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RAM DBS II

Refrigeration Solid State Starter

23

TRIP CONDITION

1.

Jam

2.

Short Circuit

3.

Thermal Overload

4.

Shorted SCR (circuit breaker
trips about 5 seconds after
energizing controller).

SOLUTION

Confirm Jam trip and trip delay
setpoints.

Resolve mechanical problems of
driven equipment.

Verify DBS controller settings;
prevent excessive loading during
start.

Remove cause of short or ground.

Reconfigure connections.

Allow motor to cool then re-start.

Compare reading from clamp-on
ammeter with readout on display unit
to confirm accurate sensing by DBS.

Motor should be started less
frequently.

Confirm setpoints:
• FLA (SW1)
• Locked rotor current
• Stall time
• Service factor
• Chassis Size (SW6)

Check SCRs per test procedure.
(See Appendix)  Call RAM if
defective.  Do not replace in field.

If SCRs are OK, replace circuit
board.

Repair or replace contactor.

Repair gate plug connection or
connector.

Reconfigure connections.

Connect motor to starter.

POSSIBLE CAUSE

Current exceeded Jam Trip level
set point longer than time delay
set point while in RUN state.

Driven equipment may be bound
or set up improperly.

Current exceeded 800% of FLA
set point while motor was
starting.

Short in starter or motor junction
box: phase-to-phase, phase-to-
ground.

Motor incorrectly connected.

Calculated thermal capacity of
motor exceeded 100% of limit.

Excessive motor current
detected.

Motor is "short-cycling".

DBS settings not within design
parameters.

Defective SCR; Current
measured when motor is not
running.

Defective circuit board.

Defective bypass contactor;
welded contacts.

Gate plug P3, P5, or P7 may be
loose.

Motor connections incorrect.

Motor not connected to starter.

TABLE 10

 

(continued)

   7.2  Trip Conditions

 (continued)

7.0 Troubleshooting

StockCheck.com

Summary of Contents for DBS II

Page 1: ...Digital Bypass Solid State Starter Operator s Guide and Instruction Manual DBS II MA 0002 REFRIGERATION DBSII JUNE 09 REV 1 INDUSTRIES LLC S t o c k C h e c k c o m...

Page 2: ...14 Table of Contents 5 0 SETUP INSTRUCTIONS 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 System...

Page 3: ...m Trip Conditions 25 TABLE 12 Monitor Menu 28 TABLE 13 Set Point Menu 28 TABLE 14 Fault History Menu 29 TABLE 15 System Setup Menu 30 List of Tables FIGURE 1 Dimensions for Standard Enclosures 8 FIGUR...

Page 4: ...warn you about possible problems you could encounter This symbol is used when there is important information that can help you avoid potential injury This symbol is used when there is important inform...

Page 5: ...hould 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...

Page 6: ...ered 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 befor...

Page 7: ...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 a...

Page 8: ...erface 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...

Page 9: ...blink until the trip is acknowledged see Section 8 3 When the trip condition is no longer present the LED will go out and normal operation can resume If the condition is acknowledged but is still pres...

Page 10: ...ly 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 inco...

Page 11: ...480 VOLTS 65 KA 480 VOLTS 65 KA 480 VOLTS WITH MAIN CIRCUIT BREAKER 480 VOLTS STARTER SIZES WITH MAIN CIRCUIT BREAKER 600 VOLTS WITH MAIN FUSED DISCONNECT 600 VOLTS 5 2 0 Specifications 2 0 Specifica...

Page 12: ...750 VA 300 FLA FOR 40 SECONDS 600 FLA FOR 10 SECONDS 0 TO 40 DEGREES C 40 TO 65 DEGREES C CONSTANT CURRENT 200 TO 425 FLA STEP RAMP 200 TO 425 FLA RAMP UP TO 500 FLA MAX RUN RELAY 2 SPST NORMALLY OPEN...

Page 13: ...4 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 AW...

Page 14: ...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 NEMA TYPE 1 A B C...

Page 15: ...ower Transformer CB1 Circuit Breaker FU1 Control Power Transformer Primary Fuses FU2 Control Power Transformer Secondary Fuse FU3 Oil Pump Starter Fuses TB1 Terminal Strip CT7 Current Transformer DBS...

Page 16: ...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 mount...

Page 17: ...in accordance with the National Electrical Code and any local codes that may apply Copper conductors for 75 deg C min shall be used for power and control wiring unless specified otherwise Minimum reco...

Page 18: ...tor 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 mai...

Page 19: ...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 Comm...

Page 20: ...R M R U N R E A D Y Relays 15 ____ 14 ____ 13 ____ 12 ____ 11 ____ 10 ____ 9 ____ 8 ____ 7 ____ 6 ____ 5 ____ 4 ____ 3 ____ 2 ____ 1 neut hot hot TB1 Ribbon Cable to Power Board gnd LEDs _ _ _ _ _ _ _...

Page 21: ...l operation via switches SW1 SW2 SW3 SW4 and SW6 on its control board See Figure 8 5 2 1 Motor FLA SW1 This 16 position rotary switch setting is based on DBS chassis size and the FLA rating of the mot...

Page 22: ...he programmed ramp time See Table 15 Section 9 In the Constant Current mode this switch sets the maximum time until the bypass contactor is energized SW3 is adjustable from 3 30 seconds in 3 second in...

Page 23: ...e operator to acknowledge a fault condition at the DBS control board when the controller door is open The DBS will not allow the motor to start until all trip conditions are cleared See Section 1 6 fo...

