Eaton Cutler-Hammer DS6 Series Manual

Effective June 2009
Instructional Leaflet IL03901001E
DS6 series soft start controllers
Introduction
Eaton’s Cutler-Hammer姞DS6 solid-state soft
start controller is an electronic, self-contained
panel- or enclosure-mounted motor soft-starting
device. It provides three-phase induction motors
with a smooth start, both mechanically and elec-
trically. The DS6 line uses four silicon-controlled
rectifiers (SCRs) that are connected in a full wave-
power bridge on two phases. The voltage and cur-
rent applied to the motor are controlled by varying
the SCR conduction period. This, in turn, controls
the torque developed by the motor. After the
motor reaches speed, a bypass contactor is ener-
gized to bypass the SCRs. The DS6 is designed
to fulfill the industrial service requirements of
applications such as chiller starters, pump panels,
and machine tools. This device meets all relevant
specifications set forth by UL姞508, IEC 60947-4-2,
CE, C-Tick, and CSA姞.
This leaflet covers basic installation and setup. No
publication can take into account every possible
situation. If you require further assistance with any
aspect of this product or a particular application,
contact Eaton.
Inspection
General
Upon receipt of the unit, verify that the catalog
number and unit options stated on the shipping
container match those stated on the order/
purchase form.
Inspect the equipment upon delivery. Report any
carton damage to the carrier prior to accepting the
delivery. Have this information noted on the freight
bill. Eaton is not responsible for damage incurred
in shipping.
Unpacking
Remove all packing material from the unit. Be
sure to remove all packing material from the
lug location.
Check the unit for any signs of shipping damage.
If damage to the product is found after unpacking,
report it to the freight company. Retain the pack-
ing materials for the carrier to review.
Verify that the unit’s catalog number and options
match those stated on the order/purchase form.

2
Instructional Leaflet IL03901001E
Effective June 2009
DS6 series soft start controllers
EATON CORPORATION www.eaton.com
Storage
It is recommended that the unit be stored in its original shipping
box/crate until it is to be installed.
The unit should be stored in a location where:
• The ambient temperature is between –13°F to 140°F
(–25°C to 60°C)
• The relative humidity is between 0% and 95%, noncondensing
• The environment is dry, clean, and noncorrosive
• The unit will not be subjected to high shock or
vibration conditions
Mounting instructions
The DS6 solid-state soft start controller is easy to mount. It does not
require any special tools. To aid you with panel layout, refer to the
dimension drawings shown in Figure 1 and Figure 2. Drill and tap
holes per mounting hole/slot locations as shown. To mount the unit,
use all the hardware specified in Table 1 of this leaflet. Tighten to
the specified torque.
Figure 1. 25- to 75-Horsepower Models
Figure 2. 100- to 150-Horsepower Models
PE
1.18
(30.0)
PE
1.18
(30.0)
0.86
(22.5)
0.86
(22.5)
3.66
(93.0)
5.08
(129.0)
6.34
(161.0)
1.38
(35.0) 5.47
(139.0)
6.89
(175.0)
1.38
(35.0) 1.38
(35.0)
0.59
(15.0)
0.59
(15.0)
4.25
(108.0)
2.07
(52.5) 7.01
(178.0)
8.47
(215.0)
PE
PE
6.22
(158.0)
7.87
(200.0)
DANGER—HIGH VOLTAGE
HAZARDOUS VOLTAGE CAN CAUSE ELECTRIC SHOCK AND BURNS. TO
AVOID SHOCK HAZARD, DISCONNECT ALL POWER TO THE CONTROLLER,
MOTOR, OR OTHER CONTROL DEVICES BEFORE ANY WORK IS PERFORMED
ON THIS EQUIPMENT. FAILURE TO DO SO WILL RESULT IN PERSONAL
INJURY, DEATH, OR SUBSTANTIAL PROPERTY DAMAGE.
DO NOT APPLY A DISCONNECT DEVICE ON THE OUTPUT OF THE DS6 SOFT
START CONTROLLER UNLESS A MEANS TO TURN OFF THE DEVICE WHEN
DISCONNECT SWITCH IS OPEN IS UTILIZED. OPENING THE DISCONNECT
WHILE THE SOFT START CONTROLLER IS OPERATING MAY CAUSE A MAL-
FUNCTION. CLOSING THE DISCONNECT SWITCH WHILE THE SOFT START
CONTROLLER IS OPERATING WILL RESULT IN POTENTIAL EQUIPMENT
DAMAGE AND PERSONNEL HAZARD.
