ABB 1SAM250000R1009 MS116-6.3 Manual Motor Starter

ABB 1SAM250000R1009 is the ABB order code for the MS116-6.3 manual motor starter. The MS116 series consists of electromechanical motor protection devices designed for the main circuit. ABB describes these devices as manual motor starters, motor protection circuit breakers, or manual motor protectors. Their primary functions are manual motor switching and protection against short-circuit, overload, and phase-failure conditions. The specific 1SAM250000R1009 version is identified as MS116-6.3, with an adjustable overload setting range of 4.0 to 6.3 A and a rated operational current of 6.3 A. :contentReference[oaicite:1]{index=1}

The MS116-6.3 combines manual operation and motor protection in a compact device intended for industrial control panels. Its 45 mm housing is designed for space-efficient panel installation, while the rotary operating handle provides a direct indication of the device state. The protection system incorporates thermal and magnetic release functions and is designed for suitable single-phase and three-phase motor applications.

Product Identification

The complete ABB product reference is 1SAM250000R1009, while MS116-6.3 identifies the corresponding product type. ABB’s product catalog lists 1SAM250000R1009 under the MS116 family with a 4.0–6.3 A setting range. The ABB product database also identifies the order number and describes the device as an MS116-6.3 manual motor starter. :contentReference[oaicite:2]{index=2}

• Manufacturer: ABB
• Product reference: 1SAM250000R1009
• Product type: MS116-6.3
• Product category: Manual motor starter
• Adjustable overload setting range: 4.0–6.3 A
• Rated operational current: 6.3 A
• Trip class: 10A
• Housing width: 45 mm
• Number of poles: 3
• Protection principle: Thermomagnetic
• Mounting: DIN rail
• Degree of protection: IP20
• Application: Motor switching and protection

Technical product data additionally identifies the device as a three-pole motor protection circuit breaker with screw connections, a turn-button operating element, thermal protection, and phase-failure sensitivity. :contentReference[oaicite:3]{index=3}

Manual Motor Starter Function

The main purpose of ABB 1SAM250000R1009 is to provide a combined switching and protection function for a motor circuit. The operator can manually switch the motor circuit through the rotary handle, while the internal protective mechanism responds to specified electrical fault conditions.

This combination distinguishes the MS116-6.3 from a simple isolating switch. The device is designed to provide protection against short circuits and overloads while also incorporating sensitivity to phase loss. ABB documentation describes the MS116 as an electromechanical protection device for the main circuit and specifies its use for manual motor switching and motor protection. :contentReference[oaicite:4]{index=4}

The result is a compact motor-control component that can be incorporated into a larger starter arrangement, including applications where the manual motor starter is combined with a contactor.

4.0–6.3 A Adjustable Setting

One of the defining characteristics of ABB 1SAM250000R1009 is its adjustable overload current range of 4.0 to 6.3 A. The adjustment mechanism allows the protection setting to be selected within the specified range according to the requirements of the connected motor. ABB’s ordering information specifically associates 1SAM250000R1009 with MS116-6.3 and the 4.0–6.3 A setting range. :contentReference[oaicite:5]{index=5}

The adjustable range is important because motor circuits do not all operate at the same current. Selecting the appropriate setting requires consideration of the motor nameplate information, operating conditions, starting characteristics, conductor sizing, and the overall protection design.

The adjustment should therefore be based on the actual motor application rather than simply selecting the maximum available value.

Overload Protection

Motor overload occurs when a motor draws excessive current for a period that can create unacceptable thermal stress. ABB MS116 devices use thermal protection to respond to overload conditions, with the MS116-6.3 specified as trip class 10A. :contentReference[oaicite:6]{index=6}

The adjustable overload setting allows the protective characteristic to be matched more closely to the connected motor. When the current remains above the appropriate protection level for the required operating period, the thermal release responds according to the device’s time-current characteristic.

Proper adjustment is essential for achieving the intended balance between allowing normal motor operation and providing protection against sustained overload.

Short-Circuit Protection

ABB specifies a rated service short-circuit breaking capacity of 50 kA at 400 VAC for the MS116-6.3. Technical product data also identifies thermomagnetic protection and a magnetic short-circuit release. :contentReference[oaicite:7]{index=7}

The magnetic protection mechanism responds rapidly to high fault currents associated with short circuits. This provides the motor circuit with a dedicated protective function within the limits of the device’s specified electrical ratings.

The actual application must still consider the prospective short-circuit current at the installation point and the coordination of the manual motor starter with upstream and downstream electrical equipment.

Phase-Failure Sensitivity

The MS116-6.3 includes phase-loss sensitivity as part of its protection characteristics. Phase failure can create an abnormal condition in a three-phase motor because the remaining phases may experience increased current and additional thermal loading.

