RAM DBS II User manual

DigitalBypassSolidStateStarter
Operator's Guide
and Instruction Manual
DBS II
MA-0002 • REFRIGERATIONDBSII/ JUNE09 /REV 1
INDUSTRIES
LLC
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CONVENTIONS ........................................................................ A
DISCLAIMERS ......................................................................... B
HANDLINGANDSTORAGE ..................................................... C
1.0 DESCRIPTION ................................................................ 1
1.1 Overview ................................................................ 1
1.2 StandardFeatures................................................. 1
1.3 SystemParameters .............................................. 2
1.4 ControlModes....................................................... 2
1.5 OperatingStates ................................................... 2
1.6 LEDAnnunciation ................................................. 3
1.7 ElectronicMotorOverload Protection
andMonitoring ...................................................... 3
1.7.1 TripConditions .......................................... 4
1.7.2 AlarmCondition ........................................ 4
2.0 SPECIFICATIONS .......................................................... 5
HPRatings ................................................................. 5
ShortCircuitCapacity Ratings ........................................ 5
DBSSpecifications.......................................................... 6
TerminalData (LineandLoad) ......................................... 7
DimensionalData forStandard Enclosures ..................... 8
PanelLayout ................................................................. 9
3.0 RECEIVING and INSTALLATION..................................10
3.1 Receiving..............................................................10
3.2 MountingandCleaning.........................................10
3.3 Environment .........................................................10
3.4 De-ratingFactor ................................................... 11
4.0 WIRING ......................................................................... 11
4.1 Incoming Power ...................................................11
4.2 Motor Connection .................................................12
4.3 Control .................................................................12
4.4 Grounding ............................................................12
4.5 Field-ConnectedRelay Outputs ..........................13
4.6 CommunicationPorts ..........................................13
4.7 PowerFactor CorrectionCapacitors ....................13
4.8 LightningArrestor .................................................13
4.9 CircuitBoard Connections ...................................14
Table of Contents
5.0 SETUPINSTRUCTIONS................................................15
5.1 Inspection ............................................................15
5.2 Setup Switches ....................................................15
5.2.1 Motor FLA Switch (SW1) .........................15
5.2.2 Current Step Switch (SW2) ......................15
5.2.3 Ramp/Bypass Time Switch (SW3) ..........16
5.2.4 SystemConfigurationDIP Switch(SW4) .17
5.2.5 ResetPushbutton(SW5) .........................17
5.2.6 Starter Size DIP Switch (SW6) ................17
5.3 DBSControlBoard...............................................18
5.4 FLASetpointTables .............................................19
6.0 START-UPINSTRUCTIONS ..........................................20
6.1 PreliminaryInspection..........................................20
6.2 Start-Up ................................................................21
6.2.1 Power-Up .................................................21
6.2.2 Starting ....................................................21
6.3 Re-Adjustments .............................................................21
7.0 TROUBLESHOOTING ...................................................22
7.1 Start-upProblems ................................................22
7.2 Trip Conditions ................................................23-24
7.3 AlarmConditions..................................................25
8.0 DBS CONTROL/DISPLAYUNIT ....................................26
8.1 Description ...........................................................26
8.2 Operation .............................................................26
8.3 AcknowledgingTrips andAlarms .........................27
8.4 Editing Set Points ................................................27
8.5 ConfirmingSystemSetup ....................................27
8.6 SystemOverrideFunctions ..................................27
9.0 DBS CONTROL/DISPLAYUNIT MENUTABLES .....28-30
10.0 DBS LOG .......................................................................31
11.0 MAINTENANCE ........................................................32-34
12.0 REPLACEMENTPARTS ...........................................35-36
APPENDIX
Starter Size Dipswitch Positions .......................................i
TypicalMotorConnections ...............................................ii
SCRTestProcedure........................................................ iii
Glossary.......................................................................... iv
CONTENTS PAGE
CONTENTS PAGE
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TABLE 1 HP Ratings ........................................................... 5
TABLE 2 Short Circuit Capacity Ratings ............................. 5
TABLE 3 DBS Specifications ............................................... 6
TABLE 4 StandardLineTerminals ....................................... 7
TABLE 5 Alternate Line Terminals ....................................... 7
TABLE 6 LoadTerminals ..................................................... 7
TABLE 7 Standard Enclosure Sizes for
Stand-AloneStarters............................................. 8
TABLE 8 RecommendedTighteningTorque .......................11
TABLE9 FLA- Starter Size Tables ....................................19
TABLE 10 Diagnostics &Troubleshooting ..................... 22-25
TABLE11 LED & Relay Status forAlarm &
TripConditions.....................................................25
TABLE 12 Monitor Menu .......................................................28
TABLE13 Set Point Menu ...................................................28
TABLE14 Fault History Menu ..............................................29
TABLE15 System Setup Menu............................................30
List of Tables
FIGURE1 Dimensions for Standard Enclosures ................... 8
FIGURE2 PanelLayout......................................................... 9
FIGURE3 Forwardand ReverseMotor Connections ...........12
FIGURE4 Power Factor Correction Capacitor
Connections.........................................................13
FIGURE5 External Connections to Boards .........................14
FIGURE6 Constant Current Mode .......................................16
FIGURE7 Step Ramp Mode .................................................16
FIGURE8 DBS Control Board - StandAlone .......................18
FIGURE9 Starter Size Dip Switch Positions ..........................i
FIGURE 10 Typical MotorConnections .....................................ii
List of Figures
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RAM DBS II
RefrigerationSolidStateStarter
Conventions used in this manual
Symbols
Thefollowinglist containsan explanation ofthe symbolsusedin thisdocument.