Table 1. Mounting Hardware and Torque Specifications
Frame Size
Screw Size + Flat
and Lock Washer Quantity
Torque
Requirements
Unit Weight
Lbs (kg)
25–75 hp 5 mm x 55 mm 2 80 lb-in (9 Nm) 4.0 (1.8)
100–150 hp 6 mm x 65 mm 2 123 lb-in (14 Nm) 8.2 (3.7)
Table 2. Environmental Requirements
Description Requirements
Operating temperature 32°F to 104°F (0°C to 40°C) up to 140°F (60°C) with derating
of 1% of rated current per Kelvin
Storage temperature –13°F to 140°F (–25°C to 60°C )
Elevation Up to 1000m; up to 2000m with derating of 1% rated current
for each 100m
Humidity Functional to 95% noncondensing.
Operating orientation Less than 30 degrees from horizontal
Minimum clearance—
upper and lower
2.165 inches (55 mm) to a wall, 0.984 inches (25 mm) to a
NZM1 (size 1), 1.378 inches (35 mm) to a NZM2 (size 2), con-
sult documentation of the breaker used (ionization emissions)
Minimum clearance—sides 0.0 inches (0 mm)
Minimum clearance—face 0.198 inches (5 mm)
Shock resistance 8g for 11 ms in any direction.
Vibration resistance 2M2 EN 60721-3-2: 10g (3.5 mm amplitude, 9 to 200 Hz)
Environment Suitable for installation in a pollution Degree 2 environment
Emissions The device is suitable for use in industrial environments in
accordance with EN 55011/22 Class A

3
Instructional Leaflet IL03901001E
Effective June 2009
DS6 series soft start controllers
EATON CORPORATION www.eaton.com
Power wiring
Using the wiring diagrams in Figure 3,Figure 4, and Table 3 as
guides, connect the line, motor, and power supply wiring in
accordance with appropriate local and national codes.
ote:N To provide optimum motor protection, the line and motor power wiring
should be tightly bundled and run perpendicular to the orientation of the DS6.
Soft start controller to motor cable length is not to exceed 325 ft (100m).
Figure 3. Power Wiring Diagram for 230/400 and 400/460V
Line Voltages
135 L1 L2 L3
246
T1 T2 T3
M
3~
DS6
Table 3. Power Wire Sizing and Torque Requirements
Frame Size Wire Size Torque Wire Strip Length
25–75 hp 12–8 AWG 53 lb-in 0.65 in
25–75 hp 6–2/0 AWG 80 lb-in 0.65 in
100–150 hp 12–8 AWG 44 lb-in 0.87 in
100–150 hp 6 AWG—350 kcmil 123 lb-in 0.87 in
DANGER
HAZARDOUS VOLTAGE. WILL CAUSE DEATH OR SERIOUS INJURY.
HAZARDOUS VOLTAGE IS PRESENT IN THE OFF/STOP STATUS OF THE SOFT
START CONTROLLER WHEN THE LINE VOLTAGE IS ENERGIZED.
Table 4. Product Selection—Horsepower Ratings
Catalog Number
Rated
Current
(A)
Motor Power
Maximum Allowable
Breaker Size 
Maximum Allowable
Fuse Size 
200V 230V 460V
(hp) (hp) (hp)
DS6-34DSX041N0-N 40 10 10 30 HFD3150L 150A Class RK5
DS6-34DSX055N0-N 52 15 20 40 HFD3200L 200A Class RK5
DS6-34DSX068N0-N 65 20 25 50 HJD3250 200A Class RK5
DS6-34DSX081N0-N 77 25 30 60 HKD3300 300A Class RK5
DS6-34DSX099N0-N 96 30 30 75 HKD3350 350A Class RK5
DS6-34DSX134N0-N 124 40 50 100 HKD3350 500A Class RK5
DS6-34DSX161N0-N 156 50 60 125 HLD3450 500A Class RK5
DS6-34DSX196N0-N 180 60 75 150 HLD3500 500A Class RK5
 Maximum values are higher than allowed per NEC姞430.52 and UL 508A 31.1.
