1.0 RATINGS MAXIMUM HORSEPOWER NEMA SIZE MOTOR VOLTAGE CONTINUOUS AMPERE RATING

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2 SECTION 1 PERFORMANCE FEATURES 1.0 RATINGS NEMA SIZE MOTOR VOLTAGE MAXIMUM HORSEPOWER CONTINUOUS AMPERE RATING

3 SECTION 1 PERFORMANCE FEATURES 1.1 Specifictions Service Conditions Rated Voltage Input: Nominal voltage (+10%) Frequency: 50/60 HZ (+3HZ) Ambient Temperature: 0 to 50 C (32 to 122 F) Altitude: Sea level to 3500 feet Efficiency at Rated Output: 98% or better depending on selected model Performance Specifications Current Limit: 150 to 500% rated current Adjustable Accel/Decel:.5 to 15 seconds Current Limit Time Shutdown: 1 to 30 seconds Current Unbalance/Phase Loss Alarm: 5 to 50% balance Overload Capacity: 150% of rated current for 1 minute Service Factor: Adjustment Ranges (Typical) Current Limit 1 (P1): 150 to 500% rated current Deceleration (P4):.5 to 15 seconds Acceleration (P5):.5 to 15 seconds Current Limit Time (P6): 1 to 30 seconds Current On Level (P7): 5 to 30% rated current Instantaneous Overload (P8): 150 to 600% rated current Phase Loss (P9): 5 to 50% current unbalance External Feedback Cal (P17): 0 to 100% signal Current Limit 2 (P18): 0 to 500% rated current, Current ramp mode limit Safety Features A. Current Limit Time: If the motor remains in current limit for too long a time during start, it is an indication that the motor is not rotating or can't get up to full speed. When the current limit timer times out it operates relay K3 and shuts down the control. B. Phase Loss: The control has the ability to sense single phase current and will shut down the control if the motor is not receiving balanced three phase power. 2

4 SECTION 1 PERFORMANCE FEATURES Safety Features C. Current Alarm: If the Digi-Fire control is turned off and the motor is still drawing current, K4 relay (Auxiliary Board) will energize. K4's output can be used to operate the shunt trip in a system circuit breaker. D. Contactor Failure Alarm: Utilized with shunt duty starters employing a bypass contactor. If an auxiliary contact on the bypass contactor does not indicate that the contactor has closed, within two seconds of the Digi-Fire telling it to close, the Digi-Fire will shut down. E. All the Digi-Fire control alarm circuits open the holding circuit to the 1CR control relay. The alarms latch in and require a manual reset. The control will also reset when power is removed from the unit. 1.2 Description of Major Components Auxiliary Board PN A. Interlock and Control Relays: All interlock and control relay contacts rated 10 amperes, 115Vac. 1CR (Start/Run) 115Vac operated relay that is energized by the external run signal (Terminal 3). A 1CR holding contact (Terminal 2) provides for optional start/stop control with momentary signals. Another 1CR contact (Terminal 5) can be utilized to pull in an isolating contactor. K1 (Run) energized by the Digi-Fire control when the output reaches full voltage. The K1 contact (Terminal 4) is utilized to operate a shunting (bypass) contactor. K2 (Current On) energized by the Digi-Fire control when the current to the motor exceeds a present minimum level. The K2 contact (terminal 10) is utilized in parallel with the 1CR contact (Terminal 5) to provide for soft ftop when a series contactor is used. K2 will hold the series contactor in until motor current drops below minimum during turn off. K3 (Alarm) energized and latched in by the Digi-Fire control as a result: Phase Loss; Instantaneous Overload; Current Limit Time; Shunt Contactor Failure or the External Alarm. K3 contact disables the run control circuit at Terminal 1. Another K3 contact (Terminal 14) can be utilized to operate a remote alarm. 3

