Related Manuals for RAM DBS II
Summary of Contents for RAM DBS II
- Page 1 DBS II Digital Bypass Solid State Starter MA-0002 • REFRIGERATION DBSII / JUNE 09 / REV 1 Operator's Guide and Instruction Manual INDUSTRIES...
-
Page 2: Table Of Contents
Table of Contents CONTENTS PAGE CONTENTS PAGE CONVENTIONS ................ A SETUP INSTRUCTIONS ..........15 DISCLAIMERS ................. B Inspection ............15 HANDLING AND STORAGE ............. C Setup Switches ............ 15 5.2.1 Motor FLA Switch (SW1) ......15 DESCRIPTION ..............1 5.2.2 Current Step Switch (SW2) ...... - Page 3 List of Tables List of Figures TABLE 1 HP Ratings ............5 FIGURE 1 Dimensions for Standard Enclosures ....8 TABLE 2 Short Circuit Capacity Ratings ......5 FIGURE 2 Panel Layout ............9 TABLE 3 DBS Specifications ..........6 FIGURE 3 Forward and Reverse Motor Connections ...
-
Page 4: Conventions
RAM DBS II Conventions Refrigeration Solid State Starter Conventions used in this manual Symbols The following list contains an explanation of the symbols used in this document. NOTE: 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. -
Page 5: Disclaimers
RAM Industries reserves the right to make changes in specifications shown herein or add improvements at any time without notice or obligation. -
Page 6: Handling And Storage
RAM DBS II Handling and Storage Refrigeration Solid State Starter 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. -
Page 7: Description
RAM DBS II 1.0 Description Refrigeration Solid State Starter 1.0 Description 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... -
Page 8: System Parameters
RAM DBS II 1.0 Description Refrigeration Solid State Starter 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) -
Page 9: Led Annunciation
RAM DBS II 1.0 Description Refrigeration Solid State Starter LED Annunciation LEDs, located on the front of the DBS control board, annunciate operating status and assist in troubleshooting while the starter door is open. READY LED (Green) indicates the DBS is in the READY state. -
Page 10: Trip Conditions
RAM DBS II 1.0 Description Refrigeration Solid State Starter 1.7.1 Trip Conditions Multiple trip conditions can be detected and displayed in either DBS control mode. The detection of a trip condition while the motor is running will cause it to stop. Refer to the Set Point Menu (Section 9, Table 13) for trip set points and defaults. -
Page 11: Specifications
RAM DBS II 2.0 Specifications Refrigeration Solid State Starter 2.0 Specifications H.P. Ratings TABLE 1 CHASSIS SIZE ---- ---- UL Short Circuit Capacity Ratings TABLE 2 of DBS Starters per UL 508 Standard WITH MAIN WITH MAIN WITH MAIN STARTER... -
Page 12: Dbs Specifications
RAM DBS II 2.0 Specifications Refrigeration Solid State Starter DBS Specifications TABLE 3 AC POWER SUPPLY 200V TO 600V RMS HP RATINGS SEE TABLE 1 CURRENT CAPACITY 69 AMPS - 900 AMPS NOTE: 115V CONTROL POWER MUST BE DERIVED CONTROL VOLTAGE 115 VAC, +/-15% FROM THE 3 PHASE POWER SOURCE. -
Page 13: Terminal Data (Line And Load)
RAM DBS II 2.0 Specifications Refrigeration Solid State Starter Terminal Data (Line and Load) Line Connections 75 Deg. Copper Only TABLE 4 Standard Line Terminals TABLE REVISED 4/8/09 230V 380V 460V 575V TRIP BREAKER WIRE RANGE AMPS FRAME SIZE 150/225 (1) #2–4/0 AWG... -
Page 14: Dimensional Data For Standard Enclosures
RAM DBS II 2.0 Specifications Refrigeration Solid State Starter Dimensional Data for Standard Enclosures TABLE 7 Standard Enclosure Sizes for Stand-Alone Starters (in) CUTOUT DISTANCE BOTTOM HP RANGE PER VOLTAGE FROM REAR CUTOUT NEMA TYPE 1 208 VOLT 230 VOLT... -
Page 15: Panel Layout
RAM DBS II 2.0 Specifications Refrigeration Solid State Starter Panel Layout FIGURE 2 M5/OL5 T1: Control Power Transformer TB1: Terminal Strip CB1: Circuit Breaker CT7: Current Transformer FU1: Control Power Transformer Primary Fuses DBS: Solid State Starter Chassis FU2: Control Power Transformer Secondary Fuse... -
Page 16: Receiving And Installation
RAM DBS II 3.0 Receiving and Installation Refrigeration Solid State Starter 3.0 Receiving and Installation 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. -
Page 17: Rating Factor
RAM DBS II 4.0 Wiring Refrigeration Solid State Starter 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: • Derate starter size 1.5% per degree C above 40 degrees C Ambient Temperature or 0.75% per degrees F above 104 degrees F Ambient Temperature. -
Page 18: Motor Connection
FORWARD Control Customer control wiring is to be connected to the controller’s main terminal block (TB1) in accor- dance with RAM wiring diagram supplied. Grounding Connect properly sized ground cable to the starter ground terminal. Refer to the National Electrical... -
Page 19: Field -Connected Relay Outputs
RAM DBS II 4.0 Wiring Refrigeration Solid State Starter 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. -
Page 20: Circuit Board Connections
RAM DBS II 4.0 Wiring Refrigeration Solid State Starter 4.9 Circuit Board Connections External Connections to Boards FIGURE 5 Relays Heatsink Thermostat SHUNT ____ SW2 SW1 Reset Configuration _ _ _ _ LEDs ____ ____ ALARM ____ • • •... -
