User Manual Bulletin 1608M MegaDySC Dynamic Voltage Sag Corrector 1608M—800 Amp, 208 Volt Models
Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
Table of Contents Ch 1 - Introduction Ch 2 - Installation Ch 3 - Communications Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 System Components . . . . . . . . . . . . . . . . . .
Table of Contents Ch 7 - Maintenance Ch 8 - Specifications 4 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Model Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Run System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 Introduction The Allen-Bradley Bulletin 1608M MegaDySC Dynamic Sag Corrector is engineered to provide years of trouble-free voltage sag (dip) protection. The patented DySC technology does not use batteries, requires only routine maintenance, includes three-stage transient voltage surge suppression, and has unparalleled energy efficiency. Most electronic devices found in industry today are susceptible to power disturbances.
Chapter 1 ATTENTION: Internal components can be easily damaged by electrostatic discharge (ESD). Do not touch circuit boards or electronic components with hands or metal objects. The MegaDySC is not rated to directly power life support equipment. • Ensure the area around the MegaDySC is clean and uncluttered. • Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the equipment.
Chapter 2 Installation System Components The Standard Run (SR) MegaDySC system consists of two enclosures including one 800A MegaDySC Module and one Automatic Bypass Switchboard. The Extended Run (ER) MegaDySC system consists of three enclosures including one 800A MegaDySC Module, one Extended Run (ER) Module and one Automatic Bypass Switchboard. The enclosures are shipped separately and must be mechanically and electrically interconnected at the time of installation.
Chapter 2 Installation SR System Layout Figure 1 - SR System Layout 6+,33,1* 63/,7 &$%/( (175< 3/$7( 723 21/< &86720(5 , 2 3/$7( 723 21/< $8720$7,& %<3$66 6:,7&+%25' $ 0(*$ '\6& 02'8/( 6+,33,1* 63/,7 8 Rockwell Automation Publication 1608M-UM003A-EN-P - December 2013
Installation Chapter 2 The ER MegaDySC system can be configured in two ways: with the ER Module mounted to the right of the 800A MegaDySC Module (side-by-side), or with the ER Module mounted behind the 800A MegaDySC Module (back-to-back). ER SBS system layout shows the side-by-side (SBS) system layout. ER BTB system layout shows the back-to-back (BTB) system layout.
Chapter 2 Installation Figure 3 - ER BTB system layout 6+,33,1* 63/,7 &$%/( (175< 3/$7( 723 21/< &86720(5 , 2 3/$7( 723 21/< $8720$7,& %<3$66 6:,7&+%25' $ 0(*$ '\6& 02'8/( 6+,33,1* 63/,7 System Clearance (5 02'8/( The two Automatic Bypass Switchboard doors are hinged on the left, the 800A MegaDySC module door is hinged on the left
Installation Chapter 2 Pre-Installation Configuration IMPORTANT Perform system configuration steps before mounting and anchoring. Follow instructions for: Preparing the SR System on page 11, or Preparing the ER System for SBS layout on page 11, or Preparing the ER System for BTB layout on page 12. Preparing the SR System 1. Remove all tan-colored masking dots, blue-colored tape, and all plastic sheets. 2. Remove all eight plastic 13mm hole plugs in the right side of the switchboard cabinet. 3.
Chapter 2 Installation Figure 4 - MegaDySC Cabinet Preparation for SBS Layout Do not remove these two (2) plugs Remove plugs from these two (2) locations Remove these two (2) 75mm” Dia. EKO’s Figure 5 - ER Storage Cabinet Preparation for SBS Layout Remove and SAVE 3/8-16 hardware from two (2) locations Remove these two (2)63mm Dia. EKO’s Preparing the ER System for BTB layout 1. Remove all tan-colored masking dots, blue-colored tape, and all plastic sheets. 2.