5 SECTION 1 PERFORMANCE FEATURES Auxiliary Board PN: (cont.) K4 (Control Failure) energized when the Digi-Fire control senses motor current while the unit is off. A time delay prevents false operation of K4 during the soft stop sequence. A K4 contact (Terminal 9) should be utilized to operate a shunt trip in the system circuit breaker. Control failure can also energize the K3 alarm relay thru control switch 4 (CS4) if a shunt trip is not used. K5 (Ready) energized approximately 2 seconds after power is turned on if there are no alarms. K5 drops out when K3 is energized and pulls back approximately 2 seconds after the alarm is reset. A K5 contact (Terminal 1) enables the run control circuit. LED 3 (RDY) located above K5 indicates that the relay is energized. B. 3 Phase Syncronization: 3 Phase line voltage is connected to terminal strip TBI. The syncronizing circuit converts these inputs into square wave signals that transition at the zero crossover of each phase. These signals are outputed to the Master Board at connector 03. C. Power Supplies: 35VCT AC power is connected from transformer T2 to connector 01. The power supplies output positive and negative unregulated 24VDC and positive and negative regulated 12VDC. LED's 1 and 2 indicate that the regulated supplies are on Master Board PN: The Master Board is divided into Two Major Sections: A. Analog Control Circuits: The analog control circuits are responsible for monitoring motor current and ramping the motor up to speed upon command. The alarm circuits monitor current balance, current overload and current limit time. Another control circuit energizes the signal to K1 relay when the motor is up to speed. The analog controls can be adjusted by the user to suit a particular application. LED 1 indicates that the starter has been enabled. B. Digital Logic Circuits: The digital logic circuits control the firing of the six power silicon controlled rectifiers (SCR's). The line sync signals and the command output from the analog section interface with the digital logic to turn each SCR on at the precise instant to allow smooth balanced current to the motor. The digital logic is not sensitive to phase rotation and can operate from 45 to 60 hertz. All SCR firing reference data is updated on every cycle. 4

6 SECTION 1 PERFORMANCE FEATURES Driver Board A. The Driver Boards isolate the SCR turn on gate, which is at line potential, from the low voltage pulses coming from the Master Board. B. Some Driver Boards also contain resistor - capacitor and metal oxide varistor (MOV) circuits to protect the SCR from potentially damaging voltage spikes Dual SCR Module A. The Dual SCR Module is an assembly of two power SCR's and two aluminum heatsinks.the SCR's are clamped between the heatsinks facing opposite directions. One SCR controls the positive half of the AC sine wave and the other SCR controls the negative half. Three dual SCR modules are required for full wave 3 phase control Heater Control Board (Optional) PN.'s & A. The Motor Winding Heater Control Board has been designed to work with the Digi-Fire Starter to energize motor windings at a reduced level to prevent water condensation in the motor. The Heater Control utilizes the Power SCR's to energize the motor windings at approximately 10% line voltage. The control turns on automatically 2 minutes after power on or motor off if the 'Heater Off-On' switch is in the On position. A 'Heater On' output can be used to operate an external pilot light to indicate heater operation. A safety circuit, built into theheater Control, will trip the starter circuit breaker if the heater current exceeds a present level Digi-Fire Monitor (Optional) PN: A. The Monitor Board can be connected into the Auxiliary Board at connector 20.This board can be mounted on the Auxiliary Board or located up to twenty feet away. The Monitor Board has an LED indicator for each of the following conditions: 1. Power On/Ready 6. Power On/Relay 2. Digi-Fire On 7. Phase Loss/IOL 3. Current On 8. Thermal Overload 4. Start Complete 9. Control Failure 5. Current Limit Timer The Monitor Board also has an alarm reset pushbutton and output terminals for an ammeter. 5

7 SECTION 1 PERFORMANCE FEATURES Thermal Watch Board (Optional) PN: A. The Thermal Watch Board monitors current amplitude with respect to time during starting and any overload condition. B. It inhibits motor restart whenever a potentially unsafe temperature condition in the motor or starter exists. C. The thermal overload indicator on the Digi-Fire monitor panel will flash on and off whenever the thermal watch board is inhibiting the starter. D. The Digi-Fire control will automatically reset and indicate 'Ready' after the thermal watch board has timed out and turned off the thermal shutdown alarm. E. The thermal watch board also incorporates a fan control relay for continuous duty or special shunt duty starters. The relay is energized when the Digi-Fire is started and stays on until the thermal watch circuit turns it off. This circuit keeps the fan running for only the time required to cool the starter power module after every run cycle. 6

