INSTALLATION INSTRUCTIONS FOR THE
MODEL 777-KW/HP-P,
777-KW/HP-575-P, 777-KW/HP-HVR-P
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-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-KW/HP-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-
KW/HP-575-P). 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 the
Model 777-KW/HP-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 amperage ranging 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 same
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 2
shows an example of the looping required for MULT = 3.
C) For amperage greater than 90 amps, external CTs (current transformers) are required. Using
CTs with terminals is recommended for ease of installation. All CT secondaries must make five
passes through the round holes on the 777-P. See Figure 3 for a typical wiring diagram using
CTs.
4. Connect 3-phase power from the line side of the contactor to the L1, L2, and L3 terminals using
12-18 AWG copper wire. These should be tightened to no more than 7 in.-lbs. Figure 1 is drawn
for a power system wired in ABC sequence. For power systems with ACB sequence, switch the
L1 and L3 connections on the 777-P.
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 of the contactor
for motor control. For alarm circuits, the NC (normally closed) contact is in series with the alarm
circuitry.
Recommended
Full Load
Amps
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
540-700
560-800
OC Range
(Amps)
2-10
2.2-11.1
2.5-12.5
2.8-14.3
3.3-16.7
4-20.1
5-25.1
6.6-33.5
10-50.3
20-100
80-140
120-210
160-280
240-420
320-560
400-700
480-840
560-980
640-992/FFF
GF Range
(Amps)
.3-2,Off
.33-2.22,Off
.37-2.5,Off
.42-2.85,Off
.5-3.33,Off
.6-4,Off
.75-5,Off
1-6.66,Off
1.5-10,Off
3-20,Off
12-80,Off
18-120,Off
24-160,Off
36-240,Off
48-320,Off
60-400,Off
72-480,Off
84-560,Off
96-640,Off
# of Passes
through each
Window
10
9
8
7
6
5
4
3
2
1
5
5
5
5
5
5
5
5
5
MULT (CT
Ratio)
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)
700 (700:5)
800 (800:5)
Table 1: Wiring Configuration Based on Motor Full Load Amps
L1
L2
L3
NO
C
NC
MODE SELE CT
#RU/ADD R
RD3
#RF
RD2
PWS
RD1
GF
TC
RU N
CUB
LV
L PS
HV
OC
VUB
MU LT
MODE 777-KW/H
L
P
OV ERL OAD RE
L AY 2 0 - 9 0 A
L1
DISP L AY / PROGR A M
U
R
E
A
L3
-L1
L2-L3
B
C
T
P
O
W
E
R
L2
L3
NO
C
NC
+
IND. CON .
T. EQ
784X
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LR46510
MODE SELECT
#RU/ADDR
#RF
RD3
RD2
PWS
RD1
GF
TC
RUN
CUB
LV
LPS
HV
OC
VUB
MULT
MODE 777-KW/H
L
P
OVER LOA D R E L A Y 2 0 -9 0 A
DISP LAY / PROGR A M
U
R
E
L3
-L
1
L2-L3
RESET/
PROGRAM
LIS TED
SUIT ABLE 10 K A RMS, 600 VAC M AX
SY MCOM INC. 800-243-8848 RAP ID CIT
Y, SD
T
P
O
WE
+
IND. CON EQ.
T.
784X
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LR46510
RESET/
PROGRAM
LISTED
SUITABLE 10 K RMS, 600 VAC MAX
A
SYMCOM INC. 800-243-8848 RAPID CIT SD
Y,
Figure 1: Typical Wiring Diagram for FLA
of 26-90A
Figure 2: Typical Wiring Diagram with
Conductor Looping
NOTE: For ACB sequence input power configuration, invert the L1 and L3 terminal connections on
the 777-P.
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2-
5/07 A1
SYMCOM RECOMMENDS USING
CTs WITH TERMINALS TO SIMPLIFY
INSTALLATION.
L1
L2
L3
NO
C
NC
MODE SE LE CT
#RU/ADDR
RD3
#RF
RD2
KWS
RD1
GF
TC
RUN
CUB
LV
L KW
HV
OC
VUB
MU LT
MODE 777-KW/H
L
P
OVE RL OAD RE L
A Y 2 0-90 A
DISP L AY / P ROGRAM
U
R
A
B
L3-L1
L2-L3
G
AV
R
E
N
T
C
+
IND. CON Q.
TE
.
784X
®
LR46510
RESET/
PROGRAM
LISTED
SUI TABLE 10 K A RMS, 600 V AC MAX
SY MCOM INC. 800-243-8848 RAPID CIT
Y, S D
Figure 3: Typical Wiring Diagram Using External CTs
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 in the
specifications table. See page 7 for a programming example.
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% voltage unbalance. 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 single-phase protection.
Voltage 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%.
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MULT
- MULT (multiplier) setting can be found on Table 1. The MULT setting is determined by the
current the 777-P will be monitoring. This allows the unit to display the correct current. Set
MULT first then set 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, 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).
LP (low power) is used to shut down the motor or pump on an underload condition. Setting
LP to 0 disables the underload trip feature. LP can be set in either kilowatts (kW) or
horsepower (hp) determined by the PWS setting.
NOTE: PWS must be set before setting LP.
LP-
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 phase 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-
P will trip on overcurrent. While the standard trip classes are 5, 10, 15, 20, and 30, TC can
be set from 2–30, with or without jam protection. These additional “non-standard” trip
classes allow the unit to follow a trip curve in-between the “standard” trip class curves
shown in Figure 4.