Installation Chapter 2 3. Remove and save for later step: four (4) hex-head bolts with lock washer and flat washer in left side of MegaDySC cabinet. [tool required: 9/16inch wrench or socket] 4. Remove two (2) electrical knock-outs (EKO) in the bottom-rear panel of MegaDySC cabinet. 5. Remove the cover plate from the bottom-rear of the ER storage cabinet. Save the cover and screws for possible later use—they are not needed for the BTB layout.
Chapter 2 Installation Finally, after all interconnection hardware is installed; tighten the anchor bolt connections to the torque specified by the anchor manufacturer.
Installation Chapter 2 Figure 7 - Mechanical interconnections between 800A MegaDySC Module, Automatic Bypass Switchboard, and ER Module for BTB layout MegaDySC Floor Mounting The MegaDySC system is floor-mounted, and should be secured using the 0.63 in. (15.9 mm) diameter mounting holes provided along the bottom channels. The system should be secured to the floor in the locations indicated in Figure 8, Figure 9, and Figure 10.
Chapter 2 Installation Figure 8 - Floor Mounting Detail – SR System ; Required Anchor Locations Figure 9 - Floor Mounting Detail – ER System SBS layout ; Required Anchor Locations ;
Installation Chapter 2 Electrical Interconnections WARNING: Equipment must be earth-grounded according to local and national electric codes. Failure to supply proper equipment grounding may result in electrical shock or death. The 800A MegaDySC Module is shipped separately from the Automatic Bypass Switchboard and the ER Module. The customer is responsible for system mounting and electrical supply and load connections.
Chapter 2 Installation Figure 11 - Switchboard covers Figure 12 - Main Power Terminals (front view) 18 Rockwell Automation Publication 1608M-UM003A-EN-P - December 2013
Installation Chapter 2 Figure 13 - Automatic Bypass Switchboard Terminations and Conduit Landing Areas &21'8,7 (175< $5($ )25 &86720(5 , 2 3/$7( 5(029( 723 72 '5,// $1' 381&+ &21'8,7 (175< $5($ )25 &$%/( (175< 3/$7( 5(029( 723 72 '5,// $1' 381&+ 6<67(0 *5281'6 1(875$/ :,5( 6<67(06 21/< 287387 72 3527(&7(' /2$'6 87,/,7< ,1387 '(7$,/ 9,(: )25 ,
Chapter 2 Installation MegaDySC System Installation Connections Checklist • Connect the Automatic Bypass Switchboard ground bus to an earth ground in accordance with the National Electrical Code and local codes. • Connect the AC input (line) conductors to the terminals labeled “R in”, “S in”, and “T in”. The set is labeled “UTILITY INPUT”. See Figure 13. • Connect the AC output (load) conductors to the terminals labeled “R out”, “S out” and “T out”. The set is labeled “PROTECTED LOAD”. See Figure 13.
Chapter 3 Communications Communication connections enter through the top of the switchboard enclosure marked CUSTOMER I/O PLATE in Figure 1, Figure 2, or Figure 3. This plate can be fitted as needed for conduit entry. Communications terminals are described on the following pages. The ports are located at the top of the left Automatic Bypass Switchboard and are shown in Figure 14. Use RJ45 port number 5 for the communications connection.
Chapter 3 Communications • CBO Closed (CR5A) - Contact is closed when the output circuit breaker (CBO) is closed. Contact is open when CBO is open. • DySC Alarm (CR7A) – Contact is closed when there is an active alarm on the MegaDySC system. Contact is open when there is no alarm on the MegaDySC system. Modbus TCP/IP Communications MegaDySC system status and other items are communicated over a Modbus TCP/IP connection.
Chapter 4 Applying Power ATTENTION: The MegaDySC system must be commissioned by factory-trained engineers. Do not energize the MegaDySC until instructed to do so by commissioning engineers. If the Automatic Bypass switchboard must be installed and energized before commissioning, contact Rockwell Automation technical support. • After installation make certain there are no metal filings or any conductive debris in or on any components inside the cabinets.