8 SECTION 2 INSTALLATION AND START-UP 2.0 Wiring Connect the incoming power to Digi-Fire terminals L1, L2, L3 or to the line side of the main circuit breaker Connect the motor leads to Digi-Fire terminals T1, T2, T3 or to the output side of the shunting contactor. (Shunt Duty Units Only) Connect the external run control circuits to TB2 on the Auxiliary Board or TB3 on the starter panel, per drawings supplied with the unit. CAUTION: ALL POWER CONNECTIONS, ON THE STARTER SHOULD BE CHEC- KED TWICE A YEAR. LOOSE CONNECTIONS CAUSE LOCALIZED HEATING DETERIORATION OF MATERIALS AND LEAD TO SYSTEM FAILURE. ALL CONTROL CONNECTIONS ON THE STARTER, SHOULD CHECKED ANNUALLY. 2.1 Operation Check all board connections for proper mating. NOTE: Reference DNH Drawing The following adjustments have been factory set and must not be field adjusted: A. P10, P11, P12 (3 Phase Timing) B. P13, P14, P15 (3 Phase Balance) C. P2 (Voltage Control) full cw for starter application D. P7 (Current On Level) E. P8 (IOL Trip) The following adjustments have been factory set, but may be field adjusted to suit the installation: A. P1 (Current Limit 1) 250% of FLA specified or Mid Range B. P3 (Stability) Mid Range C. P4 (Deceleration) Mid Range D. P5 (Acceleration) 25% CW or 9 o'clock position E. P6 (Current Limit Time) seconds standard, 1.5 minutes for extended ramp starts F. P9 (Phase Loss) approximately 60% CW equal to 25% unbalance G. P16 (External Feedback Stability) Mid Range 7

9 SECTION 2 INSTALLATION AND START-UP Adjustments(cont.) H. P17 (External Feedback Cal) 80% cw I. P18 (Current Limit 2) 400% of FLA specified or 20% cw J. DS1-1 Enables current limit 1 (P1) DS1-2 On when external feedback not used DS1-3 Enables current limit timer alarm DS1-4 Enables current limit timer reset on start initialization K. CS1 Clamps remote current limit input (04-17) and current limit 2 (P18) to common L. CS2 Enables current ramp mode utilizing (P18) NOTE: CS1 Must be off with CS2 on CS3 Bypasses output voltage command signal around Acc/Dec amplifier CS4 Connects output of Acc/Dec amplifier to voltage control amplifier Switch settings for current limit or current ramp start on standard Digi-Fire starters. A. DS-1 = ON B. CS1 = OFF DS-2 = ON CS2 = ON DS-3 = ON CS3 = ON DS-4 = ON CS4 = ON Current Limit Adjustment, Current Limit Start A. Set current limit 2 (P18) full CCW B. Refer to DNH Drawing to determine the initial setting of current limit 1 (P1) Current Limit Adjustment, Current Ramp Start Set current limit 1 (P1) for % FLA according to Dwg To determine the setting of current limit 2 (P18) use the chart ( ) and find the current limit setting for the maximum allowable current (end of ramp). Subtract the setting of P1 from this number to get the setting for P18. Example: Size 4 Digi-Fire Motor FLA = 100 Set current limit time 2 (P1) for 200% initial starting current P1 Setting = 35 Set current limit 2 (P18) for 400% maximum starting current P18 setting = = 30 8

10 SECTION 2 INSTALLATION AND START-UP Turn On Power System. The Digi-Fire will not start until the power-on-timer (Auxiliary Board) times out and pulls in the ready relay (K5). Digi-Fire "Ready" is indicated by LED 3 (Ready) on the Auxiliary Board and on the optional monitor panel Energize The Run Control Circuit A. 1CR relay (auxiliary Board) should light indicating that the starter has been turned on. B. LED 2 (Master Board) should light indicating that the starter has been turned on Current Limit Start When the run circuit is enabled the Digi-Fire control will quickly ramp the motor current up to the setting of current limit 1 (P1). LED 1 (Master Board) will light indicating that the control is operating in the current limit mode. K2 relay (Auxiliary Board) will energize indicating current flow to the motor. If the motor does not rotate increase the current limit setting (P1) slowly until the motor begins to rotate and accelerate Current Ramp Start When the run circuit is enabled the Digi-Fire control will quickly ramp the motor current limit 1 (P1) LED 1 (Master Board) will light indicating that the control is operating in the current limit mode. K2 Realy (Auxiliary Board) will energize indicating current flow to the motor. Current limit will then smoothly increase up to the setting of current limit 2 (P18). The rate of increase is determined by the acceleration control (P5). CW adjustment of P5 increases the rate of acceleration The Digi-Fire will bring the motor up to full speed. After the control has been supplying full voltage to the motor for 3-5 seconds it will energize K1 Realy (Auxilliary Board) If the starter is a shunt duty control, K1 will energize the run (Bypass) contactor or an external pilot relay for the run contactor. 9