This symbol is used when there is information you
might find especially useful. The information may
also warn you about possible problems you could
encounter.
This symbol is used when there is important
informationthatcan helpyou avoid potential
injury.
This symbol is used when there is important
information that can help you avoid the risk of
serious personal injury or death.
This symbol is used when there is important
information that can help you avoid the risk of
serious personal injury or death.
CAUTION!
DANGER!
WARNING!
A
Conventions
5NOTE:
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RAM DBS II
RefrigerationSolidStateStarter
The information contained herein is not intended as a training manual for unqualified
personnel. It does not relieve the user of responsibility to use sound practices in
application,installation,operation, andmaintenanceofthe equipmentpurchasedorin
personnelsafety precautions. Shouldaconflictarisebetween thegeneral information
containedinthispublicationandthecontentsofdrawingsorsupplementaryinformation
supplied with this equipment, the latter shall take precedence.
RAM Industries reserves the right to make changes in specifications shown herein or
add improvements at any time without notice or obligation.
WARNING
Disconnect all Sources of Power and Lockout
BeforeServicingThisEquipment
This equipment should be installed and maintained by qualified personnel only, in
accordance with recognized safety standards and applicable electrical or building
codes. The manufacturer is not responsible for damages or injuries resulting from
improper installation or use.
For the purposes of this manual, a qualified person is one who is familiar with the
installation, construction, or operation of the equipment and the hazards involved. In
addition, he has the following qualifications:
a) Is trained and authorized to energize, de-energize, clear, ground, and tag
circuits and equipment in accordance with established safety practices.
b) Is trained in the proper care and use of protective equipment such as rubber
gloves, hard hat, safety glasses or face shields, flash clothing, etc., in
accordance with established safety practices.
c) Is trained and authorized to work on exposed parts that may be energized.
d) Is trained in rendering first aid.
B
Disclaimers
Disclaimers
5NOTE:
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RAM DBS II
RefrigerationSolidStateStarter
Handling and Storage
Handling
• Strap or brace the DBS controller prior to moving it.
• Do not top-stack DBS controllers.
• Do not remove DBS controller from skid or unpack it until final installation, if possible.
• Packaged DBS controllers should be moved with a forklift and tethered with safety straps.
• Top-lifting should be done only with suitable lifting eyes attached to mounting brackets when provided.
Storage
If the DBS controller will be stored for an extended period before installation:
• Inspect for possible damage incurred in transit.
• Re-package after inspection.
• Store in clean, dry environment with a uniform temperature to prevent condensation inside the controller.
• Cover the controller to protect from dust, moisture, and falling objects.
C
HandlingandStorage
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RAM DBS II
RefrigerationSolidStateStarter
1.0 Description
1.1 Overview
The DBS (digital bypass solid state) reduced-voltage starter is a microprocessor controlled motor
starting device which utilizes six SCRs (silicon controlled rectifiers) to electronically reduce the
applied voltage to an AC induction motor, allowing the motor to start at a reduced current. Because
theDBSacceleratesthemotorinasmoothsteplessmanner,itreducesdropinthesupply voltageas
well as mechanical shock on the driven equipment, that is normally experienced with two-step,
electromechanical,reduced-voltagestartingmethods.
