EasyManua.ls Logo

RAM DBS II User Manual

RAM DBS II
48 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
Digital Bypass Solid State Starter
Operator's Guide
and Instruction Manual
DBS II
MA-0002 • REFRIGERATION DBSII / JUNE 09 / REV 1
INDUSTRIES
LLC
StockCheck.com

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the RAM DBS II and is the answer not in the manual?

RAM DBS II Specifications

General IconGeneral
BrandRAM
ModelDBS II
CategoryController
LanguageEnglish

Summary

Product Description and Features

1.1 Overview

General introduction to the DBS (digital bypass solid state) reduced-voltage starter.

1.2 Standard Features

Details the key functionalities and capabilities of the DBS starter, such as universal source matching.

1.3 System Parameters

Explains configurable system parameters like FLA, current level, and control modes.

1.4 Control Mode

Describes the operational modes available for the DBS starter, including display control.

1.5 Operating States

Defines the different operating states (READY, START, RUN, TRIP, COOLDOWN) of the DBS.

1.6 LED Annunciation

Explains the meaning of the LEDs on the DBS control board for status indication.

1.7 Electronic Motor Overload Protection and Monitoring

Details the integrated electronic motor protection features and monitoring capabilities.

1.7.1 Trip Conditions

Lists and describes various trip conditions that can cause the DBS to stop the motor.

1.7.2 Alarm Condition

Describes alarm conditions, including current unbalance, and their annunciations.

Specifications and Data

2.0 Specifications

Presents technical specifications including HP ratings and UL short circuit capacity.

HP Ratings

Table detailing HP ratings for various DBS chassis sizes across different voltages.

UL Short Circuit Capacity Ratings

Specifies UL short circuit capacity ratings for DBS starters per UL 508 Standard.

DBS Specifications

Provides a comprehensive list of DBS specifications including power supply, current capacity, and modes.

Terminal Data (Line and Load)

Details terminal data for standard and alternate line, and load connections.

Dimensional Data for Standard Enclosures

Details dimensional data for standard enclosures for stand-alone starters.

Installation and Wiring

3.0 Receiving and Installation

Guidelines for receiving, handling, mounting, and installing the DBS controller.

3.1 Receiving

Steps for inspecting the controller upon receipt and checking for shipping damage.

3.2 Mounting and Cleaning

Instructions on proper mounting techniques and cleaning procedures for the enclosure.

3.3 Environment

Specifies the environmental conditions required for optimal DBS controller operation.

3.4 Derating Factor

Explains derating requirements for DBS enclosures based on ambient temperature and altitude.

4.0 Wiring

Covers wiring requirements and best practices for the DBS controller.

4.1 Incoming Power

Details how to connect incoming power wires to the DBS controller.

Recommended Tightening Torque

Provides recommended torque values for various wire sizes and screw types.

4.2 Motor Connection

Instructions for connecting motor leads to the DBS bypass contactor.

4.3 Control

Guidance on connecting customer control wiring to the main terminal block.

4.4 Grounding

Procedures for properly grounding the starter to an earth ground.

4.5 Field Connected Relay Outputs - TB1

Details the use of field-connected relay outputs for controlling external devices.

4.6 Communication Ports - J1

Information on communication ports for display and network connectivity.

4.7 Power Factor Correction Capacitors (Option)

Guidance on connecting optional power factor correction capacitors.

4.8 Lightning Arrestor (Option)

Recommendations for installing a lightning arrestor for surge protection.

4.9 Circuit Board Connections

Illustrates external connections to the DBS control and power boards.

Setup and Configuration

5.0 Set-Up Instructions

Comprehensive guide for setting up and configuring the DBS controller.

5.1 Inspection

Initial inspection steps before applying power and making adjustments.

5.2 Setup Switches

Details the function and settings of various switches (SW1-SW6) on the DBS control board.

5.2.1 Motor FLA - SW1

Setting the 16-position rotary switch for motor FLA based on chassis size.

5.2.2 Current Step - SW2

Configuring the current step switch for Constant Current or Step Ramp modes.

5.2.3 Ramp / Bypass Time - SW3

Adjusting the ramp or bypass time using the SW3 switch.

5.2.4 System Configuration - SW4

Defining operation modes and configurations using the 8-position DIP switch.

5.2.5 Reset - SW5

Using the pushbutton to acknowledge fault conditions.

5.2.6 Starter Size - SW6

Configuring the DBS software for chassis size using the SW6 switch.

5.3 DBS Control Board

Diagram and explanation of the DBS control board layout and switch positions.

5.4 FLA Set-Point Tables

Reference tables for setting FLA values based on starter size and motor nameplate.

Start-Up Procedures

6.0 Start-Up Instructions

Step-by-step guide for safely starting up the DBS controller and motor.

6.1 Preliminary Inspection

Essential pre-start checks to ensure safety and correct installation.

DANGER! Hazard of Burn or Electrical Shock.

Critical safety warning regarding high voltage hazards during startup.

6.2 Start-Up

Procedures for powering up and starting the motor with the DBS controller.

6.2.1 Power-Up

Steps for applying power and initial system diagnostics.

6.2.2 Starting

Detailed steps for accelerating the motor and reaching full speed.

CAUTION! Do not allow motor to remain energized if it stalls.

Important caution about immediate de-energization if the motor stalls.

6.3 Re-adjustments

Guidance on fine-tuning settings after initial motor start-up.

Troubleshooting and Diagnostics

7.0 Troubleshooting

Guide to identifying and resolving common problems with the DBS controller.

7.1 Start-Up Problems

Diagnoses and solutions for issues encountered during the start-up phase.

7.2 Trip Conditions

Details various trip conditions, their possible causes, and troubleshooting solutions.

