make a note of each of the adjustable
settings. Turn all of the setpoint knobs to the minimum position, i.e., VOLT. ADJ. and RESTART
fully counter-clockwise; UNBALANCE TRIP AND TRIP DELAY fully clockwise. Apply power
momentarily, then remove power again to readjust each setting back to the noted/desired level.
Reapply power.
L1 L2 L3
190-480 VAC, 3Ø, 50/60 HZ
MODEL455
OVER
VOLT. PHASING
FAULT UNDER
VOLT.
PILOT DUTYRATING
480VAAT 240 VAC
RUN
VOLT. ADJ.
(VAC)
208
416 220
440
200
400 230
460
190
380 240
480
UNBALANCE
TRIP (NEM A %)
8
2
M1 M2 M3
SymCom. Inc.
300
100
2
MAN
RESTART
(SEC)
302
15
TRIP
DELAY
(SEC)
IND. CONT. EQ.
LISTED
784X
37/06
TROUBLESHOOTING
SYMPTOM SOLUTION
The RUN light does not blink
on initial power-up and all
three fault lights are on.
Check the RESTART DELAY knob. If it is set to the manual (MAN)
position, the Model 455 is in manual reset mode. Turn the
RESTART DELAY to “2” for several seconds until the output
contacts close.
No LEDs are lit—the unit
seems completely dead.
Measure the three line-to-line voltages. If any of the voltages are
below 150VAC, the Model 455 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 (800) 843-8848.
PHASING FAULT light is
blinking 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 correctly
connecting leads the first time. Re-apply 3-phase power.
PHASING FAULT light is
blinking after the motor has
previously been running.
The incoming lines have been reverse-phased. Swap and two
incoming power lines to the magnetic contactor.
The PHASING 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 voltages do not
exceed the NEMA unbalance setting, a single-phasing condition
has occurred on the load side of 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 and
re-applied to clear this fault condition. If the contacts and wiring are
good, call SymCom at (800) 843-8848.
The UNDERVOLT. or
OVERVOLT light is on
Measure the three line-to-line voltages and calculate the average.
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 the reset window, call SymCom at (800) 843-8848.
The RUN LIGHT 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 (800) 843-8848.
INDICATOR LIGHTS
LED INDICATOR CONDITION
UNDERVOLTAGE ON Voltage is less than 93% of nominal voltage as set by
the VOLT. ADJ. knob
OVERVOLTAGE ON Voltage is greater than 107% of nominal voltage as
set by VOLT. ADJ.
PHASING FAULT 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®.
PHASING FAULT BLINKING Incoming power is reverse-phased.
UNDERVOLTAGE, OVERVOLTAGE AND
PHASING FAULT LIGHTS ON Unit has been powered up in the manual restart
position.
RUN LIGHT ON Output contact is energized.
RUN LIGHT BLINKING The MotorSaver®is timing through the restart delay.
47/06
*50Hz will increase all delay timers by 20%
QUESTIONS OR COMMENTS?
PLEASE CALL SYMCOM AT (800) 843-8848 OR (605) 348-5580
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.
MODEL 455 SPECIFICATIONS
3-Phase Line Voltage 190–480VAC (nominal)
475–600VAC (Model 455-575)
Frequency 50*/60Hz
Low Voltage (% of setpoint)
Trip 90%
Reset 93%
High Voltage (%of setpoint)
Trip 110%
Reset 107%
Voltage Unbalance (NEMA)
Trip 2–8%
Reset 4.5%
Trip Delay Time
Low and High Voltage,
and Voltage Unbalance 2–30 seconds (adjustable)
Single-Phasing Faults 2 seconds (fixed)
Restart Delay Time
After a fault or power loss Manual, 2–300 seconds (adjustable)
Output Contact Rating – SPDT
Pilot Duty 480VA @ 240VAC
General Purpose 10A @ 240VAC
Standards Passed
Electrostatic Discharge (ESD) IEC 61000-4-2, Level 3, 6kV contact, 8kV air
Radio Frequency Immunity (RFI) IEC 61000-4-2, Level 3, 10V/m
Fast Transients IEC 61000-4-4, Level 3, 4kV input power
2kV inputs/outputs
Repeat Accuracy Protection
Fixed Conditions ±0.1%
Power Consumption 6 Watts (max.)
Weight 14 oz.
Terminal
Torque 7 in.-lbs. (max.)
Operating Temperature -40° to 70°C (-40° to 158°F)
Safety Marks
UL UL508 (File #E68520)
2880 North Plaza Drive, Rapid City, South Dakota 57702
(800) 843-8848 ·(605) 348-5580 ·fax (605) 348-5685
www.symcom.com
222 Disk Drive, Rapid City, SD 57701
(800) 843-8848 www.symcom.com
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