Table 5. Product Selection—kW Ratings According to IEC 60947-4-2
Catalog Number
Rated
Current
(A)
Motor Power
Maximum Allowable
Breaker Size 
Maximum Allowable
Fuse Size 
230V 400V
(kW) (kW)
DS6-34DSX041N0-N 41 11 22 HFD3150L 150A Class RK5
DS6-34DSX055N0-N 55 15 30 HFD3200L 200A Class RK5
DS6-34DSX068N0-N 68 15 37 HJD3250 200A Class RK5
DS6-34DSX081N0-N 81 22 45 HKD3300 300A Class RK5
DS6-34DSX099N0-N 99 30 55 HKD3350 350A Class RK5
DS6-34DSX134N0-N 134 30 75 HKD3350 500A Class RK5
DS6-34DSX161N0-N 161 45 90 HLD3450 500A Class RK5
DS6-34DSX196N0-N 196 55 110 HLD3500 500A Class RK5
 Maximum values are higher than allowed per NEC 430.52 and UL 508A 31.1.
Considerations:
1. Either XTOB, C306, or C396 series or equivalent overload protection devices may be selected.
2. Isolation contactor is optional for normal applications. It is recommended for mains isolation.

4
Instructional Leaflet IL03901001E
Effective June 2009
DS6 series soft start controllers
EATON CORPORATION www.eaton.com
Control wiring
A minimum of 16 AWG should be used between the power supply
and the 24 Vdc + and – terminals.
Terminal connections are to be secured to a torque value of 3.6 lb-in.
Control wiring is connected to the DS6 soft start controller by a
9-pin terminal block located on the front of the unit. Use the wiring
diagrams in Figure 4, Figure 5, and the information in Table 7
as guides.
Figure 4. Direct Start
Table 6. Terminal Designations
Terminal Description
OV Control ground or power supply common
+24 Plus 24 Vdc from power supply
–A2 Common with 0V, connected externally
EN Start command enable/stop command
+A1 Start command/ramp stop command
13, 14 Top of ramp contacts—NO
23, 24 Ready status contacts—NO
0V +24
TOR Ready
–A2 EN +A1 13 14 24
+24V
0V
23
0V +24 –A2 EN +A1 13 14 2423
Q1
Control Wiring Terminal Block
Figure 5. Direct Start With Soft Stop
Table 7. DS6 Terminal Control Block Wiring
Name
Block
Designation Input Connections
Circuit
common
0V Common Common
Power +24 24 Vdc nominal (see 24 Vdc power
supply requirements) section for
sizing of power supply
+24 Vdc power from
power supply
–A2 –A2 Control power common Common
Enable EN 24 Vdc maintained START command with
+A1 energized. Remove
for STOP command
+A1 +A1 24 Vdc maintained START command
with EN energized.
Remove for STOP
RAMP command
Relay 13 NO contact rated @ 250 Vac,
3A resistive, 1A inductive
Top of ramp signal–
in bypass
14 NO contact rated @ 250 Vac,
3A resistive, 1A inductive
Top of ramp signal–
in bypass
Relay 23 NO contact rated @ 250 Vac,
3A resistive, 1A inductive
READY status signal
24 NO contact rated @ 250 Vac,
3A resistive, 1A inductive
READY status signal
0V +24
TOR Ready
-A2 EN +A1 13 14 24
+24V
0V
23
Q1
S3

5
Instructional Leaflet IL03901001E
Effective June 2009
DS6 series soft start controllers
EATON CORPORATION www.eaton.com
24 Vdc power supply requirements
The 24 Vdc power supply for your DS6 soft start controller must
meet or exceed the following requirements:
• Minimum steady-state current: 1W (35 mA)
• Minimum start command current: 2W (65 mA)
• Minimum bypass contactor inrush current: 600 mA for 50 ms
• Voltage stability: 24 Vdc +10%/–15%
Operations
• 24 Vdc control voltage is applied to terminal +24
• The status light will illuminate after the starter has completed
initialization, closing contacts 23/24, and indicating READY status
• Line voltage is applied to the starter by closing the
mains contactor
• The soft start controller issues a START command by applying
+24 Vdc to terminals EN and +A1. Contacts 13 and 14 will close
when the end of the ramp time is reached
ote:N Bypass contactors close at the end of ramp time + ~0.18 seconds.