7.3 Alarm Conditions

Explains alarm conditions, their causes, and the corresponding solutions.

LED and Relay Status

Table showing LED and relay status for different alarm and trip conditions.

Control Display Unit Operation

8.0 DBS Control Display Unit - KL4

Overview of the KL4 control and display unit interface.

8.1 Description

Details the components and display characteristics of the KL4 unit.

8.2 Operation

Instructions on navigating menus, viewing status, and operating the DBS via the KL4 unit.

8.3 Acknowledging Trips and Alarms

Procedure for acknowledging trip and alarm conditions using the ENTER key.

8.4 Editing Set Points

Steps for modifying operating parameters and set points through the interface.

8.5 Confirming System Setup

How to view current system setup values using the interface.

8.6 System Override Functions

Explanation of functions like clearing thermal capacity and fault history.

Display Unit Menus

9.0 DBS Display Unit

Details the various menus available on the DBS display unit.

Monitor Menu

Description of the Monitor Menu for viewing system conditions.

Set Point Menu

Description of the Set Point Menu for editing parameters.

Fault History Menu

Description of the Fault History Menu for reviewing past faults.

System Setup Menu

Description of the System Setup Menu for current system configuration.

Data Logging

10.0 DBS Log

Provides sections for logging switch settings, fault history, set points, and system setup.

Switch Settings

Section to record current settings of the main control board switches.

Fault History Menu

Area to log detailed information about the last trip condition.

Set Point Menu

Area to log current set point values for various parameters.

System Setup Menu

Area to log current system setup parameters.

Maintenance Procedures

11.0 Maintenance

Guidelines for performing periodic preventive maintenance on the DBS controller.

WARNING: Disconnect all incoming power...

Critical safety warning for de-energizing equipment before maintenance.

Enclosures

Instructions for inspecting and maintaining the controller's enclosure.

Wiring

Checks for wiring integrity, looseness, and discoloration during maintenance.

Disconnecting Means

Maintenance checks for disconnect devices and their components.

Fuses

Procedures for inspecting and replacing fuses.

Contactors and Relays

Maintenance steps for contactors, relays, and their terminals.

General

General maintenance recommendations including part ordering and drawing updates.

Electronic Equipment

Inspection of circuit boards for signs of wear or damage.

Maintenance After a Fault Has Occurred

Procedures for inspection and repair after a fault condition.

CAUTION! After a fault has occurred, all equipment must be de-energized...

Critical caution for safe inspection and repair after a fault.

Restoring to Service

Steps to follow before re-commissioning the equipment after a fault.

Replacement Parts

12.0 Replacement Parts

List of replacement parts for various DBS chassis sizes.

DBS Chassis Sizes B1, B2, B3, C1, C2, C3 with RAM Contactor

Parts list specific to DBS chassis sizes B1, B2, B3, C1, C2, C3.

DBS Chassis Sizes D1, D2, D3, E1, E2, E3 with ABB Contactor

Parts list specific to DBS chassis sizes D1, D2, D3, E1, E2, E3.

Appendices

Appendix A: Starter Size Dipswitch Positions

Diagram and table showing dipswitch settings for determining starter size.

Appendix B: Typical Motor Connections

Illustrations of 12-lead parallel, 12-lead series, and 6-lead motor connections.

Appendix C: SCR Test Procedure

Step-by-step instructions for testing Silicon Controlled Rectifiers (SCRs).

DANGER! Hazard of Burn or Electrical Shock.

Critical safety warning regarding electrical hazards during SCR testing.

Glossary

Glossary of Terms

Definitions of key terms and acronyms used in the manual.

Alarm

Definition of an alarm signal and its indication.

Ambient Temperature

Definition of the temperature surrounding the device.

Average Current

Definition of the averaged RMS current reading.

Bypass Time

Definition of the delay before the bypass contactor engages.

Constant Current Mode

Definition of the mode where starting current is maintained at a constant level.

Current Phase A

Definition of the live current reading for Phase A.

Current Step

Definition of the initial current limit value for starting modes.

Current Unbalance

Definition of current imbalance between phases.

Elapsed Run Time

Definition of time since the last start.

Fault

Definition of an undesirable condition causing an alarm or trip.

FLA (Full Load Amps)

Definition of the current a motor normally draws at rated load.

Heatsink

Definition of metal used to dissipate heat from components.

Inline Configuration

Definition of a motor connection method passing current through SCRs.

Jam

Definition of an increase in motor load causing current to rise.

Jam Current Level

Definition of the allowed current percentage for sudden load increase.

Jam Run Delay

Definition of the time duration for exceeding Jam Current Level.

LCD (Liquid Crystal Display)

Definition of a device displaying information using liquid-crystal material.

LRC (Locked Rotor Current)

Definition of steady-state current with rotor locked.

NEMA

Acronym for National Electrical Manufacturers Association.

Phase Loss

Definition of a loss of current or voltage in a polyphase circuit.

Phase Reversal

Definition of incorrect phase rotation detection.

PLL

Definition of a phase-locked loop electronic circuit.

SCR (Silicon Controlled Rectifiers)

Definition of a semiconductor device triggered by a gate pulse.

Service Factor

Definition of allowable overload indicated by a multiplier.

Stall Time

Definition of maximum time at locked rotor current without damage.

Step Ramp Mode

Definition of a mode where current ramps to 500% over time.

Thermal Capacity

Definition of allowable thermal energy absorption.

Thermal Capacity Used

Definition of calculated thermal capacity consumed by the motor.

Thermal Overload Level

Definition of the percentage of thermal capacity consumed.

Trip

Definition of a condition stopping the motor to prevent damage.