Chapter 4 Applying Power Notes: 24 Rockwell Automation Publication 1608M-UM003A-EN-P - December 2013
Chapter 5 Operation System Description Raw utility power enters and routes through the Automatic Bypass switchboard to the load. In maintenance bypass mode the power bypasses the MegaDySC cabinet and passes directly to the load. In this mode the load is unprotected from voltage sags. In the Normal operation mode the MegaDySC cabinet is energized and the power is directed through the MegaDySC, protecting the load. See the following sections for MegaDySC and Automatic Bypass operation details.
Chapter 5 Operation whenever the MegaDySC system is in the maintenance bypass mode (CBB closed and CBI open). A list of conditions and indications is given in Table 1. Refer to Chapter 6 for further information on system alarms and status display. Table 1 - Operational Conditions and Indications CONDITION DEFINITION Touchscreen Display STATUS text* INVERTER OPERATION BYPASS MODE Normal: 88.5% < V LINE < 110% Green “OK” Standby Static BP Sag Event: V LINE < 88.5% for less than available runtime.
Operation Chapter 5 ATTENTION: Follow these instructions to avoid interrupting load power! Contact the factory immediately if the system fails to operate as outlined below. Voltage sag protection is not available whenever CBB is closed (red lamp lighted) Automatic Bypass Switchboard Operating Instructions Automatic System Bypass (CBB) will close in the event of a fault in the MegaDySC system. System will remain in bypass until manually transferred to back to the MegaDySC.
Chapter 5 Operation Figure 16 - Schematic diagram of Automatic Bypass Switchboard Power Circuit Transient Voltage Surge Suppressor (TVSS) Over voltage transient protection is provided on the output of the MegaDySC. Indicator lights for each phase on the front of the TVSS panel (upper left compartment of the Automatic Bypass Switchboard) are illuminated under normal operation. In case of a severe over-voltage transient event, internal fuses in the TVSS module may open.
Operation Chapter 5 Normal Mode The NORMAL mode for the MegaDySC is Input Breaker (CBI) and Output Breaker (CBO) closed. The bypass breaker (CBB) must be open or the MegaDySC will not be able to correct voltage sags. There is a red indicator light on the bypass enclosure that is lighted when the bypass is closed. The green “OK” status box should be shown on the touchscreen display. The green “OK” box indicates that the voltage at the output of the MegaDySC is within the +10%, 13% normal window.
Chapter 5 Operation protect the inverter module from peak over currents during sag protection operation. IMPORTANT In the event of the operation of any over current protection function, check the touchscreen display on the MegaDySC for error codes that may indicate the type of over current condition. ATTENTION: Circuit Breaker settings must not be changed without consulting Technical Support. Each of CBB, CBI, CBO contains an electronic trip unit with adjustable trip settings.
Operation Chapter 5 Open circuit alarm conditions: 1. Open static switch (failure in static switch path) 2. Open main input fuse (F1-F2-F3-F4-F5-F6) 3. Overload of static switch (may cause over-current trip in CBI; see Specifications) 4. Over-temperature of static switch heatsink 5. Over temperature of MegaDySC cabinet ambient air 6. Open cabinet door NOTE: Alarm types 1, 2, and 3 may result in momentary interruption of power to the load before transferring to mechanical bypass.
Chapter 5 Operation Notes: 32 Rockwell Automation Publication 1608M-UM003A-EN-P - December 2013
Chapter 6 Display Screen Overview The MegaDySC® touch screen display is a window to voltage sags and MegaDySC protection. The display provides system status, voltage sag notification and history, runtime statistics and system history in a simple and intuitive touch-based user interface. When the system first starts, a welcome screen displaying the MegaDySC product logo appears. This screen disappears after 5 seconds, when the “Home” screen appears.