11 SECTION 2 INSTALLATION AND START-UP If the Digi-Fire control trips out immrdiately, while attempting to start, it is an indication that a sever current unbalance or a fault condition exists. Check all wiring from the Digi- Fire to the motor. Check to see the motor is wired correctly. If everything is in order, turn P9 one increment counter clockwise and restart the motor If the Digi-Fire control trips out several seconds after initiating a start, it is probably due to current limit timer. This is an indication that the current limit is set too low. For current limit starts, adjust current limit 1 (P1) cw until the motor accelerates to full speed within the allowed time. For current ramp starts you can adjust current limit 1 (P1) cw which moves the whole ramp higher. You ca adjust current limit 2 (P18) cw, which raises the end point of the ramp higher and you can decrease the acceleration time (P5) A normal stopping sequence occurs when the run control circuit is opened. On shunt duty units, the bypass contactor will immediately drop out. The control turns off the solid state power devices (SCR's) instantaneously or over a time determined by the deceleration ramp (P4) when soft stop is utilized If the motor becomes overloaded while operating the thermal or electronic overload relay or the Digi-Fire control current limit time will turn the unit off. The overload will have to be reset manually. The motor and the connected load should be checked before attempting a restart If the Digi-Fire control senses motor current, while the run circuit is de-energized, it trip the control failure circuit on the Auxiliary Board and energize K4 relay. The output of K4 relay can be used to energize the shunt trip solenoid in the system circuit breaker to remove all power to the unit. This alarm can be an identification of a shorted SCR (Silicon Controlled Rectifier). They can be checked (All Power Off) by putting an ohmeter across L1 &T1; L2 & T2; very low resistance (less than 2 ohms). 10

12 SECTION 3 MAINTENANCE 3.0 Master Board Replacement A. Carefully remove connectors 04 thru 09 noting where they are connected. B. The board is held by 6 nylon keepers. Carefully push the keeper tab into the center post and lift the board slightly. When all 6 have been done lift the board off. C. Place the new board on keepers and carefully push down until all 6 keepers snap into position. D. Replace all connectors. E. Repeat operation instructions. 3.1 Auxiliary Board A. Carefully remove connectors 01 thru 03 noting where they are connected. B. Remove wires from terminal strips TB1 and TB2. C. Remove and replace board in the same manner as described in Master Board section. D. Replace all connectors and wires to TB1 and TB2. Note: Take extra care to put all wires to proper terminal. E. Repeat operation instructions. 3.2 Auxiliary Board And Heater Control Board Replacement. A. If the starter was supplied with a Heater Control Board mounted over the Auxiliary Board, remove this board first. It is held by 4 nylon keepers similar to the Master Board. If the Heater Board is to be replaced, remove the control wires, one circuit at a time, from TB4 and attach to TB4 of the new board. Do not disconnect the wires to TB4 if only the Auxiliary Board is being replaced. Remove the 4 standoffs that mount the Heater Board. B. Carefully remove connectors 01 thru 03 from the Auxiliary Board noting where they are connected. C. Remove wires from Terminal strips TB1 and TB2. 11

13 SECTION 3 MAINTENANCE 3.2 Auxiliary Board And Heater Control Board Replacement(cont.) D. Remove and replace the board in the same manner as described in the Master Board section. E. Replace all connectors and wires to Tb1 and Tb2. Note: Take extra care to put all wires to the proper terminals. F. Repeat operation instructions. 3.3 SCR Module Replacement A. Carefully remove all circuit boards and wiring as required to enable removal of the power module cover. Note: Larger Digi-Fire Starters (Above 300HP) may have extensive wiring to the top cover. DO NOT remove this wiring unless you have a drawing or sketch of the connections. B. Remove the cover from the power module. It is held by screws located in the middle of the cover. C. Remove the power connections from the defective module. D. Pull the module out of its nest far enough to remove any control connections and then take it all the way out. E. Place the new SCR module into the nest connecting all control wiring. Note: Be sure that the insulator board retainers, if required, are in place on the SCR module. F. Replace the power connections. G. Check the position of all SCR modules and wires and replace the top cover. H. Carefully relace all circuit boards and wiring. I. Double check all connectors and terminals. J. Repeat operation instructions. 12

