Instructional Leafl et IL03901003E Effective January 2011 DS7 series soft start controllers, Frame 1 (412A) Introduction Eatons DS7 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 DS7 line uses four silicon-controlled rectifiers (SCRs) that are connected in a full wave-power bridge on two phases. The voltage and current applied to the motor are controlled by varying the SCR conduc- tion period. This, in turn, controls the torque devel- oped by the motor. After the motor reaches speed, a bypass relay is energized to bypass the SCRs. The DS7 is designed to fulfill the industrial service requirements of applications such as chiller start- ers, pump panels, and machine tools. This device meets all relevant specifications set forth by UL 508, IEC 60947-4-2, CE, C-Tick, and CSA . 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 units catalog number and options match those stated on the order/purchase form.Instructional Leafl et IL03901003E DS7 series soft start controllers, Frame 1 (412A) Effective January 2011 Table 2. Environmental requirements Storage Description Requirement It is recommended that the unit be stored in its original shipping Operating temperature 32 to 104F (0 to 40C) up to 140F (60C) with box/crate until it is to be installed. derating of 1% of rated current per Kelvin The unit should be stored in a location where: Storage temperature 13 to 140F (25 to 60C ) The ambient temperature is between 13 to 140F (25 to 55C) Elevation Up to 1000m up to 2000m with derating of 1% rated current for each 100m The relative humidity is between 0% and 95%, noncondensing Humidity Functional to 95% noncondensing The environment is dry, clean, and noncorrosive Operating orientation Less than 30 degrees from horizontal The unit will not be subjected to high shock or vibration conditions Minimum clearance 2.165 in (55 mm) to a wall, 0.984 in (25 mm) to an Upper and lower upper and lower NZM1 (size 1), 1.378 in (35 mm) to an NZM2 (size 2), consult documentation of the Mounting instructions breaker used (ionization emissions) The DS7 solid-state soft start controller is easy to mount. It does Minimum clearancesides 0.0 in (0 mm) not require any special tools. To aid you with panel layout, refer to Minimum clearanceface 0.198 in (5 mm) the dimension drawings shown in Figure 1. Drill and tap holes per Shock resistance 8g for 11 ms in any direction mounting hole/slot locations as shown. To mount the unit, use all the Vibration resistance 2M2 EN 60721-3-2: 10g (3.5 mm amplitude, hardware specified in Table 1 of this leaflet. Tighten to the specified 9 to 200 Hz) torque. Environment Suitable for installation in a pollution Degree 2 environment Approximate Dimensions in Inches (mm) Emissions The device is suitable for use in industrial environments in accordance with EN 55011/22 Class A 5.12 Power wiring 4.80 4.92 (130.0) (122.0) (125.0) Using the wiring diagram in Figure 2 and Table 3 as guides, connect the line and motor wiring in accordance with appropriate local and national codes. M4 Note: To provide optimum motor protection, the line and motor power wiring 3.74 should be tightly bundled and run perpendicular to the orientation of the DS7. (95.0) Soft start controller to motor cable length is not to exceed 325 ft (100m). 1.38 1.78 (35.0) (45.0) 1 L1 3 L2 5 L3 Figure 1. 4 to 12 ampere models DS7 DANGERHIGH 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 2 T1 4 T2 6 T3 INJURY, DEATH, OR SUBSTANTIAL PROPERTY DAMAGE. M DO NOT APPLY A DISCONNECT DEVICE ON THE OUTPUT OF THE DS7 3~ 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 Figure 2. Power wiring diagram CAUSE A MALFUNCTION. CLOSING THE DISCONNECT SWITCH WHILE THE SOFT START CONTROLLER IS OPERATING WILL RESULT IN POTENTIAL EQUIPMENT DAMAGE AND PERSONNEL HAZARD. Table 3. Power wire sizing and torque requirements Wire Size Torque Wire Strip Length Table 1. Mounting hardware and torque specifications 1810 AWG 10.62 lb-in 10 mm Screw Size + 2 x 2120 AWG 10.62 lb-in 10 mm Flat and Lock Torque Unit Weight Washer Quantity Requirements Lbs (kg) M4 4 10 lb-in (1.2 Nm) 0.8 (0.35) 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. 2 EATON CORPORATION www.eaton.com