Eaton Cutler-Hammer DS6 Series Handbuch

Effective June 2009

Instructional Leaﬂet IL03901001E

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 elec-

trically. The DS6 line uses four silicon-controlled

rectifiers (SCRs) that are connected in a full wave-

power bridge on two phases. The voltage and cur-

rent 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 ener-

gized 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 pack-

ing materials for the carrier to review.

Verify that the unit’s catalog number and options

match those stated on the order/purchase form.

Instructional Leaﬂet IL03901001E

Effective June 2009

DS6 series soft start controllers

EATON CORPORATION www.eaton.com

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.

Figure 1. 25- to 75-Horsepower Models

Figure 2. 100- to 150-Horsepower Models

1.18

(30.0)

1.18

(30.0)

0.86

(22.5)

0.86

(22.5)

3.66

(93.0)

5.08

(129.0)

6.34

(161.0)

1.38

(35.0) 5.47

(139.0)

6.89

(175.0)

1.38

(35.0) 1.38

(35.0)

0.59

(15.0)

0.59

(15.0)

4.25

(108.0)

2.07

(52.5) 7.01

(178.0)

8.47

(215.0)

6.22

(158.0)

7.87

(200.0)

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 MAL-

FUNCTION. 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

Screw Size + Flat

and Lock Washer Quantity

Torque

Requirements

Unit Weight

Lbs (kg)

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)

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

of 1% of rated current per Kelvin

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

for each 100m

Humidity Functional to 95% noncondensing.

Operating orientation Less than 30 degrees from horizontal

Minimum clearance—

upper and lower

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), con-

sult documentation of the breaker used (ionization emissions)

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

accordance with EN 55011/22 Class A

Instructional Leaﬂet IL03901001E

Effective June 2009

DS6 series soft start controllers

EATON CORPORATION www.eaton.com

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).

Figure 3. Power Wiring Diagram for 230/400 and 400/460V

Line Voltages

135

L1 L2 L3

246

T1 T2 T3

DS6

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.

Table 4. Product Selection—Horsepower Ratings

Catalog Number

Rated

Current

(A)

Motor Power

Maximum Allowable

Breaker Size 

Maximum Allowable

Fuse Size 

200V 230V 460V

(hp) (hp) (hp)

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

 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

Catalog Number

Rated

Current

(A)

Motor Power

Maximum Allowable

Breaker Size 

Maximum Allowable

Fuse Size 

230V 400V

(kW) (kW)

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.

Instructional Leaﬂet IL03901001E

Effective June 2009

DS6 series soft start controllers

EATON CORPORATION www.eaton.com

Control wiring

A minimum of 16 AWG should be used between the power supply

and the 24 Vdc + and – terminals.

Terminal connections are to be secured to a torque value of 3.6 lb-in.

Control wiring is connected to the DS6 soft start controller by a

9-pin terminal block located on the front of the unit. Use the wiring

diagrams in Figure 4, Figure 5, and the information in Table 7

as guides.

Figure 4. Direct Start

Table 6. Terminal Designations

Terminal Description

OV Control ground or power supply common

+24 Plus 24 Vdc from power supply

–A2 Common with 0V, connected externally

EN Start command enable/stop command

+A1 Start command/ramp stop command

13, 14 Top of ramp contacts—NO

23, 24 Ready status contacts—NO

0V +24

TOR Ready

–A2 EN +A1 13 14 24

+24V

0V +24 –A2 EN +A1 13 14 2423

Control Wiring Terminal Block

Figure 5. Direct Start With Soft Stop

Table 7. DS6 Terminal Control Block Wiring

Name

Block

Designation Input Connections

Circuit

common

0V Common Common

Power +24 24 Vdc nominal (see 24 Vdc power

supply requirements) section for

sizing of power supply

+24 Vdc power from

power supply

–A2 –A2 Control power common Common

Enable EN 24 Vdc maintained START command with

+A1 energized. Remove

for STOP command

+A1 +A1 24 Vdc maintained START command

with EN energized.