14 SECTION 4 ADDENDUM 4.0 List of Standard Drawings Typical Wiring Diagram Standard Starter Wiring Diagram Board Set Connection Diagram Master Board Calibration Starting Current Adjust Outline HP Shunt Duty Outline 150/200HP Shunt Duty Outline 250HP Shunt Duty Outline 300/350HP Shunt Duty Outline 400/500HP Shunt Duty System Monitor Panel Rev B Rev E Rev B Rev E Rev C Rev B Rev B Rev A Rev B Rev A Rev B 13

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26 SOLID STATE REDUCED VOLTAGE AC MOTOR STARTER MAINTENANCE AND REPAIR MANUAL TABLE OF CONTENTS SECTION 1 SECTION 2 SECTION 3 PREVENTATIVE MAINTENANCE TROUBLESHOOTING PROBLEMS PARTS REPLACEMENT NOTICE ONLY QUALIFIED ELECTRICIANS OR ELECTRONIC TECHNICIANS TRAINED IN THE SAFE AND PROPER USE OF ELECTRICAL TEST EQUIPMENT AND FAMILIAR WITH 600 VOLT CLASS ELECTRICAL SYSTEMS SHOULD PERFORM SERVICE OR MAINTENANCE ON THIS EQUIPMENT A

27 SECTION 1 - PREVENTIVE MAINTENANCE 1.0 DIGI-FIRE MAJOR COMPONENTS The basic Digi-Fire Starter is made up of two primary circuit boards plus either, one three phase SCR driver board or three single phase driver boards The Master Board contains all the analog control circuits: current, voltage and speed feedback, current limit, phase loss and acceleration and deceleration ramps. This board also contains the digital timing circuits that control the firing of the six SCR's required for a standard soft start controller The Auxiliary Board contains the DC power supplies, three phase line reference, control and alarm relays and a barrier type terminal strip for connecting the Digi-Fire into the system control circuit The Driver Board(s) contain the pulse transformers which isolate the SCR firing pulses and the SCR snubber circuit, which prevents false firing of the SCR's due to voltage transients Some Digi-Fire's may utilize other boards: Voltage Feedback, Pump Control, Power Saver, etc., for specialized applications. Descriptive data on these boards is supplied, in the instruction manual, provided with the starter. 1.1 PERIODIC MAINTENANCE When a Digi-Fire Starter is installed, all the electrical connections and particularly the power connections should be checked for proper torque Power connections should be checked every six (6) months after installation A

28 1.1 PERIODIC MAINTENANCE - (Continued) Control connections should be checked every twelve (12) months after installation Filters used with cooling fans should be cleaned every six (6) months under normal conditions and every three (3) months under severe conditions Any cooling fan that is not operating properly (noisy or slow) should be replaced immediately Larger Digi-Fire Starters may have a fuse in series with each snubber circuit. This fuse will open if the voltage transient is excessive. If the fuse opens, an indicator will light (starter is off). The system power should be turned off and the fuse replaced before attempting to operate the starter. If the fuse blows as soon as power is turned on, then, most likely a snubber component has failed and must be replaced The Digi-Fire Starter should be protected from any type of liquid spray. The circuit boards are coated with a clear epoxy for moisture protection but the power modules (operating at line voltage) could arc phase to phase or phase to ground under severe moisture conditions. SECTION 2 - TROUBLE-SHOOTING PROBLEMS 2.0 STARTER WILL NOT OPERATE AT ALL Check all system interlocks in the control circuit. Often remote alarm or control contacts are not closed. Look at the Digi-Fire monitor panel to see that the power on/ready light is on A

