Cutler Hammer, Div of Eaton Corp DS6 Series Instruction Manual
Instructional Leafl et IL03901001E
Effective June 2009
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 electrically. The DS6 line uses four silicon-controlled
rectifiers (SCRs) that are connected in a full wavepower bridge on two phases. The voltage and current 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 energized 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 packing materials for the carrier to review.
Verify that the unit’s catalog number and options
match those stated on the order/purchase form.
Instructional Leafl et IL03901001E
Effective June 2009
DS6 series soft start controllers
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.
1.18
(30.0)
1.18
PE
(93.0)
1.38
(35.0)
3.66
(30.0)
1.38
(35.0)
PE
(129.0)
(22.5)
PE
5.08
0.86
6.34
(161.0)
6.89
(175.0)
1.38
(35.0)
5.47
(139.0)
0.86
(22.5)
Figure 1. 25- to 75-Horsepower Models
0.59
(15.0)
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 MALFUNCTION. 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
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)
Screw Size + Flat
and Lock Washer Quantity
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
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
Humidity Functional to 95% noncondensing.
Operating orientation Less than 30 degrees from horizontal
Minimum clearance—
upper and lower
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
of 1% of rated current per Kelvin
for each 100m
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), consult documentation of the breaker used (ionization emissions)
accordance with EN 55011/22 Class A
Torque
Requirements
Unit Weight
Lbs (kg)
7.87
(200.0)
8.47
(215.0)
2.07
(52.5)
PE
4.25
(108.0)
0.59
(15.0)
6.22
(158.0)
Figure 2. 100- to 150-Horsepower Models
2
EATON CORPORATION www.eaton.com
7.01
(178.0)
DS6 series soft start controllers
Instructional Leafl et IL03901001E
Effective June 2009
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).
5
1
L2 L3
L1
3
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.
DS6
T1
4
T2
M
3~
2
T3
6
Figure 3. Power Wiring Diagram for 230/400 and 400/460V
Line Voltages
Table 4. Product Selection—Horsepower Ratings
Motor Power
Rated
Current
Catalog Number
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
(A)
200V 230V 460V
(hp) (hp) (hp)
Maximum Allowable
Breaker Size
Maximum Allowable
Fuse Size
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
Motor Power
Rated
Current
Catalog Number
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.
(A)
230V 400V
(kW) (kW)
Maximum Allowable
Breaker Size
EATON CORPORATION www.eaton.com
Maximum Allowable
Fuse Size
3
Loading...