Chapter 6 Display Screen Note: To recalibrate from any screen, hold anywhere on the screen for 10 seconds. You will see a small progress bar at the bottom of the screen. When the progress bar reaches 100 percent, the calibration screen will open. Step 3: The “Touch Screen Figure 19 - Touch Screen Calibration Calibration” screen will then appear (See Figure 19). Press and hold on the center of the touch target, release when the touch target begins to flash. Repeat with the next two touch targets.
Display Screen Home Screen Chapter 6 The “HOME” screen of the display provides a snapshot view of the status of the entire system (See Figure 21). You can return to this screen from any other screen by pressing the “HOME” button. After 5 minutes of inactivity (i.e. not pressing the screen), the touch screen will automatically return to the “HOME” screen. The “HOME” screen is divided into four main areas described inTable 2.
Chapter 6 Display Screen System Status The “System Status” screen displays the real-time overall system status.
Display Screen Voltage Sag Events Chapter 6 A voltage sag is defined as the period when input RMS voltage drops to less than 88.5% of the rated DySC voltage. Details of each voltage sag and corresponding MegaDySC protection are captured and saved to the voltage sag log. Voltage Sag Log The “Voltage Sag Log” screen (See Figure 26) displays a list of the last 61 voltage sags. Reach this screen by pressing “VOLTAGE SAGS” button on the “HOME” screen.
Chapter 6 Display Screen Voltage Sag Detail Voltage Sag Detail” screen (See Figure 27) displays all information related to the selected event. Details for the most recent sag event can also be accessed by pressing anywhere in the Last Voltage Sag area of the HOME screen. The worst-case RMS voltage recorded during the event is displayed in the upper window along with the corresponding voltage percentage and the event duration. Table 5 describes the remaining screen content.
Display Screen Voltage Sag RMS Voltage Charts Chapter 6 The line and load RMS voltage (L-N) of each phase is recorded for 8 cycles prior to the start of the voltage sag followed by the first 300 cycles of the voltage sag (See Figure 28). Reach this screen by pressing “CHARTS” on the “Voltage Sag Detail” screen as shown in Figure 27 on page 38. Figure 28 - RMS Voltage Charts Line voltage is shown in red and load voltage is shown in green.
Chapter 6 Display Screen System Events The MegaDySC tracks all operational events which are classified into five groups based on severity. Table 6 - System Event Description Description Function Informational Purely informational. No action is required. Auto-Resetting The MegaDySC will reset within 60 seconds. No user action is required. User Attention User action may be required to correct a problem. The MegaDySC will reset 60 seconds after the error condition is corrected.
Display Screen System Event Detail Chapter 6 The “System Event Detail” screen is displayed when a specific system event is selected by pressing on the “SELECT” button on the “SYSTEM EVENT LOG” screen (See Figure 30 on page 40). It provides detailed information that was recorded during the event (See Figure 31). Figure 31 - System Event Detail Table 8 - System Event Detail Description Time/Duration Function Time: Date and start time of the system event Duration: The amount of time the event lasted.
Chapter 6 Display Screen System Event Notification When the MegaDySC system first detects an event condition, the “System Fault Detection” dialog box will be displayed (See Figure 32). Within the “System Fault Detection” box, the name, severity, and location of the event will be displayed. Figure 32 - System Fault Detection Pressing the “OK” button will open the “System Event Detail” screen. The event will appear in the event list after the event is over.
Display Screen System Configuration Chapter 6 Press the “CONFIG” button at the bottom of the “HOME” screen to enter the “System Configuration” screen (See Figure 34). The “SET SYSTEM CLOCK” and “CALIBRATE TOUCH SENSOR” functions are described at the start of this chapter. Figure 34 - System Configuration Model Information Touch “VIEW MODEL INFORMATION” to go to the “Model Information” screen. (See Figure 35).
