ABB MS495 1SAM550000R1008 Replacement for MS Series

Product Overview

ABB MS495 1SAM550000R1008 Replacement for MS Series: Smooth Transition & Legacy System Compatibility

When your existing motor protection circuit is built around the ABB MS Series platform and a key component like the MS495 (1SAM550000R1008) reaches end-of-life or becomes unavailable through standard distribution channels, the pressure to restore operations quickly is immediate. This manual motor starter is a direct-fit replacement and upgrade solution engineered to slot into existing MS Series control architectures with minimal rewiring, no PLC program changes, and no control cabinet redesign. Whether you are replacing a failed unit on a running production line or proactively upgrading aging motor protection devices before they cause unplanned downtime, the MS495 1SAM550000R1008 delivers the electrical and mechanical compatibility your system demands.

The MS495 is rated for motor protection applications across a broad current adjustment range, making it suitable for a wide variety of three-phase induction motor loads in manufacturing, water treatment, HVAC, and process automation environments. Its compact DIN-rail or direct-mount footprint matches the physical envelope of earlier MS Series starters, meaning your existing cable ducts, terminal blocks, and mounting rails remain fully usable. The bimetal overload trip mechanism and magnetic short-circuit protection are factory-calibrated to IEC 60947-4-1 standards, ensuring compliance with the same protection coordination requirements your original system was designed around.

Compatibility Comparison Table

Seamless Upgrade Solutions

A successful migration from an aging motor protection scheme to the MS495 1SAM550000R1008 rarely involves a single component swap. In practice, field engineers working on MS Series retrofit projects also address the surrounding control architecture to ensure long-term reliability. During the replacement process, it is common to simultaneously evaluate the ABB MS490 auxiliary contact block mounted alongside the original starter — if the existing aux block shows contact wear or is a discontinued variant, replacing it with the current MS Series auxiliary contact module ensures consistent signal integrity back to the PLC digital input card.

On the power distribution side, the ABB OT series disconnect switch upstream of the motor starter should be verified for current rating compatibility with the MS495’s adjusted trip range. In control cabinets where multiple motor starters share a common busbar, the ABB CP-S series power supply module feeding the 24 VDC control circuit should be load-checked to confirm it can support the updated protection relay logic without voltage droop during simultaneous trip events.

For systems that use fieldbus communication to report motor status to a SCADA or DCS platform, the ABB Profibus DP communication adapter compatible with the MS Series can be retained from the outgoing unit and transferred to the MS495 without reconfiguration, provided the GSD file version matches the master controller’s configuration. In installations where the original system used a DeviceNet adapter module for integration with Allen-Bradley ControlLogix or CompactLogix PLCs, the same adapter is forward-compatible with the MS495 frame, eliminating the need for EDS file updates or network re-addressing.

Terminal wiring to the motor load side typically uses the same cable cross-sections and lug types as the predecessor model. However, field teams upgrading from very early MS325 or MS450 units should verify that the cable entry terminal block pitch matches — in most cases a standard 4 mm² or 6 mm² ferrule-terminated conductor connects directly without adapter sleeves. Where the control cabinet also houses an ABB AF series contactor interlocked with the motor starter, the auxiliary contact wiring between the contactor and the MS495 follows the same NC/NO logic as the outgoing device, so no ladder logic or function block changes are required in the upstream PLC program.

In applications where the motor starter feeds a variable-speed drive rather than a direct-on-line motor, the MS495 functions as the upstream short-circuit and isolation device ahead of the ABB ACS580 variable frequency drive. The trip class and current setting on the MS495 should be coordinated with the drive’s input current rating to avoid nuisance tripping during drive inrush. For installations requiring signal isolation between the motor protection relay output and a legacy 4–20 mA analog input on a DCS I/O module, a DIN-rail signal isolator / repeater module adjacent to the MS495 provides the necessary galvanic separation without modifying the existing field wiring. Where the cabinet integrates an ABB CP600 series HMI panel for local motor status visualization, the trip and run status signals from the MS495 auxiliary contacts can be wired directly to the HMI’s discrete input terminals using the existing cable schedule.

Retrofit Guidance FAQ

Q: Can I reuse the existing control wiring when replacing my old MS Series starter with the MS495 1SAM550000R1008?
A: Yes. The MS495 uses the same terminal designation and wiring convention as the MS Series predecessors. Control wiring for auxiliary contacts, trip signal outputs, and reset inputs can be reconnected to the same terminal positions without modification. Always verify terminal torque specifications against the MS495 datasheet before energizing.

Q: Do I need to update my PLC program after installing the MS495?
A: No program changes are required if the replacement is within the same MS Series family. The digital I/O signals — trip output, ready status, and remote reset — maintain the same logic polarity and timing characteristics. If your system uses a Profibus or DeviceNet communication module, retain the existing GSD or EDS file configuration unless the firmware version of the communication adapter has changed.

Q: How do I set the overload trip current on the MS495 after installation?
A: The MS495 features a front-panel rotary adjustment dial calibrated in amperes. Set the dial to match the full-load current (FLC) of the motor as shown on the motor nameplate. For motors with a service factor above 1.0, the trip current may be set up to 10% above FLC per IEC 60947-4-1 guidelines. Record the setting in your maintenance log for future reference.

Q: Will the MS495 fit in the same DIN rail slot as my existing MS490 or MS450?
A: The MS495 shares the same DIN rail mounting width and depth profile as the MS490 and MS450 within the same frame size. Verify the frame size designation (e.g., Size 2 or Size 3) matches between the outgoing and incoming units. If the frame size differs, a DIN rail adapter plate may be required to fill the width gap in the control cabinet door cutout.

Q: What communication protocols does the MS495 support for SCADA integration?
A: The MS495 supports optional Profibus DP and DeviceNet communication via plug-in adapter modules. For Modbus RTU integration, a gateway converter module mounted on the same DIN rail can bridge the MS495 trip and status signals to a Modbus register map readable by most SCADA systems. Native EtherNet/IP integration requires the appropriate communication adapter from the MS Series accessory catalog.

Q: What is the lead time and shipping arrangement for the MS495 1SAM550000R1008?
A: Units are held in stock at our Xiamen warehouse and are dispatched within 1–3 business days of order confirmation. International shipments are routed via DHL Express or FedEx International Priority depending on destination. Export documentation including commercial invoice, packing list, and certificate of origin is prepared for all cross-border orders.

Warranty Assurance

Every ABB MS495 1SAM550000R1008 unit supplied by TOPNLMS is covered by a 12-month warranty from the date of shipment. Prior to dispatch, each unit undergoes a pre-shipment functional inspection that verifies the overload trip mechanism, auxiliary contact continuity, and terminal integrity. Units that do not pass inspection are quarantined and not shipped.

In the event of a warranty claim, TOPNLMS provides a replacement unit or full refund at the buyer’s election. Warranty claims are processed within 5 business days of receipt of the returned unit and supporting documentation. Our after-sales response team is reachable via email at [email protected] or by phone at +86 18359293191 during business hours (GMT+8, Monday–Friday).

Procurement teams requiring third-party inspection reports, material certifications, or batch traceability documentation should request these at the time of order. TOPNLMS maintains shipment records for a minimum of three years to support audit and compliance requirements in regulated industries.

For volume orders exceeding 5 units, priority allocation and extended payment terms are available upon request. Contact our sales team to discuss framework agreements, blanket purchase orders, and consignment stock arrangements tailored to your maintenance and MRO procurement cycle.