The DBS can be programmed to provide a gradual build up of torque, from zero to almost full motor
locked rotor torque, or to limit starting currents to a constant value, which prevents an excessive
voltagedropduring motor starting.
1.2 Standard Features
UniversalSource Matching: TheDBSautomaticallyadjustsitselftoanyinputvoltagebetween200
and 600 VAC and any frequency from 45 to 65 Hz.
Closed Loop Starting: The DBS starts a motor in a continuous controlled current mode, which
eliminates mechanical shock to the motor.
Automatic Bypass: The DBS includes a bypass contactor that is automatically engaged after the
motorhasreached fullspeed,orwhen thebypassdelayhasexpired. Thebypasscontactorreduces
power losses and heat build-up so that the DBS controller, in an unventilated enclosure in a 40oC
ambient, can continuously operate a fully-loaded motor.
Electronic Motor Overload Protection: The DBS has integral electronic motor protection. This
micro-processor-based feature provides comprehensive motor overload protection as well as
monitoring and annunciating system alarm and shutdown conditions. See Section 1.7 for full
explanationof motoroverloadprotection features.
LED Diagnostics: The DBS has four LEDs provided on the front of its control board to indicate the
operating state of the DBS.
Motor Connection: Nospecial motoris required. Anystandard 3-phasemotor canbe connectedto the
DBS. See Figure 10 in the Appendix for typical 3-wire connection diagrams.
StartingModes: Two startingmodesprovide optimumperformancetomatchtheDBStothe motorload
characteristics:
a. Constant Current Mode: Starting current is limited to a maximum level, adjustable from
200-425%ofFLA,untilthemotorattainsfullspeed. Thismodeisrecommendedforlightto
moderate inertial-type loads. See Figure 6, Section 5.
b. Step Ramp (Current Ramp) Mode: After the starting current quickly reaches the current
steplimit,itcanrampupto500%FLA. Theramptimeallowedcanbesetfrom3-30seconds.
This mode is recommended for heavy inertial and friction-type loads. See Figure 7,
Section 5.
Control:Aprogrammer/displayunit(KL4)ismountedinthedoorofthecontroller'senclosure. The
motor'soperating conditionsaredisplayed andmotorspecificationsandoperatingparametersare
programmedthoughtheKL4.
ULand CUL Approved: Allmodelshavebeentested andapprovedbyUnderwritersLaboratoryper
UL 508 Standard, and conform to Canadian National standards.
1
1.0 Description
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RAM DBS II
RefrigerationSolidStateStarter
1.3 System Parameters
The motor and load characteristics and the control method define system parameters. These are
configured with switches on the control board of the DBS controller.
- Full Load Amps (FLA)
- Constant Current Level (% FLA)
- Ramp Bypass Time (Seconds)
- Control Mode (Display)
- Overload Protection (Enabled / Disabled)
- Starting Mode (Constant Current / Step Ramp)
- Configuration (Inline)
NOTE: System parameters can be changed only when motor is not running.
Refer to Figure 8, Section 5, for switch configurations.
1.4 Control Mode
The DBS Refrigeration Solid State Starter is set up to operate in the Display control mode by means
of DIP switches located on the DBS control board. Refer to Figure 8, Section 5, for switch
configurations.
The KL4 control/display unit, mounted on the front of the enclosure door and connected to the
DBS via an RS-232 port, provides the interface to program and monitor the DBS controller.
1.5 Operating States
The operating states, annunciated by means of status codes on the KL4 control/display unit, de-
scribe the DBS conditions seen by its microprocessor. - See Section 8.1 for Status Codes.
READY - The DBS is ready to start the motor. The DBS has passed all the preliminary system
checks,includingverifying thereare no shortedSCRs, allinternalsystem testshavepassed, andno
phase reversal or trip condition is present.
START - The DBS is in the process of starting the motor. Full speed has not been attained, and the
bypass contactor has not been turned on.
RUN - The motor has reached full speed, or the end of the bypass time has been reached, and the
bypass contactor has been turned on.
TRIP - The DBS has detected a trip condition and stopped the motor.
COOLDOWN - The motor has exceeded its thermal capacity and will not be allowed to start until
enough time has elapsed to allow the motor to cool. The time until the motor can be re-started can
be viewed in the Monitor Menu under “Time Till Start.”
