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INSTALLATION INSTRUCTIONS FOR THE
BE SURE POWER IS DISCONNECTED PRIOR TO INSTALLATION!
FOLLOW NATIONAL, STATE AND LOCAL CODES.
READ THESE INSTRUCTIONS ENTIRELY BEFORE INSTALLATION.
The Model 777-TS 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-TS-575). The output relay is a Form C contact, which can control a
contactor or other device within the output relay contact rating. In addition, the 777-TS, when used
with a *SUBTROL®-equipped submersible motor, can detect high motor temperatures. The unit can
be programmed prior to installation by applying 120VAC to terminals L1 and L2 (except ModeL 777-
TS-575). The unit cannot be tested for proper operation using this voltage. For testing purposes, 3-
phase power needs to be used with a minimum voltage of 190VAC (450VAC for Model 777-TS-575).
CONNECTIONS
1. Disconnect power and verify power is off.
2. Using the four corner tabs or the DIN rail mount, install the Model 777-TS 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 26-90 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 26 amps, loop the motor conductors according to Table 1. Figure 3
shows an example of the looping required for current ranging from 8.1-12 amps (MULT=3).
C) For amperages greater than 90 amps, external CTs (current transformers) are required.
SymCom recommends CTs with terminals be used for ease of installation. All CT secondaries
must make five passes through the round holes on the MotorSaver®. 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
communicating with the device through the RS-485 network.
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.
*SUBTROL is a registered trademark of Franklin Electric Co., Inc.
MODEL 777-TS
ELECTRONIC OVERLOAD RELAY
WITH TEMPERATURE SENSOR
2880 North Plaza Drive
Rapid City, SD 57702 · (800) 843-8848
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Summary of Contents for SymCom 777-TS
- Page 1 1. Disconnect power and verify power is off. 2. Using the four corner tabs or the DIN rail mount, install the Model 777-TS 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.
- Page 2 # of Conductors through MULT Setting Full Load Amps each Phase (A, B and C) (CT ratio) 2.0 - 2.5 2.6 - 3.0 3.1 - 3.5 3.6 - 4.0 4.1 - 5.0 5.1 - 6.0 6.1 - 8.0 8.1 – 12 13 –...
- Page 3 Figure 2: Typical Wiring Diagram Using External CTs. Figure 3: Looping Example Showing Three Conductors (MULT=3 from table 1) (No other necessary connections are shown.) - 3 - 1/05...
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Page 4: Programmable Parameters
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. - Page 5 RD1 - RD1 (restart delay one) is the rapid-cycle timer in seconds. This timer is initiated when power is first applied to the unit. If voltages are within the programmed limits and no SP (single-phase) or RP (reverse-phase) condition exists when power is applied to the device, the output relay will energize (the NO will close and the NC will open) as soon as RD1 expires).
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Page 6: Operation
5. Continue steps 1-4 until all parameters are programmed. OPERATION The relay operation of the Model 777-TS is designed to be fail safe. This means when everything is within the limits programmed into the unit, the relay will energize, the NO contact will close and the NC contact will open. -
Page 7: Application Description
Trip Class Application Description 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. -
Page 8: Programming Examples
PROGRAMMING EXAMPLES Example #1 Motor to be protected: 3-phase, 460 Volt, 25 hp air compressor with a full load amperage rating of 34A and maximum service factor amps of 37.4. Use the following calculations and reasoning to determine the appropriate settings for this application. 460 x 0.90 = 414 460 x 1.10 = 506 VUB/TS-... -
Page 9: System Display
#RU- In this application, we know that the well will eventually recharge itself, #RU = A (Automatic). #RF- This well is known for sand to jam the impeller, therefore “oc” should be included so that the pump will attempt to automatically restart after an overloaded condition. History shows that 2 or 3 starts and stops usually clears the sand out of the impeller. - Page 10 COMMUNICATIONS PORT/REMOTE RESET The unit comes with a 9-pin sub-D connector for remote communications and/or for using a remotely located reset button. If communications are desired, a communication module (part number RS485MS-2W) needs to be plugged into this 9-pin connector (this is mandatory when communicating with the unit).
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Page 11: Troubleshooting
TROUBLESHOOTING The MotorSaver® will display a fault code alternating with a number or with “run” when it is in a trip condition. If the unit is showing a fault code (see Table 4) alternating with “run,” it has tripped on a current (amperage) condition. - Page 12 MODEL 777-TS SPECIFICATIONS Electrical 200-480VAC, 3-phase (Standard) Input Voltage 500-600VAC for Model 777-TS-575 Frequency 50 or 60Hz 2-25A, 3-phase (Loops Required) Motor Full Load Amp Range 25-90A, 3-phase (Direct) 80-800A, 3-phase (External CTs) Power Consumption 10W (Maximum) Pilot duty rating: 480VA @ 240VAC General...
- Page 13 GF- Ground Fault Current Threshold or OFF NOTES: SymCom's overload relay can be preprogrammed prior to installation by applying 120VAC between the L1 and L2 terminals (except 575 volt model). Power applied must be 110VAC or greater. * 575 volt Model.
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Page 14: Ground Fault Testing Procedure
CLEARING LAST FAULT The last fault stored can be cleared on the MotorSaver® by following these steps: 1. Rotate the MODE SELECT switch to GF. 2. Press and hold the RESET/PROGRAM button. Adjust the DISPLAY/PROGRAM adjustment 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. - Page 15 SymCom 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 and workmanship for a period of two (2) years from the date of Manufacture.
- Page 16 Visit our website at www.symcominc.com for our complete catalog and new product listings! 2880 North Plaza Drive Rapid City, SD 57702 · (800) 843-8848 - 16 - 1/05...
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