Page 21: Setup Instructions
RAM DBS II 5.0 Set-Up Instructions Refrigeration Solid State Starter 5.0 Set-Up Instructions CAUTION! Equipment is at possibly lethal AC line voltage when AC power is connected. All phases must be disconnected by shutting down main power feed to this unit before it is safe to touch motor terminals or control equipment parts. -
Page 22: Ramp/Bypass Time Switch (Sw3)
RAM DBS II 5.0 Set-Up Instructions Refrigeration Solid State Starter 5.2.3 Ramp / Bypass Time - SW3 In the Step Ramp mode this 10-position rotary switch sets the amount of time the current draw is allowed to increase from its initial Current Step level (set by SW2) to a maximum of 500% FLA. The maximum time until the bypass contactor is energized is 5 seconds, plus the programmed ramp time. -
Page 23: Reset Pushbutton (Sw5)
RAM DBS II 5.0 Set-Up Instructions Refrigeration Solid State Starter 5.2.4 System Configuration - SW4 This 8-position DIP switch defines the operation of Control Mode, Overload Protection, Step Ramp/ Constant Current Mode and Chassis Configuration. The DBS system parameters are factory preset and require no changes for normal operation. -
Page 24: Dbs Control Board
RAM DBS II 5.0 Set-Up Instructions Refrigeration Solid State Starter 5.3 DBS Control Board FIGURE 8 READY LED RUN LED ALARM LED TRIP LED RESET PUSHBUTTON 16 POSITION ROTARY (See Table 10) #4 300% #0 200% #8 400% CURRENT #5 325%... -
Page 25: Fla Setpoint Tables
RAM DBS II 5.0 Set-Up Instructions Refrigeration Solid State Starter 5.4 FLA Set-Point Tables TABLE 9 Values shown are 100% FLA. Use value which most closely matches the motor nameplate current. NOTE: Maximum Service Factor of 125% for FLA Switch #0-8, 115% for FLA Switch #9-B, 100% for FLA Switch #C-F. -
Page 26: Start-Up Instructions
12) Inspect the motor lead connections and verify that the motor wires are connected to the DBS chassis in the right order for correct motor rotation per Figure 3, Section 4. 13) Verify that the control wire connections are made per the RAM wiring diagram. -
Page 27: Start-Up
RAM DBS II 6.0 Start-Up Instructions Refrigeration Solid State Starter Start-Up When starting the DBS controller, it is recommended that a clamp-on AC ammeter be used to continu- ously monitor current during the start-up procedure. A voltmeter placed across the starter output terminals (T1, T2, and T3) is also recommended. -
Page 28: Troubleshooting
RAM DBS II 7.0 Troubleshooting Refrigeration Solid State Starter 7.0. Troubleshooting CAUTION! Equipment is at possibly lethal AC line voltage when AC power is connected. All Phases must be disconnected by shutting down main power feed to this unit before it is safe to touch motor terminals or control equipment parts. -
Page 29: Trip Conditions
Shorted SCR (circuit breaker Defective SCR; Current Check SCRs per test procedure. trips about 5 seconds after measured when motor is not (See Appendix) Call RAM if energizing controller). running. defective. Do not replace in field. Defective circuit board. If SCRs are OK, replace circuit board. -
Page 30: Trip Conditions
Bypass contactor not energizing. Check continuity between terminals 2 and 3 on 15-pin connector on DBS control board; If none, call RAM Technical Services. NOTE: Control power must be Phase Reversal cycled OFF then ON to reset trip. -
Page 31: Alarm Conditions
RAM DBS II 7.0 Troubleshooting Refrigeration Solid State Starter TABLE 10 (continued) 7.3 Alarm Conditions SOLUTION ALARM CONDITION POSSIBLE CAUSE Check for voltage balance between Current between two phases Current Unbalance phases. Customer must consult power exceeds the setpoint value longer supplier if balance is abnormal. -
Page 32: Dbs Control/Display Unit
6. edit = EDIT MODE Operation • When power is applied, the display screen will read “RAM Industries.” After the DBS chassis performs preliminary system diagnostics, “MONITOR MENU” will appear on the display screen. • During normal operation the MONITOR menu should be selected. From this menu the operator can acknowledge alarm or trip conditions, monitor the current operating status of the system, and view the motor operating conditions. -
Page 33: Acknowledging Trips And Alarms
RAM DBS II 8.0 DBS Control Display Unit Refrigeration Solid State Starter Acknowledging Trips and Alarms • If an alarm or trip condition occurs, it will be displayed regardless of the menu selected at the time it occurs. • The display screen will read “Alarm - Enter = Ack” or “Trip - Enter = Ack”. -
Page 34: Dbs Control/Display Unit Menu Tables
RAM DBS II 9.0 DBS Display Unit Refrigeration Solid State Starter 9.0 DBS Display Unit Monitor Menu TABLE 12 This menu is used to display the current system conditions of the DBS controller. SELECTION UNITS DESCRIPTION Average Current Amps Current measured by the three current inputs averaged together and displayed as an rms value. - Page 35 RAM DBS II 9.0 DBS Display Unit Refrigeration Solid State Starter 9.0 DBS Display Unit (continued) Fault History Menu TABLE 14 This menu displays the fault history of the system. Refer to this menu when troubleshooting. DESCRIPTION SELECTION UNITS Last Trip Condition Type of trip last recorded.
