DS-6
DEICING SYSTEM CONTROLLER
INSTALLATION MANUAL

CAUTION: Read all instructions carefully before installation.
Save this Installation Manual for future reference.

Introduction
Thank you for purchasing the DS-6 Deicing System Controller. Properly installed and maintained the DS-6 will provide years of trouble free service. The following paragraphs contain instructions on how to install, configure, operate, and maintain the unit.

DS-6 Mounting
The DS-6 is housed in a sturdy UL 508 NEMA 6/CSA 6/IEC 529 IP68-11 approved fiberglass enclosure. The overall dimensions of the DS-6 are 8¾"(223) x 11½"(292) x 5½"(140). The unit weighs 9 pounds.

The thermal probe for the DS-6 protrudes from the base of the enclosure. A mounting location should be selected that is away from heat sources or warm exhaust. The DS-6 enclosure should be mounted using the holes provided on the top and bottom of the enclosure. DO NOT DRILL HOLES THROUGH THE ENCLOSURE FOR MOUNTING! This can allow water to enter the enclosure causing a potential shock or fire hazard.

The DS-6 can be ordered with or without pre-punched conduit knockouts. If knockouts are to be punched in the field it is recommended that the DS-6 mounting plate assembly be removed. Disconnect the thermal probe, control switch, and indicator connectors in the upper right corner of the printed circuit board. Then, while supporting the DS-6 mounting plate, remove the four corner mounting screws. Reinstall the mounting plate with the supplied screws once the knock-outs are complete. Reconnect the thermal probe, control switch. and indicator connectors.

Voltage Selection, Power & Load Connection
The DS-6 controller power supply can operate from a 100-120VAC or 200-240VAC voltage source. In a three phase system this voltage will normally be derived by using one phase of the supplied power and neutral. Two voltage selection jumpers are supplied with each DS-6. The selection header is resident on the printed circuit board below the power supply transformer. For 100-120VAC use install two jumpers, one each across the header pins marked "120." For 200-240VAC use install one jumper across the header pins marked "240."

Four circuit breakers are mounted on DIN rail right and center. These circuit breakers are used to protect the DS-6 relays and attached loads. The 5A breaker to the far right supplies power for both the controller electronics and a low power load such as feed or sub-reflector deicing pads. In a three phase system this voltage will normally be derived by using one phase of the supplied power and neutral. The remaining three 25A breakers are used to supply power for the main reflector heating pads. One phase of a three phase system will normally be connected to each breaker in order to balance the load. Terminals 42, N1, N2, and N3 are supplied jumpered together and are used for neutral distribution. The green and yellow terminal block to the right of the 5A breaker is bonded to the enclosure and should be used for the earth ground connection point.

Power consumption for the DS-6 is 20W, 50-60 Hz. Each load relay is rated for 277 Vac at 30 Amps. Each breaker is rated at the nameplate current up to 415VAC. Consult local electrical codes for the wire color and size for both power and load connections.

Terminals 41/42 are normally used for connection of a low power (< 5A) load such as feed and/or sub-reflector heating pads. The remaining terminal blocks are used for connection of the main reflector deicing system. As can be seen in the diagram, a number of different methods may be used for terminating the deicing pads to the DS-6. The terminal blocks supplied will each accept up to two 10AWG leads. Therefore, up to 12 pads may be terminated without inserting two wires into any terminal block connection.

The group of four terminal blocks for each phase can be used to create a controller that can be field restrapped for different supply voltage ranges. The following figures do not consider current in-rush and are used as an example only. The diagram shown above demonstrates a method of wiring six 120VAC heating pads in a dual voltage configuration. We will assume each pad has a resistance of 15 ohms. When strapped for 120VAC the pads are placed in parallel. Therefore, the total resistance is 15 / 2 or 7.5 ohms. 120VAC / 7.5 ohms = 16A. 120VAC * 16A yields 1920W of heat. When strapped for 220VAC the pads are placed in series. The total resistance is 15 * 2 or 30 ohms. 220VAC / 30 ohms = 7.33A. 220VAC * 7.33A yields 1613W of heat, approximately the same as the 120VAC configuration.

If dual voltage operation is not a concern the terminal blocks may be used in any manner that limits the total current through each relay to the protected maximum of 25A.