29 2.0 STARTER WILL NOT OPERATE AT ALL - (Continued) If the Digi-Fire will not even try to start, turn off main power and check all control fuses. NOTE: Fuses should be removed from the circuit and then checked for continuity Turn on power and observe that +_12V and -12V LED's are lighted on Auxiliary Board If one or both LED's are off, check AC voltage input at connector 01. You should have VAC from pin 1 to pin 2 and also from pin 1 to pin If there's no voltage on connector 01 and there is voltage (120 VAC) at TB2-6 to TB2-8 replace transformer T Turn off power and unplug connector 02 from Auxiliary Board. Turn power back on and observe LED's. If both LED's come on then there is most likely a fault on the Master Board If, after completing step , the LED's do not change, then the Auxiliary Board is bad. The Master Board could still be bad as well. Replace Auxiliary Board but do not plug in connector 02. Turn on power and check LED's. If LED's are now correct; turn off power, connect connector 02 and turn on power. If either power supply or LED does not light, turn power off and replace Master Board With power on check Digi-Fire Monitor Panel for indication of alarm If multiple alarms exist then do step A

30 2.0 STARTER WILL NOT OPERATE AT ALL - (Continued) If the Current Limit Timer, Phase Loss/IOL trip, or Control/SCR failure lights are on and the reset pushbutton does not clear, then the Master Board is most often bad If the Run Contactor Failure Light is on and the reset pushbutton does not clear, then the Auxiliary Board is bad If the Thermal Overload Light is on and cannot be reset, disconnect wires to Auxiliary Board TB2-18. If light still cannot be reset then the Auxiliary Board is bad If disconnecting wires to TB2-18 allows the Thermal Overload alarm light to clear, then check all devices connected to that circuit. Problem could be bad heatsink thermostat or faulty thermal overload relay. NOTE: If starter was running and then shut down on thermal overload, allow minutes for these devices to reset before energizing the reset button If Starter on light comes on when initiating a start, but nothing happens, check for on LED (LED2) on Master Board. If it is also on then Master Board is bad. Replace Master Board. 2.1 STARTER TRIES TO START BUT TRIPS OUT ON PHASE LOSS/IOL ALARM If the Starter attempts to start and the motor starts to bump and growl, shut off immediately. Check the three reference fuses supplying line voltage to the Auxiliary Board terminals L1, L2, and L3. With power off remove the fuses and check for continuity A

31 2.1 STARTER TRIES TO START BUT TRIPS OUT ON PHASE LOSS/IOL ALARM - (Continued) With a DC voltmeter set to the 20 volt scale, check for -6 +/- 0.5 volt between TPC on the Auxiliary Board and connector's 03-1, 03-2, and NOTE: Remove cap from connector 03 to facilitate this measurement If the unit passes and 2.1.2, the Auxiliary Board is most likely bad If the unit passes test and 2.1.2, the Master Board is most likely bad There is also the possibility that one or more of the power SCR's are bad. With power on and the starter off, check across the 'L' and 'T' terminals of each heatsink assembly. Your meter should be rated for line voltage and be set to atleast the 750 VAC range. You should read approximately 50% line voltage across each phase 'L' and 'T'. This reading is with the motor connected and the starter off. If you read very low (less than 50V) then there is one or two bad SCR's in that phase If the Starter attempts to start but the motor just sits there humming and doesn't rotate, then trips out on phase loss/iol alarm, a single phase condition exists. Either one phase of the AC line is open, one phase to or in the motor is open or the Starter is not firing all six (6) SCR's Check incoming lines to the Starter for three phase power. Check the motor leads for continuity thru all windings. Check that connectors 07, 08, and 09 are connected at the Master Board. Check AC volts to A

32 2.1 STARTER TRIES TO START BUT TRIPS OUT ON PHASE LOSS/IOL ALARM - (Continued) the Auxiliary Board terminals L1, L2, and L3. If all voltages are present then the Master Board is probably bad. 2.2 STARTER TIRES TO START BUT TRIPS OUT ON CURRENT LIMIT TIME If the motor attempts to start and doesn't get up to speed before the current limit timer trips out, you could have an overloaded motor, P1/P18 current setting adjusted too low, P5 acceleration setting adjusted for too long a time or P6 current limit timer adjusted for too short a time. NOTE: Refer to the Digi-Fire instruction manual for proper adjustment of these controls Use caution in adjusting the acceleration (P5) and current limit time (P6) to very long time settings. This could result in the motor or starter overheating, during start, and tripping out on thermal overload. 2.3 STARTER BRINGS MOTOR UP TO SPEED AND THEN DROPS OUT INDICATING RUN CONTACTOR FAILURE The Auxiliary contact on the bypass contactor is not closing the circuit between Auxiliary Board terminals TB2-15 and TB2-16, this is usually the problem. On rare occasions the Auxiliary Board could be bad. NOTE: These terminals are jumpered on continuous duty starters A

