SymCom MotorSaver Plus 777-P Series Manuals

INSTALLATION INSTRUCTIONS FOR THE MODEL 777-P, 777-575-P, 777-HVR-P ELECTRONIC OVERLOAD RELAY BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION! FOLLOW NATIONAL, STATE AND LOCAL CODES. READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION. The Model 777-P is a solid-state (electronic) overload relay. It is fully programmable for customized protection and is designed to protect 3-phase systems with operating voltages of 190-480VAC (500- 600VAC for the Model 777-575-P). 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 Model 777-575-P). The unit cannot be tested for proper operation using this voltage. For testing purposes, 3-phase power must be applied with a minimum voltage of 190VAC (450VAC for the Model 777-575-P). The 777-P offers more advanced network programmable features than the 777 and will work with SymCom’s DeviceNet COM-DN and CIO-DN; and Modbus RS485MS-2W Communications Modules. CONNECTIONS 1. Disconnect power and verify power is off. 2. Using the four corner tabs or the DIN rail mount, install the 777-P 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 snaps onto the rail. 3. A) For amperages from 25-90 amps, insert the motor conductors through the holes marked A, B, and C. Make certain 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 amperages 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 8-12 amps (MULT=3). C) For amperages greater than 90 amps, external CTs (current transformers) are required. SymCom recommends using CTs with terminals for ease of installation. All CT secondaries must make five passes through the round holes on the MotorSaver ®Plus. See Figure 2 for a typical wiring diagram using external CTs. NOTE: Pay close attention to this diagram to eliminate any power factor errors, when ommunicating with the device through the RS-485 network. c 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 no more than 7 inch lbs. 5. Connect the control circuit wires to the appropriate terminals. The relay is designed for fail-safe operation, thus 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. 2880 North Plaza Drive, Rapid City, South Dakota 57702 (800) 843-8848 · (605) 348-5580 · fax (605) 348-5685 HTUwww.symcom.com Recommended - 2 - 6/07 A1 Full Load Amps OC Range (Amps) UC Range (Amps) # of Passes through each Window MULT (CT Ratio) 2-2.5 2-10 0, 1-9.8 10 10 2.5-3 2.2-11.1 0, 1.1-10.8 9 9 3-3.5 2.5-12.5 0, 1.2-12.2 8 8 3.5-4 2.8-14.3 0, 1.4-14 7 7 4-5 3.3-16.7 0, 1.6-16.3 6 6 5-6 4-20.1 0, 2-19.6 5 5 6-8 5-25.1 0, 2.5-24.5 4 4 8-12 6.6-33.5 0, 3.3-32.6 3 3 12-25 10-50.3 0, 5-49 2 2 25-90 20-100 0, 10-98 1 1 80-110 80-140 0, 40-140 5 100 (100:5) 110-160 120-210 0, 60-210 5 150 (150:5) 160-220 160-280 0, 80-280 5 200 (200:5) 220-320 240-420 0, 120-420 5 300 (300:5) 320-420 320-560 0, 160-560 5 400 (400:5) 400-520 400-700 0, 200-700 5 500 (500:5) 480-600 480-840 0, 240-840 5 600 (600:5) 540-700 560-980 0, 280-980 5 700 (700:5) 560-800 640-992/FFF 0, 320-992/FFF 5 800 (800:5) Table 1: Wiring Configuration Based on Motor load Amps Figure 1: Typical Wiring Diagram for FLA of 26-90 Figure 2: Typical Wiring Diagram Using External CTs. Figure 3: Looping Example Showing Three Conductors (MULT=3 from Table 1) - 3 - 6/07 A1 (No other necessary connections are shown.) - 4 - 6/07 A1 PROGRAMMABLE PARAMETERS The following settings MUST be programmed by the user in order to provide proper protection for the application. All parameters are actual values except for the VUB and CUB settings; these are programmed as percentages. The range each parameter can be programmed to is found on the electrical specifications table on pages 15 and 16. See pages 9 and 10 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. 90% and 110% of 230 is 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 to 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. Setting VUB to 999 will disable voltage unbalance protection but will not disable voltage SP protection. V oltage 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%. MULT - MULT (multiplier) setting is found on Table 1. The MULT setting is determined by the current the unit will be monitoring. This allows the unit to display the correct current. Set MULT first then set UC, OC and GF. OC- OC (overcurrent) is typically set to the service factor amperage (SFA) of the motor or 100- 115% of motor full-load amps (FLA), which are determined by the motor manufacturer. If any one leg exceeds the OC setting, the 777-P will follow the TC settings to determine when to trip; in seconds or by following the trip class curve (see Figure 4). UC - UC (undercurrent) is typically set to 80% of the full-load amperage (FLA) of the motor. This is usually adequate for protection of loss of load for many pumps and motors, including submersibles. If the motor is not pulling near full load amperage then the UC may have to be set to something higher than 80% of FLA for adequate protection. UC can be set to 0 if UC protection is not desired. The 777-P examines average current to determine if an undercurrent trip condition exists. CUB - CUB (current unbalance) is factory set to 7%. SymCom recommends contacting the motor manufacturer for a specific setting. Current unbalance is calculated the same way voltage unbalance is calculated (see formula above). Current unbalance protection can be disabled by programming CUB to 999. This will disable current unbalance protection and current single phasing protection. TC - The TC (trip class) setting determines how quickly the 777-P will trip when an overload (overcurrent) 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 to establish when the 777-