Chapter 6 Display Screen Run System Tests Press the “RUN SYSTEM TESTS” to enter the “System Tests” screen. Press “2 MINS” to run the system fans for 2 minutes (See Figure 36). Figure 36 - System Tests Diagnostics Mode This is not a user function. It is numerical code protected for authorized service personnel.
Chapter 7 Maintenance Preventative Maintenance The MegaDySC requires very little preventative maintenance. The MegaDySC should be checked periodically for proper air flow and status indicator operation. Monthly Checks • Ensure the touch screen display is working and no active events are displayed. • Verify that the bypass switch is in the NORMAL mode. • Update system time, if needed, Figure 20 on page 34. • Use a soft cloth to clean the touch display.
Chapter 7 Maintenance Table 10 - System Event Table Event Code Code Name Full Name Severity Area Event Description Event Resolution 1 POWER_ON DySC Power On Informational Unit Power re-applied to the DySC. No action needed. 4 T_FAN_ST Fan Test Start Informational Unit Start acknowledgment of DySC fan test. No action needed. 5 T_IN_ST_1 Inverter Test (.5 cycles) Start Informational Unit No action needed.
Chapter 7 Event Code Maintenance Code Name 34 AC_V_CHK 35 ROLL_CALL 36 COM_VER 37 CNFG_TO 38 CNFG_ERR 39 FIRM_TO 40 FIRM_DIFF 41 SRL_TO 42 SRL_DIFF 44 Full Name Area Call Service Inverter Call Service Unit Call Service Unit Call Service Unit Call Service Unit Call Service Unit Call Service Unit Call Service Unit Start-Up Test: Serial Number Mismatch Informational Unit T_INV_TO Inverter Test Timeout Call Service Unit 46 DOOR_OPEN DySC Cabinet Door Open Manua
Chapter 7 Maintenance Servicing ATTENTION: Service must be performed by qualified personnel only. Before attempting any servicing that requires opening the MegaDySC doors first put the system into Maintenance Bypass mode as described in the section Automatic Bypass Switchboard Operation on page 26 WARNING: The MegaDySC and optional ER cabinets are interlocked.
Maintenance Chapter 7 Automatic Bypass Switchboard Fuses Refer to the fuse listing label located on the switchboard cover for fuse size and type. Before replacing a switchboard fuse authorized service personnel will require removal of power to the Automatic Bypass switchboard by opening and locking-out the upstream circuit breaker. WARNING: De-energize the Bypass switchboard before removing covers to access fuses.
Chapter 7 Maintenance Table 11 - MegaDySC Fuse Schedule MegaDySC Main Cabinet Fuses Fuse Reference F1, F2, F3, F4, F5, F6 F7, F8, F9 F10, F11, F12 F13, F14, F15 F16, F17 F18 - F29 F30, F31 Fuse Reference F1, F2 F3 50 Fuse Location Fuse Rating Main Cabinet: 800A/500V Main Power Input Main Cabinet: 800A/500V Inverter Input Main Cabinet: 500A/600V Cross-Coupling Transformer Main Cabinet: 110A/600V Series Injection Transformer Main Cabinet: 2A/600V Input Control Transformer Main Cabinet: 25A/600Vdc Dynam
Chapter 8 Specifications Table 12 - Technical Specifications 800A MegaDySC Electrical Input/Output (Normal Mode—Static Switch) Connection Configuration Series-connected with load. Under normal line condition, the static switch passes utility voltage directly to the load Standard Input Voltage DySC 3-Phase: 208V Voltage Range ±10% Static Bypass Current 800A-rms continuous, 110%-150% @ 60 sec., 150%-300% @ 5 sec., 300%-400% @ 0.5 sec., 400%-600% @ 0.05 sec.
Chapter 8 Specifications Table 13 - MegaDySC Heat Loading and Typical Efficiency Rated Voltage SR/ER Heat Loss (W) Heat Loss (BTU/h) Efficiency 208V SR 3500 11900 > 98.5% 208V ER 3900 13300 > 98.
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