Page 24: ...OVERLOAD ENABLED LEFT CONSTANT CURRENT LEFT STEP RAMP RIGHT INLINE LEFT SWITCH IS TO LEFT SWITCH IS TO RIGHT SWITCHES SHOWN IN FACTORY DEFAULT POSITIONS 0 3 2 1 4 5 6 7 8 9 0 3 2 1 4 5 6 7 8 9 0 3 2...

Page 25: ..._____ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ __...

Page 26: ...tch SW1 located on the DBS control board is set in the position that corresponds to the DBS chassis size and FLA of the motor being used DBS chassis size is shown on the chassis nameplate See Compress...

Page 27: ...OR EQUIPMENT DAMAGE MAY RESULT To jog motor follow Starting Instruction below and equipment start up instructions that apply 1 Make sure the motor is ready to be started in an unloaded condition 2 Set...

Page 28: ...Connect motor per motor nameplate Setpoint values cannot be changed while motor is running Status code rdy trip or cool must appear on display Motor leads must be properly configured and connected to...

Page 29: ...in field If SCRs are OK replace circuit board Repair or replace contactor Repair gate plug connection or connector Reconfigure connections Connect motor to starter POSSIBLE CAUSE Current exceeded Jam...

Page 30: ...re does not exceed 40 deg C NOTE Controller load capacity must be derated when ambient temperature exceeds 40 deg C Replace defective heat sink cable P N HA 0879 Chassis B C HA 0880 Chassis D E Replac...

Page 31: ...___________________ ___________________________________________________________________________________________________________ ________________________________________________________________________...

Page 32: ...alarm or trip condition The LED will blink until the alarm or trip condition is acknowledged STATUS CODES Astatus code denoting the operating state of the DBS controller is displayed continually in t...

Page 33: ...h on the display screen Press the UP DOWN keys to increase or decrease the set point value If a subsequent key is not pressed within 30 seconds the previously stored value will be retained To abort th...

Page 34: ...current reading for phase B Current Phase C Amps Live current reading for phase C Elapsed Run Time Hr Min Time since last start Thermal Capacity Used Cap Calculated thermal capacity used by the motor...

Page 35: ...________________________________________________________________________ _______________________________________________________________________________________________ _______________________________...

Page 36: ...____________________________________________________________________________ _______________________________________________________________________________________________ ___________________________...

Page 37: ...___ Minutes Total No of Starts ________ TotalRunTime ________ Hours Total No of Jam Trips ________ Total No of Short Circuit Trips ________ Total No of Phase Loss Trips ________ TotalNo ofPhaseReversa...

Page 38: ...cracks or openings which may have allowed moisture to enter the enclosure and eliminate the source of moisture on the outside of the enclosure Thoroughly dry all cabinet surfaces which may be damp or...

Page 39: ...ual spring tension Indications of light sooty deposits minor pitting or material displacement do not indicate a problem if all surfaces are worn equally Do not attempt to file or dress contact surface...

Page 40: ...k and related parts that show signs of binding warping or abnormal wear Inspect circuit breakers for any signs of damage or deterioration If it is suspected that the circuit breaker has opened several...

Page 41: ...Current Transformer XF 0196 XF 0198 XF 0198 XF 0199 XF 0302 XF 0303 8 SCR Module Eupec CR 0096 CR 0096 CR 0096 CR 0097 CR 0097 CR 0097 8a SCR Module Jinglai CR 0140 CR 0140 CR 0140 CR 0141 CR 0141 CR...

Page 42: ...0143 CR 0143 CR 0143 CR 0144 CR 0144 7 Thermostat Harness HA 0880 HA 0880 HA 0880 HA 0880 HA 0880 HA 0880 8 Thermostat SW 0345 SW 0345 SW 0345 SW 0345 SW 0345 SW 0345 9 Temp Sensor IC 0036 IC 0036 IC...

Page 43: ...ER SIZE STARTER SIZE 1 UP 2 DOWN 3 DOWN 4 UP 1 DOWN 2 UP 3 DOWN 4 UP 1 UP 2 UP 3 DOWN 4 UP 1 DOWN 2 DOWN 3 UP 4 UP 1 DOWN 2 UP 3 UP 4 UP B1 B2 B3 C1 C2 C3 SWITCH SWITCH 1 DOWN 2 UP 3 DOWN 4 DOWN 1 UP...

Page 44: ...tion Solid State Starter Typical Motor Connections 3 Wire Configuration FIGURE 10 ii 12 Lead Parallel Connection 12 Lead Series Connection Dual Voltage Typical 6 Lead Motor Appendix B Appendix B S t o...

Page 45: ...is required to properly test the SCRs If an analog meter is used select the highest resistance scale R x 10 000 scale 6 Start by measuring from L1 to T1 Reverse the polarity of the meter leads and me...

Page 46: ...mit and then allows the controller to continue the ramp to 500 Current Unbalance When any one of the three current phases exceeds the average of the three current phases by more than a predetermined p...

Page 47: ...sible loading Stall Time The maximum time at which the motor can be at locked rotor current without damage Step Ramp Mode In this mode the starter provides an initial current that is a percent of FLA...

Page 48: ...RT 61 PO Box 629 Leesport PA 19533 800 999 8183 www ramusa com 610 916 3939 FAX 610 926 9799 MA002 REFRIGERATION DBSII JUNE 09 REV 1 INDUSTRIES LLC S t o c k C h e c k c o m...

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