It is important to correctly set the ramp time, so the bypass contactors will
close within 5 seconds after the motor has achieved rated RPM.
• To initiate a STOP command, remove +24 Vdc from terminal EN
and +A1 or EN
• To initiate a RAMP STOP command, remove +24 Vdc from
terminal +A1
Adjusting the soft start controller parameters
There are three adjustments to the DS6 soft start controller:
• t-Start = ramp time
• u-Start = initial voltage (torque)
• t-Stop = stop ramp time
ote:N In all cases, motor rotation should begin within 2–3 seconds after the
START command is sent to the soft start controller.
Figure 6. DS6 Ramp Functions
u-Start
U
t-Start t-Stop
t
t-Stop = 0
13 14
TOR
(Top of Ramp)

6
Instructional Leaflet IL03901001E
Effective June 2009
DS6 series soft start controllers
EATON CORPORATION www.eaton.com
Table 8. DS6 Parameters
Application t-Start t-Stop u-Start Break-Away Torque Remarks
Axial-flow compressor 25s — 48% 50%
Bandsaw 10s — 42% 35%
Drill, unloaded 10s — 29% 10%
Crusher, empty at start 20s — 56% 75% Possible high inertia
Carding machine (combing cotton) 20s — 64% 100%
Conveyor, horizontal, loaded 25s 30s 76% 150%
Conveyor, horizontal, unloaded 25s 30s 48% 50%
Conveyor, vertical, loaded 25s 30s 82% 175%
Conveyor, vertical, unloaded 25s 30s 59% 85%
Conveyor, vertical drop, loaded 25s 30s 37% 25%
Conveyor, vertical drop, unloaded 25s 30s 44% 40%
Crusher, swing hammer 25s — 70% 125% Eccentric load, high starting torque
Chiller 5s — 37% 25%
Piston compressor, unloaded 10s — 64% 100%
Circular saw 20s — 48% 50% Possible high inertia
Ball mill 20s — 48% 50% Eccentric load
Flour mill 20s — 44% 50%
Mixer, liquids 10s — 37% 40%
Mixer, plastic materials 10s — 70% 125% Possible high starting torque
Mixer, powder materials 10s — 70% 125% Possible high starting torque
Mixer, dry materials 15s — 56% 75%
Pelletizing machine 20s — 64% 100%
Pump, piston 25s 30s 82% 175% Possible high starting torque
Pump, centrifugal 10s 30s 37% 25%
Moving pavement, unloaded 20s — 37% 25%
Escalator 10s — 48% 50%
Rotary compressor, unloaded 20s — 42% 35%
Agitator 15s — 42% 35%
Grinder, unloaded 10s — 37% 25% Possible high inertia
Feed screw 20s — 82% 175% Possible high starting torque
Compressor, screw, unloaded 25s — 40% 30%
Press, flywheel 25s — 76% 150% Possible high starting torque
Drier, rotating 20s — 64% 100%
Blower, axial fan, flaps closed 40s — 37% 25%
Blower, axial fan, flaps open 30s — 37% 25%
Blower, centrifugal fan, valve closed 40s — 42% 35%
Blower, centrifugal fan, valve open 30s — 35% 20%
Vibroconveyor 25s — 76% 150% Possible high starting torque
Vibrating screen 20s — 51% 60% Possible high starting torque
Rolling mill 25s — 48% —
Washing machine 25s — 64% 100% High transmission ratio
Centifuge 60s — 61% 90% High inertia, long ramp time
otes:N u-Start % values are voltage settings, as the starting torque is dependent on the application.
Applications with high starting torque are not suitable for DS6 soft start controllers. In some cases, over-sizing to a larger unit may be a solution.
Consult Eaton’s Technical Resource Center at [phone].