The phase-failure sensitivity of the manual motor starter is intended to respond to the corresponding electrical condition and contribute to motor protection. ABB identifies phase loss sensitivity as a standard feature of the MS116 product family. :contentReference[oaicite:8]{index=8}

This feature is particularly relevant to industrial motor applications where reliable three-phase power is required for normal motor operation.

Trip Class 10A

ABB specifies trip class 10A for the MS116-6.3. Trip class defines the operating characteristic of the overload protection and is an important parameter when matching a manual motor starter to a particular motor.

Motor starting current can be substantially higher than normal operating current. The protection characteristic therefore needs to accommodate the motor’s normal starting behavior while responding appropriately to sustained overload. The 10A classification provides a defined protection characteristic for suitable motor applications.

The trip class should be evaluated together with the motor’s rated current and starting characteristics when selecting the device.

Manual Rotary Operation

The MS116-6.3 uses a rotary operating handle with clear ON and OFF position indication. ABB identifies clear switch-position indication as one of the standard features of the MS116 series. :contentReference[oaicite:9]{index=9}

The rotary mechanism gives operators a direct physical method of switching the motor circuit and provides a visible indication of the selected position. This can be particularly useful in industrial control cabinets where several motor protection devices are arranged in close proximity.

The handle also contributes to the disconnect function of the manual motor starter, allowing the motor circuit to be manually switched off according to the applicable operating procedure.

Disconnect Function

ABB includes a disconnect function in the MS116 series. This allows the manual motor starter to provide a defined means of opening the associated motor circuit through its operating mechanism. :contentReference[oaicite:10]{index=10}

A disconnect function is useful in motor-control panels because the motor circuit may need to be separated from its power source during equipment operation, inspection, maintenance, or other authorized procedures.

The device’s disconnect capability should be considered as part of the complete electrical isolation design and should always be used in accordance with applicable electrical safety requirements.

Temperature Compensation

The MS116-6.3 includes temperature compensation. ABB specifies temperature compensation for an ambient range from -25 to +55 °C in the MS116 technical documentation. :contentReference[oaicite:11]{index=11}

Thermal protection devices can be influenced by ambient temperature because their operating characteristics depend partly on thermal conditions. Temperature compensation helps maintain the intended protective behavior across the specified operating range.

The surrounding control-panel temperature and installation conditions should nevertheless remain within the applicable product limits.

Trip-Free Mechanism

Another important characteristic of the MS116-6.3 is its trip-free mechanism. The mechanism is designed so that the protective function can operate when a fault condition requires the device to trip.

This is particularly relevant to protective switching equipment because the manual handle should not prevent the internal protection system from interrupting the circuit when the applicable trip condition is reached.

The trip-free design contributes to the independent operation of the protective mechanism and the manual operating mechanism.

Three-Phase and Single-Phase Applications

ABB states that MS116 manual motor starters are suitable for both three-phase and single-phase applications. :contentReference[oaicite:12]{index=12}

The MS116-6.3 has three poles and can therefore be integrated into suitable motor circuits according to the wiring configuration and application requirements. For a three-phase motor, the device can monitor and protect the corresponding phases. For a single-phase application, the installation must follow the applicable ABB wiring arrangement and product instructions.

The exact connection method should always be determined from the electrical schematic and installation documentation rather than from the physical appearance of the device.

Compact 45 mm Housing

The MS116-6.3 is designed with a compact 45 mm housing width. ABB product data identifies the device as a compact 45 mm wide manual motor starter. :contentReference[oaicite:13]{index=13}

The compact housing is useful in industrial control panels where multiple motor protection devices must be installed within a limited amount of DIN rail space. The standardized panel format also allows the device to be combined with related control components and accessories.

Technical data lists approximate dimensions of 45 mm width, 90 mm height and 85.6 mm depth. :contentReference[oaicite:14]{index=14}

Electrical Ratings

The MS116-6.3 has a rated operational current of 6.3 A. Technical product data lists a rated operational power of 2.2 kW at 400 V AC-3 and an operating voltage range extending to 690 V AC for the relevant device specifications. :contentReference[oaicite:15]{index=15}

The device’s electrical ratings must be considered together rather than independently. Motor power, operating voltage, current, utilization category, short-circuit conditions, and the characteristics of the installation all affect the suitability of the manual motor starter.

The 4.0–6.3 A overload setting range remains one of the key selection parameters for matching the device to a motor circuit.

Technical Specifications

The specifications above are based primarily on ABB technical documentation and ABB-associated product data for 1SAM250000R1009. :contentReference[oaicite:16]{index=16}

DIN Rail Installation

ABB 1SAM250000R1009 is designed for installation in industrial control panels and is identified with DIN rail mounting in technical product data. The compact format allows it to be positioned alongside other motor-control and protection components. :contentReference[oaicite:17]{index=17}

When installing the device, sufficient clearance, conductor routing, terminal access, and panel arrangement should be considered. The mounting position should also allow the rotary handle to remain accessible where manual operation is required.