2
1.0 Description
5
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RAM DBS II
RefrigerationSolidStateStarter
1.6 LEDAnnunciation
LEDs, located on the front of the DBS control board, annunciate operating status and assist in
troubleshootingwhilethe starterdoor is open.
READY LED (Green) indicates the DBS is in the READY state.
RUN LED(Green)indicates theDBS isineither theSTARTorRUN state. TheLED willblinkwhen in
the START state, then turn on steady once the RUN state is reached.
ALARM LED (Yellow) indicates the DBS has detected anALARM condition. The LED will blink until the
alarm is acknowledged (see Section 8.3). When the condition is no longer present, the LED will go out,
and normal operation can resume. If the condition is acknowledged, but is still present, the LED will turn
on steady and remain on until the alarm condition is removed. The control/display unit or Frick computer
will show the cause of the alarm.
TRIP LED (Red) indicates the DBS is in the TRIP state. The LED will blink until the trip is acknowledged
(seeSection8.3). Whenthe trip conditionis nolongerpresent, theLEDwill goout, and normaloperation
can resume. If the condition is acknowledged, but is still present, the LED will turn on steady and remain
on until the trip condition is removed. The KL4 control/display unit will show the cause of the trip.
1.7 Electronic Motor Overload Protection and Monitoring
The DBS electronically monitors and protects the motor, during both start and run states, by using, in
additiontouserpresets,auniquemodelofoperatinglimitsforthemotorcreatedfromthree-phasecurrent
andvoltageinputsignals.Italsorecordspertinentoperatinghistoryfortroubleshootingandmaintenance
purposes.
Faultconditionsareannunciatedandacknowledged throughtheDBSdoor-mountedKL4control/display
unit.
The DBS electronic overload affords motor protection against the following conditions:
- Stalling
-Overheating
- Locked Rotor
Additionally the DBS microprocessor will detect the following conditions:
- Jam
- Short Circuit
- Phase Loss
- Current Unbalance
-PhaseReversal
3
1.0 Description
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RAM DBS II
RefrigerationSolidStateStarter
1.7.1 TripConditions
Multipletripconditions canbe detectedanddisplayed ineither DBScontrolmode. The detectionof atrip
conditionwhile themotorisrunningwill causeit tostop. Refer tothe SetPointMenu(Section9,Table13)
for trip set points and defaults.
SHORT CIRCUIT - This trip will occur if the current exceeds 800% FLAwhile the DBS is in the START
state. This condition will activate the circuit breaker shunt trip.
THERMAL OVERLOAD - This trip will occur when the calculated thermal energy stored in the motor
exceeds 100% of the motor’s thermal capacity. The motor will be allowed to start again when the motor
has sufficiently cooled.
SHORTED SCR - This trip will occur if one or more of the SCRs is shorted. A trip will occur if line
voltage / 1.73 is not present from line to load across each phase of the starter when the motor is
properly connected. This voltage is checked only after a run signal is received. This trip will also occur
if current flow is detected when the motor is not running. This current is an indication of a "runaway"
motor and will result in the activation of the shunt trip.
PHASE REVERSAL - This trip will occur if phase rotation on the incoming power is not: L1 - L2 - L3. A
reversal condition is checked only after a run signal is received and can be corrected by swapping any
two line input phases. Control power must be cycled to clear this fault.
PHASE LOSS - This trip will occur if one or more of the incoming voltage phases is lost when the motor
is not running. This voltage is checked only after a run signal is received. This trip will also occur if one
or more of the current feedback signals on TB2 of the power board is lost when the motor is running.
HEAT SINK OVERTEMPERATURE - This trip will occur when the DBS heat sink temperature has
exceededsafeoperating conditions.
PLL FAILURE - Indicates poor power quality.
This check is performed only when the DBS is in the START state.
JAM - This trip will occur if the current is above the Jam Current Level and the Jam run delay has
expired. This trip will occur only in the run state.
1.7.2 AlarmCondition
Analarm conditionwill beannunciated ontheKL4control/displayunitandcausetheyellowAlarm LEDon
the DBS control board to light. - Refer to Set Point Menu, Section 9, Table 13, for alarm set points and
defaults.
CURRENT UNBALANCE - This alarm will be activated when the current unbalance % exceeds the
CurrentUnbalancelevel andthe Current UnbalanceDelay hasexpired.