7
Instructional Leaflet IL03901001E
Effective June 2009
DS6 series soft start controllers
EATON CORPORATION www.eaton.com
Table 9. DS6 Basic Troubleshooting Guide
Possible Problem Possible Solution
Fault LED illuminates during the operation of the DS6 soft start controller
Control voltage loss Check for the following conditions: power supply failure and/or intermittent operation and volt-
age stability. Check all connections for condition and security. Verify proper size and capacity
of the power supply.
EN and heat sink temperature less than 0°C Verify that unit temperature is not below 0°C during application of control voltage or starter
operation.
Fault LED illuminates during start ramp, TOR, or stop ramp
Mains connection open or undervoltage Check for the following conditions: verify presence and stability of mains voltage. Check sys-
tem for phase loss. Check main breaker and/or isolation contactor and/or reversing contactors
are not open or have been cycled during starter operation, and verify proper operation. Verify
all connections for condition and security.
Motor connection open Check for the following conditions: verify proper motor cable connections, and check for condi-
tion and security. Verify installation and integrity of motor coupling to load. Test motor for
proper condition. Check that isolation and/or reversing contactors are not open.
Heat sink temperature less than 0°C or above 80°C Verify that unit temperature is not below 0°C or above 80°C.
Bypass contactor(s) closed during start ramp or stop ramp time Verify that bypass contactor(s) do not close when START command is initiated and remain
open until top of ramp is achieved. Verify that bypass contactor(s) open when STOP command
or STOP RAMP command are initiated.
Bypass contactor not closed after ramp time Verify that bypass contactor(s) close at top of ramp and remain closed until STOP command or
STOP RAMP command are initiated.
SCR fault Verify that one or more of the SCRs are not open. Verify that one or more of the SCRs are
not shorted.
Faults
In the event of a motor stop due to a trip condition by the soft start
controller, the FAULT status LED will be illuminated (flashing). In this
case, one or more conditions found in Table 9 may have occured.
Use standard troubleshooting techniques to determine the cause of
the trip. The DS6 does not provide any specific method of identifying
the cause of the trip.

Eaton Corporation
Electrical Sector
1000 Cherrington Parkway
Moon Township, PA 15108
United States
877-ETN-CARE (877-386-2273)
Eaton.com
© 2009 Eaton Corporation
All Rights Reserved
Printed in USA
Publication No. IL03901001E / Z8490
June 2009
PowerChain Management is a registered
trademark of Eaton Corporation.
All other trademarks are property of their
respective owners.
Instructional Leaflet IL03901001E
Effective June 2009
DS6 series soft start controllers
Service
For additional information on this product, please call Eaton’s
Technical Resource Center at [phone] or visit our Web site
at www.eaton.com.
Service and repair is available from Eaton or several factory-
authorized regional service centers. Please contact Eaton’s Product
Integrity Center at [phone] for the location nearest to you.
For field service or start-up assistance 24 hours a day, 7 days a
week, please call [phone].
The following chart describes LED operation during motor start,
run, and stop conditions.
Table 10. LED Operation During Motor Start, Run, and
Stop Conditions
Condition Motor Status
Ready
Contacts
TOR
Contacts Error LED Run LED
24 Vdc applied
and initialization
complete
Off Closed Open Flashing—
short pulse
Flashing—
short pulse
Terminal EN
energized
Off Closed Open Off Flashing—
short pulse
Terminals EN and
+A1 energized
START
command—
motor rotation
Closed Open Off Flashing—
long pulse
End of ramp time At rated RPM Closed Closed Off On
Terminal +A1
de-energized
EN-energized
STOP
command—
ramp stop
Closed Open Off Flashing—
long pulse
Terminal EN
de-energized
STOP
command—
coast
Closed Open Flashing—
short pulse
Flashing—
short pulse
Error detected Off Open Open Flashing—
long pulse
Off
otes:N Terminals EN and +A1 may be connected together to provide START
and STOP commands. If this is the case, a normal ramp start with a normal
stop (coast) will be selected.
When signaling a STOP command, either terminal may be de-energized. If
terminal +A1 is de-energized, a ramp stop will be selected. If terminal EN is
de-energized, a normal stop (coast) will be selected. To initiate another start,
simply re-energize the controlled (switched) terminal.
During ramp start or ramp stop, the RUN LED will be flashing—long pulse.