33 2.4 START TRIPS THE SYSTEM CIRCUIT BREAKER APPROXIMATELY TEN (10) SECONDS AFTER BREAKER IS TURNED ON The current on level control (P7) may have been set fully ccw. It should be set at the 10 o'clock position There may be bad SCR's in the Starter causing current to flow as soon as power is applied. Check SCR's per The Master Board may be bad and operating the K2 relay on the Auxiliary Board when no current is actually flowing. SECTION 3 - PARTS REPLACEMENT 3.0 MASTER BOARD REPLACEMENT Carefully remove connectors 04 thru 09 noting where they are connected The board is held by six (6) nylon keepers. Carefully push the keeper tab into the center post and lift the board slightly. When all six (6) have been done lift the board off Place the new board on keepers and carefully push down until all six (6) keepers snap into position., Replace all connectors Set field adjustments on new board to same position as the board that was replaced A

34 3.1 AUXILIARY BOARD REPLACEMENT Carefully remove connectors 01 thru 03 noting where they are connected Remove wires from terminal strips TB1 and TB Remove and replace board in the same manner as described in Master Board section Replace all connectors and wires to TB1 and TB2. NOTE: Take extra care to put all wires to proper terminals Repeat operation instructions. 3.2 AUXILIARY BOARD AND HEATER CONTROL BOARD REPLACEMENT If the Starter was supplied with a Heater Control Board mounted over the Auxiliary Board, remove this board first. It is held by 4 nylon keepers similar to the Master Board. If the Heater Board is to be replaced, remove the control wires, one circuit at a time, from TB4 and attach to TB4 of the new board. Do not disconnect the wires to TB4 if only the Auxiliary Board is being replaced. Remove the four (4) standoffs that mount the Heater Board Carefully remove connectors 01 thru 03 from the Auxiliary Board noting where they are connected Remove wires from terminal strips TB1 and TB Remove and replace the board in the same manner as described in Master Board section A

35 3.2 AUXILIARY BOARD AND HEATER CONTROL BOARD REPLACEMENT - (Continued) Replace all connectors and wires to TB1 and TB2. NOTE: Take extra care to put all wires to the proper terminals Repeat operation instructions. 3.3 SCR MODULE REPLACEMENT Carefully remove all circuit boards and wiring as required to enable removal of the Power Module cover. NOTE: Larger Digi-Fire Starters (above 300 HP) may have extensive wiring to the top cover. DO NOT remove this wiring unless you have a drawing or sketch of the connections Remove the cover from the power module. It is held by screws along 2 sides. On larger Digi-Fire units there may be additional screws located in the middle of the cover Remove the power connections from the defective module Pull the module out of its nest far enough to remove any control connections and then take it all the way out A

36 3.3 SCR MODULE REPLACEMENT - (Continued) Place the new SCR Module into the next connecting all control wires. NOTE: Be sure that the insulator board retainers, if required, are in place on the SCR Module Replace the power connections Check the position of all SCR Modules and wires and replace the top cover Carefully replace all circuit boards and wiring Double check all connectors and terminals Repeat operation instructions A