4
a 33 A1+ 29A2+ 34 A3= 96 ATOTAL
__________________________ = 32 AAVERAGE
3
b 33 A1- 32 AAVERAGE = 1 A
29 A2- 32 AAVERAGE = -3 A Largest value: 3 ADEVIATION
34 A3- 32 AAVERAGE = 2 A
c3A
DEVIATION
________ x 100% = 9.4%
32 AAVERAGE
Example
1.0 Description
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RAM DBS II
RefrigerationSolidStateStarter
B
C
D
E
UL Short Circuit Capacity Ratings
of DBS Starters per UL 508 Standard
18 KA @ 600 VOLTS
30 KA @ 600 VOLTS
42 KA @ 600 VOLTS
42 KA @ 600 VOLTS
TABLE 2
100 KA @ 600 VOLTS
100 KA @ 600 VOLTS
100 KA @ 600 VOLTS
100 KA @ 600 VOLTS
65 KA @ 480 VOLTS
65 KA @ 480 VOLTS
65 KA @ 480 VOLTS
65 KA @ 480 VOLTS
WITH MAIN
CIRCUITBREAKER
@ 480 VOLTS
STARTER
SIZES
WITH MAIN
CIRCUITBREAKER
@ 600 VOLTS
WITH MAIN
FUSED DISCONNECT
@ 600 VOLTS
5
2.0 Specifications
2.0 Specifications
TABLE 1 H.P. Ratings
30
50
60
60
75
100
125
150
200
250
300
208
V230 V
75
100
125
150
200
250
300
400
450
600
700
460
V575 V
B1
B2
B3
C1
C2
C3
D1
D2
D3
E1
E3
DBS
CHASSIS
SIZE
40
50
60
75
100
125
150
200
----
300
350
100
125
150
200
250
300
400
500
----
700
900
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RAM DBS II
RefrigerationSolidStateStarter
6
2.0 Specifications
DBS Specifications
TABLE 3
AC POWER SUPPLY
HPRATINGS
CURRENTCAPACITY
CONTROLVOLTAGE
LINEFREQUENCY
CONTROLVOLTAGE
VADEMAND
PERCHASSISSIZE
THERMALOVERLOAD
CAPACITY
OPERATINGTEMPERATURE
STORAGETEMPERATURE
STANDARDSTARTING
MODES
USERACCESSIBLE
RELAYS
COMMUNICATIONPORTS
NOTE: 115V CONTROL POWER MUST BE DERIVED
FROM THE 3 PHASE POWER SOURCE.
200VTO600V RMS
SEE TABLE 1
69AMPS - 900AMPS
115 VAC, +/-15%
45TO65 HZ
B1, B2: 150 VA
B3, C1, C2, C3: 250 VA
D1, D2, D3: 500 VA
E1, E3: 750 VA
300%FLAFOR 40 SECONDS
600%FLAFOR 10 SECONDS
0 TO 40 DEGREES C
-40 TO 65 DEGREES C
CONSTANTCURRENT-200%TO425% FLA
STEP RAMP - 200% TO 425% FLA, RAMP UP TO 500% FLA MAX
RUNRELAY: (2) SPSTNORMALLYOPEN CONTACTS
-10AMPS @ 25OVOLTAC, INDUCTIVERATING
SHUNTTRIPRELAY: (1)SPSTNORMALLYOPENCONTACT
-10AMPS @ 250VOLTAC, INDUCTIVERATING
ALARMRELAY:(1)SPDT1-NORMALLYOPEN,1-NORMALLYCLOSEDCONTACT
-10AMPS @ 250VOLTAC, INDUCTIVERATING
DISPLAY PORT(J1) - RS232, 9600 BAUD
NETWORK PORT - RS485, 19,200 BAUD; Receive (RX) LED (yellow) and
Transmit (TX) LED (green) indicate network activity.
Jumpers JP1 (+) and JP3 (-) select 10k bias resistors: 1-2 Enable, 2-3 Disable.
Jumper JP2 selects 120ohm termination resistor: 1-2 Enable, 2-3 Disable
(See Figure 5).
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RAM DBS II
RefrigerationSolidStateStarter
Terminal Data (Line and Load)
LineConnections
75 Deg. Copper Only
7
NOTE!
Information subject to change.