Remove for STOP

RAMP command

Relay 13 NO contact rated @ 250 Vac,

3A resistive, 1A inductive

Top of ramp signal–

in bypass

14 NO contact rated @ 250 Vac,

3A resistive, 1A inductive

Top of ramp signal–

in bypass

Relay 23 NO contact rated @ 250 Vac,

3A resistive, 1A inductive

READY status signal

24 NO contact rated @ 250 Vac,

3A resistive, 1A inductive

READY status signal

0V +24

TOR Ready

-A2 EN +A1 13 14 24

+24V

Instructional Leaﬂet IL03901001E

Effective June 2009

DS6 series soft start controllers

EATON CORPORATION www.eaton.com

24 Vdc power supply requirements

The 24 Vdc power supply for your DS6 soft start controller must

meet or exceed the following requirements:

• Minimum steady-state current: 1W (35 mA)

• Minimum start command current: 2W (65 mA)

• Minimum bypass contactor inrush current: 600 mA for 50 ms

• Voltage stability: 24 Vdc +10%/–15%

Operations

• 24 Vdc control voltage is applied to terminal +24

• The status light will illuminate after the starter has completed

initialization, closing contacts 23/24, and indicating READY status

• Line voltage is applied to the starter by closing the

mains contactor

• The soft start controller issues a START command by applying

+24 Vdc to terminals EN and +A1. Contacts 13 and 14 will close

when the end of the ramp time is reached

ote:N Bypass contactors close at the end of ramp time + ~0.18 seconds.

It is important to correctly set the ramp time, so the bypass contactors will

close within 5 seconds after the motor has achieved rated RPM.

• To initiate a STOP command, remove +24 Vdc from terminal EN

and +A1 or EN

• To initiate a RAMP STOP command, remove +24 Vdc from

terminal +A1

Adjusting the soft start controller parameters

There are three adjustments to the DS6 soft start controller:

• t-Start = ramp time

• u-Start = initial voltage (torque)

• t-Stop = stop ramp time

ote:N In all cases, motor rotation should begin within 2–3 seconds after the

START command is sent to the soft start controller.

Figure 6. DS6 Ramp Functions

u-Start

t-Start t-Stop

t-Stop = 0

13 14

TOR

(Top of Ramp)

Instructional Leaﬂet IL03901001E

Effective June 2009

DS6 series soft start controllers

EATON CORPORATION www.eaton.com

Table 8. DS6 Parameters

Application t-Start t-Stop u-Start Break-Away Torque Remarks

Axial-flow compressor 25s — 48% 50%

Bandsaw 10s — 42% 35%

Drill, unloaded 10s — 29% 10%

Crusher, empty at start 20s — 56% 75% Possible high inertia

Carding machine (combing cotton) 20s — 64% 100%

Conveyor, horizontal, loaded 25s 30s 76% 150%

Conveyor, horizontal, unloaded 25s 30s 48% 50%

Conveyor, vertical, loaded 25s 30s 82% 175%

Conveyor, vertical, unloaded 25s 30s 59% 85%

Conveyor, vertical drop, loaded 25s 30s 37% 25%

Conveyor, vertical drop, unloaded 25s 30s 44% 40%

Crusher, swing hammer 25s — 70% 125% Eccentric load, high starting torque

Chiller 5s — 37% 25%

Piston compressor, unloaded 10s — 64% 100%

Circular saw 20s — 48% 50% Possible high inertia

Ball mill 20s — 48% 50% Eccentric load

Flour mill 20s — 44% 50%

Mixer, liquids 10s — 37% 40%

Mixer, plastic materials 10s — 70% 125% Possible high starting torque

Mixer, powder materials 10s — 70% 125% Possible high starting torque

Mixer, dry materials 15s — 56% 75%

Pelletizing machine 20s — 64% 100%

Pump, piston 25s 30s 82% 175% Possible high starting torque

Pump, centrifugal 10s 30s 37% 25%

Moving pavement, unloaded 20s — 37% 25%

Escalator 10s — 48% 50%

Rotary compressor, unloaded 20s — 42% 35%

Agitator 15s — 42% 35%

Grinder, unloaded 10s — 37% 25% Possible high inertia

Feed screw 20s — 82% 175% Possible high starting torque

Compressor, screw, unloaded 25s — 40% 30%

Press, flywheel 25s — 76% 150% Possible high starting torque

Drier, rotating 20s — 64% 100%

Blower, axial fan, flaps closed 40s — 37% 25%

Blower, axial fan, flaps open 30s — 37% 25%

Blower, centrifugal fan, valve closed 40s — 42% 35%

Blower, centrifugal fan, valve open 30s — 35% 20%

Vibroconveyor 25s — 76% 150% Possible high starting torque

Vibrating screen 20s — 51% 60% Possible high starting torque

Rolling mill 25s — 48% —

Washing machine 25s — 64% 100% High transmission ratio

Centifuge 60s — 61% 90% High inertia, long ramp time

otes:N u-Start % values are voltage settings, as the starting torque is dependent on the application.