Trip classes 2–30 can be set from approximately the 7 o’clock to 11 o’clock position on the
DISPLAY/PROGRAM dial. Trip classes J02–J30, which include jam protection, can be set
from the 11 o’clock to 2 o’clock position (this additional jam protection feature, when
enabled is initiated 1 minute after the motor starts and provides a 2-second trip delay for
motors exceeding 400% of the OC setting).
The linear overcurrent trip delay can be set after the 2 o’clock position from 0–60 seconds
(L00–L60) or to “oFF.” If TC is set to L00, the 777-P will trip off within 1 second when an
overcurrent condition is detected. If both trip class and linear trip delay settings are
programmed, the 777-P will follow the faster trip time. E.g., let’s say TC is set to J15 and
L20, and the amperage is 200% of the OC setting. Following the trip class 15 curve, the
777-P will trip off in approximately 100 seconds. Thus the 777-P will follow the linear trip
delay setting, because it is faster, and will trip off in 20 seconds.
The motor manufacturer should be contacted for an exact TC setting. Table 3 describes the
trip classes, and Figure 4 shows the trip class curves.
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. Typically, this is set to 20-30 seconds. This will provide adequate protection for
successive power outages or short cycling caused by other motor controls.
This timer is also initiated when another control shuts the motor off (current goes to zero). If
the user does not want the unit’s relay to de-energize when another control shuts the motor
off, RD1 must be set to zero. This will also ensure that when an alarm circuit is used, an
alarm will sound only when there is a fault or when power is lost.
RD2 -
RD2 (restart delay two) is the restart timer, in minutes (standard), used when the unit has
shut off due to a current unbalance, current single-phasing, high power, or an overload
condition (if “oc” is the prefix to the number in #RF, see #RF description). This timer is
known as a motor cool-down timer. A setting of 5-10 minutes will give most motors
adequate time to cool down after an overload condition. The motor manufacturer should be
contacted for an exact value.
RD3 (restart delay three) is the restart timer, in minutes (standard), used after an underload
(LP) trip. It is also known as a dry-well recovery timer in pumping applications. This would
be the time it takes a well to recharge after pumping dry. This setting varies widely from
application to application and there is no typical setting. RD3 can be set from 2-500 minutes
or to A to enable the automatic Dry-Well Recovery Calculator.
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5/07 A1
RD3 -
The Automatic Dry-Well Recovery Calculator allows the 777-P to automatically select a
restart delay based on the run time of the last run cycle. Table 2 shows the next restart
delay vs. run time. In general a longer run time produces a shorter restart delay. This
feature allows the 777-P to optimize running and rest times automatically.
Next Restart
Delay (minutes)
Run Time
Starts/Hr
> 1Hr
6
10
30 min.- 59.99 min.
15
4
15 min.- 29.99 min.
30
2
< 15 min.
60
1
Table 2. Automatic Dry-Well Recovery Timer
#RU/ADDR
- The #RU/ADDR is a dual-function setting. #RU is displayed when the
DISPLAY/PROGRAM knob is between the 7 o’clock and 11 o’clock position of the dial.
ADDR is displayed above the 11 o’clock position on the DISPLAY/PROGRAM dial.
#RU is the number of restarts the 777-P will attempt after a low power fault before the unit
locks out and requires a manual reset. #RU can be set to 0, 1, 2, 3, 4, or A. This counter is
cleared one minute after restarting if the 777-P does not trip again on low power.
EXAMPLE: #RU set to 1
If the 777-P trips on low power, restarts automatically (after RD3), then trips again on low
power within one minute, the 777-P will lock out and require a manual reset. On the other
hand, if the 777-P restarts after a low power fault, but runs without tripping on low power for
more than a minute, the unit will not lock out if a low power fault occurs.
If #RU is set to “0,” the 777-P will require manual resetting after all low power faults.
If #RU is set to “A,” the 777-P will always restart automatically after low power faults.
ADDR is the RS-485 address of the 777-P. This is only used when communicating with an
RM-2000, RM-1000, COM-DN, CIO-DN, a PLC, or a PC. The address can be 1–99 (A01–
A99).
#RF
-
#RF is the number of restarts the 777-P will attempt after current unbalance or current
single-phase faults. This counter will be cleared one minute after start-up if the unit does not
trip again on a current unbalance, or current single-phase condition (see example for #RU).
Available settings are 0, 1, 2, 3, 4 and A, or to include overcurrent and high power faults in
this restart function, #RF can be set to oc1, oc2, oc3, oc4 or ocA.
If #RF is set to “0,” the 777-P will require manual resetting after all current unbalance,
single-phase, overcurrent, and high power faults.
If #RF is set to “A,” the 777-P will always restart automatically after current unbalance and
single-phase faults.
If #RF is set to “ocA,” the 777-P will always restart automatically after current unbalance,
single-phase, overcurrent, and high power faults.
PWS (power scale) is the range
setting for the LP setting.
PWS Setting
1
2
3
4
5
6
7
8
LP Range
0.01 - 0.99 kW
1.00 - 9.95 kW
10.0 - 99.5 kW
100 - 650 kW
0.01 - 1.30 hp
1.34 - 13.3 hp
13.4 - 133.0 hp
134 - 871 hp
PWS-
GF -
GF (ground fault) is the
maximum allowable current that can flow to ground before the 777-P de-energizes its relay.
This is a residual, class II ground fault system and should not be used for personnel safety.
A typical setting for GF is 10–20% of motor FLA (in amps). The GF test procedure in this
instruction manual must be conducted before the device is brought online.
NETWORK PROGRAMMABLE PARAMETER
HPS-
HPS
(high power setting) is used to shut down the motor or pump on a high power
condition. This setting is only accessible via an RS-485 network using the RS485MS-2W
communications module,
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5/07 A1
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