Pleasecheckwebsite
for latest data.
www.ramusa.com
2.0 Specifications
#8 AWG - #1 AWG
#14 AWG - #2/0 AWG
#6 AWG - #3/0 AWG
#4AWG - 500KCMIL
(2)#2AWG - 600KCMIL
(2)#2/0 AWG - 500 KCMIL
(3)#2/0 AWG - 500 KCMIL
(3)#2/0 AWG - 500 KCMIL
TABLE 6
Load Terminals
STARTERSIZEBYHP CHASSIS
SIZE TERMINALS
T1 - T2 - T3
230 VOLT
15 - 25
30 - 40
50 - 60
75 - 100
125
134- 206
235- 250
263- 350
460 VOLT
25 - 50
60 - 75
100- 125
134- 206
235- 250
263- 450
482- 600
643- 735
CSS
B1
B2 - B3
C1 - C2
C3
D1 - D3
E1
E3
208 VOLT
60 - 75
100
125- 150
200- 235
250
380 VOLT
60
75 - 100
125- 150
200
250- 365
400- 500
600
575 VOLT
100
125- 154
175- 250
263- 305
335- 570
600- 800
870- 900
SEE
TABLE 1
FOR
CHASSISSIZE
TABLE 5
Alternate Line Terminals
ABB
BREAKER
FRAMESIZE WIRERANGE RAM
P/N MFG P/N
CB-0290
CB-0291
CB-0292
CB-0293
CB-0291
CB-0292
CB-0293
CB-0294
CB-0295
CB-1089
CB-0296
CB-0297
TL-0236
S3
S3/S4
S3/S4
S3/S4
S4
S4
S4
S4
S5
T5
S5
S6
S6
S7
TRIP
AMPS
150/225
150/225
150/225
150/225
250
250
250
250
400
400
400
600/800
600/800
1200
(1) #14–2 AWG
(1) #14–1/0 AWG
(1) #2–4/0 AWG
(1) #4 AWG–300 KCMIL
(1) #14–1/0 AWG
(1) #2–4/0 AWG
(1) #4 AWG–300 KCMIL
(1) #6 AWG–350 KCMIL
(1) 250–500 KCMIL
(1) 250–500 KCMIL
(2) 3/0 AWG–250 KCMIL
(2) 250–500 KCMIL
(3) 2/0 AWG–500 KCMIL
NOALTERNATE
K3TA
K4TB
K4TC
K4TD
K4TB
K4TC
K4TD
K4TE
K5TF
KT5300-3
K5TG
K6TH
ATK750/3
TABLE 4
Standard Line Terminals
230V
MAX
HP
380V
MAX
HP
460V
MAX
HP
575V
MAX
HP
ABB
BREAKER
FRAME SIZE WIRERANGE RAM
P/N MFG P/N
CB-0292
CB-0293
CB-0293
CB-1086
CB-0296
CB-1091
CB-0297
CB-0298
CB-0298
CB-0299
30
50
75
75
100
100
150
200
300
350
50
75
125
129
150
172
250
350
450
600
60
100
150
175
250
250
300
400
600
700
75
125
150
175
250
250
350
500
700
900
S3
S3
S4
T4
S5
T5
S6
S6
S6
S7
TRIP
AMPS
150/225
150/225
250
250
400
400
600
600
800
1200
(1) #2–4/0 AWG
(1) #4 AWG–300 KCMIL
(1) #4 AWG–300 KCMIL
(1) #6 AWG–350 KCMIL
(2) 3/0 AWG–250 KCMIL
(2) 3/0 AWG–250 KCMIL
(2) 250–500 KCMIL
(3) 2/0 AWG–400 KCMIL
(3) 2/0 AWG–400 KCMIL
(4) 4/0 AWG–500 KCMIL
K4TC
K4TD
K4TD
KT4250-3
K5TG
KT5400-3
K6TH
K6TJ
K6TJ
K7TK
TABLEREVISED4/8/09
TABLEREVISED4/8/09
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RAM DBS II
RefrigerationSolidStateStarter
8
Dimensional Data for Standard Enclosures
2.0 Specifications
TABLE 7
Standard Enclosure Sizes for Stand-Alone Starters
(in)
CUTOUT
DISTANCE
FROMREAR
42 x 24 x 14
48 x 24 x 14
72 x 24 x 16
HPRANGEPERVOLTAGE
230 VOLT
30 – 60
75 – 125
150– 350
460 VOLT
60 – 125
150– 250
300– 700
208 VOLT
30 – 50
60 – 100
125– 250
380 VOLT
60 – 100
125– 200
250– 500
575 VOLT
75 – 150
200– 300
350– 900
NEMATYPE1
ABC
BOTTOM
CUTOUT
DEFG
4.00
4.00
3.52
2.60
2.60
2.75
9.00
9.00
10.00
9.00
9.00
13.00
TOP VIEW
CABLEENTRYLOCATION
9.000
C
BOTTOMVIEW
CABLEENTRYLOCATION
G
3.47
D
F
2.00
E
17.000
FIGURE 1
A
B
KL4
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RAM DBS II
RefrigerationSolidStateStarter
Panel Layout
CB1
T1
FU1
FU2
TB1
FU3
CT7
DBS
M5/OL5
T1: ControlPower Transformer
CB1: Circuit Breaker
FU1: Control Power Transformer Primary Fuses
FU2: Control Power Transformer Secondary Fuse
FU3: OilPumpStarterFuses
TB1: Terminal Strip
CT7: CurrentTransformer
DBS: SolidState Starter Chassis
M5/OL5: OilPumpStarter
9
FIGURE 2
2.0 Specifications
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RAM DBS II
RefrigerationSolidStateStarter
10
3.0 Receiving and Installation
3.1 Receiving
•Upon receipt of the DBS controller, immediately unpack it and look for any shipping damages.