Applications with high starting torque are not suitable for DS6 soft start controllers. In some cases, over-sizing to a larger unit may be a solution.

Consult Eaton’s Technical Resource Center at (877) 386-2273.

Instructional Leaﬂet IL03901001E

Effective June 2009

DS6 series soft start controllers

EATON CORPORATION www.eaton.com

Table 9. DS6 Basic Troubleshooting Guide

Possible Problem Possible Solution

Fault LED illuminates during the operation of the DS6 soft start controller

Control voltage loss Check for the following conditions: power supply failure and/or intermittent operation and volt-

age stability. Check all connections for condition and security. Verify proper size and capacity

of the power supply.

EN and heat sink temperature less than 0°C Verify that unit temperature is not below 0°C during application of control voltage or starter

operation.

Fault LED illuminates during start ramp, TOR, or stop ramp

Mains connection open or undervoltage Check for the following conditions: verify presence and stability of mains voltage. Check sys-

tem for phase loss. Check main breaker and/or isolation contactor and/or reversing contactors

are not open or have been cycled during starter operation, and verify proper operation. Verify

all connections for condition and security.

Motor connection open Check for the following conditions: verify proper motor cable connections, and check for condi-

tion and security. Verify installation and integrity of motor coupling to load. Test motor for

proper condition. Check that isolation and/or reversing contactors are not open.

Heat sink temperature less than 0°C or above 80°C Verify that unit temperature is not below 0°C or above 80°C.

Bypass contactor(s) closed during start ramp or stop ramp time Verify that bypass contactor(s) do not close when START command is initiated and remain

open until top of ramp is achieved. Verify that bypass contactor(s) open when STOP command

or STOP RAMP command are initiated.

Bypass contactor not closed after ramp time Verify that bypass contactor(s) close at top of ramp and remain closed until STOP command or

STOP RAMP command are initiated.

SCR fault Verify that one or more of the SCRs are not open. Verify that one or more of the SCRs are

not shorted.

Faults

In the event of a motor stop due to a trip condition by the soft start

controller, the FAULT status LED will be illuminated (flashing). In this

case, one or more conditions found in Table 9 may have occured.

Use standard troubleshooting techniques to determine the cause of

the trip. The DS6 does not provide any specific method of identifying

the cause of the trip.

Eaton Corporation

Electrical Sector

1000 Cherrington Parkway

Moon Township, PA 15108

United States

877-ETN-CARE (877-386-2273)

Eaton.com

Printed in USA

Publication No. IL03901001E / Z8490

June 2009

PowerChain Management is a registered

trademark of Eaton Corporation.

All other trademarks are property of their

respective owners.

Instructional Leaﬂet IL03901001E

Effective June 2009

DS6 series soft start controllers

Service

For additional information on this product, please call Eaton’s

Technical Resource Center at (877) 386-2273 or visit our Web site

at www.eaton.com.

Service and repair is available from Eaton or several factory-

authorized regional service centers. Please contact Eaton’s Product

Integrity Center at (800) 345-0434 for the location nearest to you.

For field service or start-up assistance 24 hours a day, 7 days a

week, please call (800) 498-2678.

The following chart describes LED operation during motor start,

run, and stop conditions.

Table 10. LED Operation During Motor Start, Run, and

Stop Conditions

Condition Motor Status

Ready

Contacts

TOR

Contacts Error LED Run LED

24 Vdc applied

and initialization

complete

Off Closed Open Flashing—

short pulse

Flashing—

short pulse

Terminal EN

energized

Off Closed Open Off Flashing—

short pulse

Terminals EN and

+A1 energized

START

command—

motor rotation

Closed Open Off Flashing—

long pulse

End of ramp time At rated RPM Closed Closed Off On

Terminal +A1

de-energized

EN-energized

STOP

command—

ramp stop

Closed Open Off Flashing—

long pulse

Terminal EN

de-energized

STOP

command—

coast

Closed Open Flashing—

short pulse

Flashing—

short pulse

Error detected Off Open Open Flashing—

long pulse

Off

otes:N Terminals EN and +A1 may be connected together to provide START

and STOP commands. If this is the case, a normal ramp start with a normal

stop (coast) will be selected.

When signaling a STOP command, either terminal may be de-energized. If

terminal +A1 is de-energized, a ramp stop will be selected. If terminal EN is

de-energized, a normal stop (coast) will be selected. To initiate another start,

simply re-energize the controlled (switched) terminal.

During ramp start or ramp stop, the RUN LED will be flashing—long pulse.

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