37 DNH INDUSTRIES FRAMPTON AVE., BLDG B, HARBOR CITY, CALIFORNIA TEL: FAX: E'MAIL: WEB: dnhindustries.com STANDARD CONDITIONS OF SALE (Applicable to all Quotations and Orders) CONTRACT Any acceptance by the Company of the Buyer's order is expressly made conditional on the Buyer's assent to any additional or different terms contained herein. All orders are received subject to acceptance and may be accepted only at the Company's headquarters at Harbor City, California. TAXES The Company's prices do not include any applicable sales, use, excise or similar taxes; the amount of any such tax which the Company may be required to pay or collect will be added to each invoice unless the Buyer has furnished the Company with an appropriate tax exemption certificate acceptable to the taxing authorities. PRICES Prices are FOB the Company's plant in Harbor City, California. Prices are subject to change without notice. Prices in effect at the time of shipment will apply. TERMS Terms are cash Net 30 days. Amounts past due are subject to a service charge. If the Company deems that, by season of the financial condition of the Buyer or otherwise, the continuance of production or shipment on the terms specified herein is not justified, the Company may require full or partial payment in advance. Certain orders may, because of their nature or the delivery involved, require progress payments. DELIVERY Shipping dates given by the Company are approximate and are based on prompt receipt of all necessary information regarding the order. The Company will use its best efforts to meet the scheduled date shown on the face hereof, but does not guarantee to do so. Failure to make shipments as scheduled does not constitute a cause for cancellation and/or for damages of any character. In the event of any delay requested by the Buyer or any delay caused by lack of shipping instructions, the Company will store all items ordered at the Buyer's risk and expense, and will invoice the Buyer for the full contract price of the apparatus on or after the date on which the same is ready for delivery. The Company is not responsible for any loss, damage or delay that may occur after goods have been accepted for shipment by the Transportation Company. Any such claim should be made to the carrier in accordance with Section 2 of the Uniform Bill of Lading. PACKING The Company does not charge for its standard packing for domestic shipment. The Buyer will be charged for export packing or other special packing required. No credit or deduction will be allowed if no packing is required. CANCELLATION All undelivered parts of any order may be cancelled by the Buyer at any time but only with the written approval of an authorized representative of the Company at the main office in Harbor City, California. If the Buyer fails to make payments to the Company in accordance with the terms hereof, the Company may at its option cancel all undelivered parts of any other by written notice to the Buyer. In the event of any cancellation of this order by either party, the Buyer shall pay to the Company the reasonable costs and expenses (including engineering expenses and all commitments to its suppliers and subcontractors) incurred by the Company prior to receipt of notice of such cancellation plus the Company's usual rate of profit for similar work. ENGINEERING DATA All engineering data, design information, engineering and shop drawings used in the completion of this order are the property of DNH Industries. SHIPPING CHARGES Shipments are FOB point of shipment. Freight will be prepaid and billed as a separate item on the product invoice on the basis of the charge listed by the Company applying to shipment from the point of manufacture to the destination. The above applies to all shipments with the following exceptions: FOB point of shipment, freight collect Parts, billable repaired apparatus, superceded apparatus sold at depreciated prices, mechanical accessories purchases and shipped separately. WARRANTY - PRODUCT Except as otherwise provided herein, all new apparatus sold by the Company is warranted to be free from defects in material and workmanship to the original user for one year from date of shipment by the Company or a period of 18 months from the date of shipment to the Buyer, whichever period is shorter. If within this period the Company receives from the Buyer written notice of any alleged defect in any such apparatus and if the apparatus is found not to be in conformity with this warranty (the Buyer having provided the Company a reasonable opportunity to perform any appropriate tests thereon) the Company will, at its option and expense, either repair the same or supply a replacement therefore. The Company under either option shall have the right to require the Buyer to deliver the apparatus for this purpose to a designated service center and the Buyer shall pay all charges for inbound and outbound transportation and for services of any kind, diagnostic or otherwise, accepting only the direct and actual cost of apparatus repair or replacement as provided above. Apparatus sold but not manufactured by the Company will be warranted as to defects in material and workmanship consistent with the warranty policy of the original manufacturer of the apparatus. WARRANTY - GENERAL The Company's liability under this warranty or any other warranty whether expressed or implied in law or fact shall be limited to the repair or replacement of defective material and workmanship and in no event shall it be liable for consequential or indirect damages. There are no other warranties, express or implied, including the implied warranties of merchantability and fitness for a particular purpose. REGULATORY LAWS AND/OR STANDARDS The Company makes no promise or representation that its product will conform to any federal, state or local laws, ordinances, regulations, codes or standards, except as particularly specified and agreed upon for compliance in writing as a part of the contract between Buyer and Company. The Company prices do not include the cost of any related inspections or permits or inspection fees. EXPORTS Special procedures involved in Export business require the use of DNH Industries Standard Conditions of Sale to be modified. In general, these modifications will cover: FOB point and method of shipment Freight inside and outside U.S.A. spelled out Payment generally an irrevocable confirmed letter of credit through a Los Angeles, California bank acceptable to DNH Industries. Down payment or payment in full with a purchase order. Export documentation charges at $35.00 per shipment Export packaging, if required