If any shipping damages are encountered, file a claim with the freight carrier within 15 days of
receipt.
•Verify that the ratings sticker on the DBS chassis matches the motor’s HP, current, and voltage
rating for the installation.
•Check for loose mechanical connections and assemblies, and wires which may have
broken or loosened during shipping and installation.
•Manually exercise all electromechanical devices to make sure they work freely.
3.2 Mounting and Cleaning
•When mounting a “stand-alone” DBS controller, make sure there is sufficient clearance (12"
minimum) around the enclosure for cooling, wiring, and maintenance purposes.
•Make sure that the manner in which the controller is mounted meets the latest requirement of
the National Electrical Code and any other local code requirements for working space (NEC
Code Articles 110-13 and 110-16).
•Freestanding controllers should be securely mounted to a flat, level, base using mounting holes
provided. Shim base of enclosure to prevent racking or door misalignment.
•Wall-mount type controllers should be securely mounted to a flat, vertical surface or framework
using mounting holes provided using hardware that will adequately support its weight. Shim
rear of enclosure to prevent racking or door misalignment.
•When drilling or punching holes in the enclosure, cover the electrical components to prevent
metal filings and debris from causing short circuits or reducing electrical clearances.
WARNING! Remove all sources of power before cleaning controller.
•After mounting and wiring is completed, thoroughly clean and vacuum the enclosure, and make
sure that all filings, metal chips, and other materials are removed before start-up.
3.3 Environment
The DBS controller may be installed and operated at nameplate rating in an area where the
followingconditionsexist:
•Ambient Temperature shall not exceed 40 degrees C (104 degrees F) with a 15 degree C rise inside
the enclosure as maximum.
•Ambient Temperature shall not be less than 0 degrees C (32 degrees F).
•Altitude above sea level shall be 6000-ft. (2000 m.) or less.
•Ambient air is reasonably clean, dry, and free of flammable or combustible vapors, steam, or corrosive
gases.
3.0Receivingand Installation
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RAM DBS II
RefrigerationSolidStateStarter
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3.4 Derating Factor
WARNING! When a DBS enclosure is mounted in an environment not in
accordance with Paragraph 3.3 as described above, it must be
derated as follows:
•Deratestartersize1.5%perdegreeCabove40degreesCAmbientTemperatureor0.75%perdegrees
F above 104 degrees F Ambient Temperature.
•Derate starter size 1% for every 100m above 2000m or every 300 ft. above 6000 ft. elevation.
4.0 Wiring
•TheDBScontrollershallbewiredinaccordancewiththeNationalElectricalCodeandanylocalcodesthatmay
apply.
•Copperconductors for75 deg.C (min.) shallbe usedfor powerand control wiringunless specifiedotherwise.
•Minimumrecommended wiresizes are#14AWG forcontrol voltage and#12AWGforline voltage.
•Tightenconnectionspertorquevalues shown ondevices. Otherwise,refer to torquevalues inTable8.
4.1 Incoming Power
Connect properly sized power wires to the input terminals on the DBS chassis marked L1, L2, & L3.
CAUTION! Incoming power wires must be connected in the correct order: L1, L2, L3.
Because the DBS controller is phase sensitive, it will not operate unless the
phase sequence is in this order. If not, a Phase Reversal trip will occur.