The installation must follow the applicable ABB instructions and the electrical requirements governing the motor-control system.

Accessory Integration

The MS116 family supports a range of accessories that can extend the functionality of the basic manual motor starter. ABB documentation identifies auxiliary contacts, signaling contacts, undervoltage releases, shunt trips, three-phase busbars, power in-feed blocks, and locking devices among the available accessory options. :contentReference[oaicite:18]{index=18}

Auxiliary contacts can provide additional status information to a control circuit, while signaling contacts can communicate a specific switching or trip condition. Undervoltage releases and shunt trips can support remote control functions where required.

Busbar and power in-feed accessories can also be used to simplify panel arrangements containing multiple manual motor starters. The correct accessory must be selected according to the MS116 configuration and applicable ABB documentation.

Motor Starter System Architecture

The MS116-6.3 can be used as part of a larger motor starter arrangement. ABB documentation notes that fuseless starter combinations can be configured together with contactors. :contentReference[oaicite:19]{index=19}

In such an arrangement, the MS116-6.3 provides the motor circuit switching and protection functions, while the contactor can provide electrically controlled switching according to the machine control system.

This architecture is common in industrial automation because it separates the motor protection function from the automatic control function while allowing the components to operate together as a coordinated motor starter.

Application in Industrial Automation

ABB 1SAM250000R1009 can be incorporated into motor-control systems used for pumps, fans, conveyors, compressors, machine tools, material-handling equipment, and other industrial machinery with motor circuits falling within the device’s specified current range.

Its 4.0–6.3 A adjustable range makes it suitable for motors whose required overload protection setting falls within this range. The device can also provide a local manual switching function in addition to its protective role.

The final application should always be evaluated using the motor nameplate data, supply voltage, motor starting characteristics, conductor specifications, and the requirements of the complete protection system.

Maintenance Considerations

Maintenance of ABB 1SAM250000R1009 should include inspection of the operating handle, mounting position, terminal connections, conductors, and surrounding motor-control components. The manual mechanism should operate consistently between its intended positions.

The adjustable current setting should be checked against the motor protection requirements after maintenance or modification of the motor circuit. Any signs of abnormal heating, loose connections, mechanical damage, or irregular tripping should be investigated.

Where auxiliary contacts or other accessories are installed, their mechanical engagement and electrical connections should also be checked as part of the overall maintenance procedure.

Product Selection Within the MS116 Series

ABB offers the MS116 family in multiple current ranges. The product sequence includes MS116-4.0 with article number 1SAM250000R1008, MS116-6.3 with 1SAM250000R1009, MS116-10 with 1SAM250000R1010, MS116-12 with 1SAM250000R1012, and MS116-16 with 1SAM250000R1011. :contentReference[oaicite:20]{index=20}

This sequence demonstrates why the complete ABB article number is important when identifying the correct product. Similar MS116 devices can have different overload ranges and therefore different motor applications.

For technical records and product identification, ABB 1SAM250000R1009 should be retained together with the MS116-6.3 designation and 4.0–6.3 A setting range.

Identification and Documentation

The product reference 1SAM250000R1009 is also associated with GTIN or EAN 4013614320323 in ABB catalog information. The same catalog identifies the product as MS116-6.3 with a 4–6.3 A setting range. :contentReference[oaicite:21]{index=21}

When recording an installed component, it is useful to document the ABB article number, product type, current setting, supply characteristics, associated motor, and any installed accessories. This creates a more complete technical record than the model designation alone.

The article number should also be used when distinguishing the MS116-6.3 from neighboring MS116 current ratings.

Conclusion

ABB 1SAM250000R1009 is the MS116-6.3 manual motor starter, designed to provide manual motor switching and electromechanical protection against short circuits, overloads, and phase failures. Its adjustable overload setting range is 4.0–6.3 A, with a rated operational current of 6.3 A and trip class 10A. :contentReference[oaicite:22]{index=22}

The device combines thermal and magnetic protection, phase-loss sensitivity, a disconnect function, temperature compensation from -25 to +55 °C, a trip-free mechanism, and clear ON/OFF indication. ABB technical data identifies a 45 mm housing, three poles, screw connections, and a rated service short-circuit breaking capacity of 50 kA at 400 VAC. :contentReference[oaicite:23]{index=23}

For industrial automation and motor-control applications, ABB 1SAM250000R1009 should be identified specifically as MS116-6.3 rather than simply as an MS116 device. The complete article number and 4.0–6.3 A adjustment range provide the most precise identification for engineering documentation, motor protection selection, control-panel design, and equipment maintenance.