- Page 36 RAM DBS II 9.0 DBS Display Unit Refrigeration Solid State Starter System Setup Menu TABLE 15 This menu displays the current system setup in the DBS controller. DEFAULT PARAMETERS SELECTION *Full Load Amps Motor nameplate full load current (SW1) See FLA - Starter Size Table 9...
-
Page 37: Dbs Log
RAM DBS II 10.0 DBS Log Refrigeration Solid State Starter 10.0 DBS Log Serial Number___________________ Switch Settings Fault History Menu (Copy settings as currently set on main control board) (Sw Pos) Setting Switch 1 - FLA __________ Last Trip Condition... -
Page 38: Maintenance
RAM DBS II 11.0 Maintenance Refrigeration Solid State Starter 11.0 Maintenance WARNING: Disconnect all incoming power to this equipment and lock-out and tag circuits prior to performing preventive maintenance. Discharge capacitors, if present. Positively ascertain that the equipment is totally de-energized, including possible foreign sources by using appropriate metering. - Page 39 RAM DBS II 11.0 Maintenance Refrigeration Solid State Starter Fuses • Examine all fuse clips and fuse blocks for signs of overheating or looseness. If there is any indication of reduced spring tension or overheating, replace the fuse clips or fuse block assembly.
- Page 40 RAM DBS II 11.0 Maintenance Refrigeration Solid State Starter Maintenance After a Fault Has Occurred CAUTION! After a fault has occurred, all equipment must be de-energized, disconnected, and isolated to prevent accidental contact with live parts. Check voltage on all terminals before touching or working on equipment.
-
Page 41: Replacement Parts
RAM DBS II 12.0 Replacement Parts Refrigeration Solid State Starter 12.0 Replacement Parts DBS Chassis Sizes B1, B2, B3, C1, C2, C3 with RAM Contactor Item Replacement Parts Circuit Board Set RAM-400339-AF RAM-400339-AF RAM-400339-AF RAM-400339-AF RAM-400339-AF RAM-400339-AF Bypass Contactor RI1-F115A-120... - Page 42 RAM DBS II 12.0 Replacement Parts Refrigeration Solid State Starter 12.0 Replacement Parts (continued) DBS Chassis Sizes D1, D2, D3, E1, E2, E3 with ABB Contactor Item Replacement Parts D1-1 D1 or D2 Circuit Board Set RAM-400339-AF RAM-400339-AF RAM-400339-AF RAM-400339-AF RAM-400339-AF RAM-400339-AF...
-
Page 43: Starter Size Dipswitch Positions
RAM DBS II Appendix A Refrigeration Solid State Starter Appendix A Starter Size Dipswitch Positions FIGURE 9 to Determine Starter Size STARTER STARTER SWITCH SWITCH SIZE SIZE DOWN DOWN DOWN DOWN DOWN DOWN DOWN DOWN DOWN DOWN DOWN DOWN DOWN... -
Page 44: Typical Motor Connections
RAM DBS II Appendix B Refrigeration Solid State Starter Appendix B FIGURE 10 Typical Motor Connections 3 Wire Configuration 12 Lead 12 Lead Typical Parallel Connection Series Connection 6 Lead Motor (Dual Voltage) -
Page 45: Scr Test Procedure
RAM DBS II Appendix C Refrigeration Solid State Starter Appendix C SCR Test Procedure DANGER! Hazard of Burn or Electrical Shock. Make certain that all incoming sources of power have been disconnected, locked out, and tagged prior to working on this equipment. -
Page 46: Glossary
RAM DBS II Glossary Refrigeration Solid State Starter Glossary Alarm - A warning signal that an undesirable condition has been detected. The alarm LED will blink when an alarm condition is detected. See Section 1.6 for more alarm LED information. - Page 47 RAM DBS II Glossary Refrigeration Solid State Starter Glossary LCD (Liquid Crystal Display) - A readout device in which each digit is formed by strips of liquid-crystal material. LRC (Locked Rotor Current) - The steady-state current taken from the line with the rotor locked (stopped) and with the rated voltage and frequency applied to the motor.
- Page 48 INDUSTRIES 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...