Avoid routing cable connections near the main circuit board. Refer to the National Electrical Code for
wire sizing and lug torque.
11
WIRE SIZE
(AWG or kcmil)
35
40
45
50
50
50
50
50
50
50
SLOTTEDHEADNO.10ANDLARGER
20
25
35
35
40
Recommended Tightening Torque
UNLESSOTHERWISENOTED ONINDIVIDUALDEVICE
TABLE 8
18-10
8
6 -4
3
2
1
1/0- 2/0
3/0- 4/0
250-400
500-750
HEX HEAD OR
SCREWS
SOCKETHEAD
SLOT WIDTH <3/64 IN
SLOT LENGTH <1/4 IN SLOT WIDTH >3/64 IN SLOT LENGTH >1/4 IN
TORQUE - IN/LB
75
75
110
150
150
150
180
250
325
375
4.0 Wiring
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RAM DBS II
RefrigerationSolidStateStarter
12
FORWARD REVERSE
L1 L2 L3
T1 T2 T3 T2 T1 T3
L1 L2 L3
4.2 Motor Connection
Connect properly sized motor leads to terminals T1, T2, and T3 on the DBS bypass contactor.
If motor rotation needs to be reversed, swap the position of any two motor leads connected to
the DBS bypass contactor. See Figure 3.
NOTE: Do not swap incoming wires to reverse the motor’s rotation as this will cause a
Phase Reversal trip.
4.3 Control
Customer control wiring is to be connected to the controller’s main terminal block (TB1) in accor-
dance with RAM wiring diagram supplied.
4.4 Grounding
Connect properly sized ground cable to the starter ground terminal. Refer to the National Electrical
Code for proper size, and make sure the ground conductor is connected to a solid earth ground.
FIGURE 3
4.0 Wiring
5
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RAM DBS II
RefrigerationSolidStateStarter
13
4.5 Field Connected Relay Outputs - TB1
The contacts of two relays on the DBS control board are available for controlling external devices
when not being utilized by the starter's basic control circuit. These contacts are connected to TB1
on the DBS control board. - See Figure 5, Section 4, for illustration of contacts and Table 3, Section
2, for contact values.
Run Relay - Energized when a start sequence is initiated.
N.O. Contact connected to terminals 7 and 8 may be used as a dry contact.
N.O. Contact connected to terminals 5 and 6 should be used ONLY as part of the start circuit.
Alarm Relay - Energized when an alarm condition exists.
N.O. Contact is connected to terminals 11 and 12.
N.C. Contact is connected to terminals 12 and 13.
4.6 Communication Ports - J1
Display Port - RJ-45 modular connector provides RS-232 communication for display. Refer to
Sections 8 and 9 for control/display unit operation. See Figure 5, Section 4.
4.7 Power Factor Correction Capacitors (Option)
CAUTION! Power factorcorrection capacitors,when provided,shall always beconnected
on the line side of the DBS controller.
4.8 Lightning Arrestor (Option)
A lightning arrestor is recommended in areas where frequent lightning occurs. It should be installed
on the line side of the controller’s circuit breaker.
FIGURE 4
4.0 Wiring
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RAM DBS II
RefrigerationSolidStateStarter
14
4.0 Wiring
FIGURE 5 External Connections to Boards
P3
P4
P5
P6
P7
P8
P2
Heatsink
Thermostat Configuration
SW4
SW3 SW2 SW1 Reset
SW5
TB12
NetworkPort
1
2
3
tr+
tr-
gnd
DisplayPort
3
2
1
J2
HeatsinkSensor
gnd
signal
+5
P1
CONTROL BOARD
POWERBOARD
to CT1
TRIP
ALARM
RUN
READY
Relays
15
____
14
____
13
____
12
____
11
____
10
____
9
____
8
____
7
____
6
____
5
____
4
____
3
____
2
____
1
neut
hot
hot
TB1
RibbonCable toPower Board
gnd
LEDs
_ _ _ _
_ _ _ _
_ _ _ _
_ _ _ _
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
SHUNT
ALARM
BYPASS
RUN
RUN
INPUT
6
____
5
____
4
____
3
____
2
____
1
to CT2
to CT3
TB2
FU1
J1
L3
C
L2
B
L1
A
RX TX
Starter Size
SW6
1
4
_A
JP1
JP2
JP3
3 2 1
•••
•••
•••
CONTROL
FUSE
LEDs
4.9 Circuit Board Connections
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