Installing the Moisture Grid
Unlike the smaller DS series controllers the DS-6 is meant to be mounted close to the controlled load. A remote mount moisture grid is provided to allow open-sky placement without compromising controller location. The moisture grid is housed in a terminal adapter with a standard 3/4" male thread and has 4-#22 pigtails for connection to an extension cable terminated to the DS-6. Two conductors provide line voltage for powering the grid heater. The remaining two provide the moisture detection signal. A companion multi-conductor shielded 4-#22 cable is sufficient for interconnection. However, it is recommended that the cable be rated for at least 300VAC operation and that the cable be encased in either rigid or flexible conduit.

The white and green leads of the moisture grid power the grid heater and should be connected to positions 4 and 5 of the moisture grid interface terminal block. The red and black leads connect to the grid itself and should be terminated to positions 2 and 3 of the terminal block. Position 1 provides a ground connection for the cable shield.

Manual Override Switch Operation
An override switch is mounted on the side of the enclosure for testing and special operational requirements. Placing the switch in the "Automatic" position will allow the sensor to operate normally, activating the controlled equipment as needed. Placing the switch in "Manual On" will close the load relays, activating the controlled equipment. The "Standby/Reset" position provides two functions. Placing a non-triggered unit in "Standby/Reset" will prohibit triggering of the unit. Placing a triggered unit in "Standby/Reset" will clear the delay timer, open the load relays, and prohibit retriggering of the unit. The manual override switch works in concert with the external control/monitor inputs discussed below. Note that a "Standby/Reset" input from one source will override an "Automatic" or "Manual On" input from the other source.

External Control/Monitor Operation
An external control/monitor jack is provided on the DS-6. This interface can be used to either connect to the ASE DP-7B Remote  Control/Status Panel or support a customer-supplied remote control/monitor interface. Order the optional "C/M Cable" to access this feature.  The table to the left lists the signals carried by the cable.

Connecting Black to White will activate the "Manual On" function. Connecting Green to White will activate the "Standby/Reset" function. The Red/Orange leads are connected to an internal low power monitor relay. This relay, rated at 24 VAC/VDC at 400 mA, will close with the load relay and can be used to externally monitor activation of the sensor.

Moisture Grid Replacement
It is recommended that the DS-6 be powered down and the grid wiped clean with clear water at least once every 4 months. However, after a number of years, the corrosive elements left behind when water is evaporated out of the moisture grid will eventually damage the grid rings. The moisture grid can be easily replaced by ordering and installing a new "Moisture Grid Assembly".

THIS PROCEDURE SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL!

Open all power and load breakers connected to the DS-6. Open the cover of the condulet interconnect point for the moisture grid and interconnect cabling. Disconnect the old moisture grid leads, noting the order of connection. While holding the reducing bushing, unscrew and remove the old moisture grid. Install the supplied thread sealing tape onto the replacement moisture grid, place the new grid into the top hole and screw the assembly into the reducing bushing. Tighten the grid hand tight plus ¼ turn. Reconnect the new cable to the interconnect cable. Close the cover and reapply power.

Limited Warranty
The DS-6 is warranted against defects in workmanship and materials for two years from date of sale. This warranty does not apply to damage resulting from accident, misuse, or alteration nor where connected voltage is more than 10% above the configured operating voltage, nor to equipment improperly installed or wired or maintained in violation of this Installation Manual. No other written or oral warranty applies. No employee, agent, dealer or other person is authorized to give any warranties on behalf of ASE.

The customer shall be responsible for all costs incurred in the removal or reinstallation and shipping of the product for repairs. Within the limitations of this warranty, inoperative units should be returned, freight prepaid, to ASE, and we will repair or replace, at our option, at no charge to you with return freight paid by ASE. It is agreed that such repair or replacement is the exclusive remedy available from ASE and that ASE IS NOT RESPONSIBLE FOR DAMAGES OF ANY KIND, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGE. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above exclusion may not apply to you. The warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

AUTOMATED SYSTEMS ENGINEERING, INC.
2519 EAST SAINT VRAIN STREET
COLORADO SPRINGS, COLORADO 80909
PHONE: 719.599.7477 FAX: 719.599.7482