User Manual Bulletin 1608P HC-DySC Dynamic Voltage Sag Corrector 1608P-200A480V...-HC and 1608P-200A480V...
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 Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ch 1 - Introduction Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ch 2 - Installation Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Ch 6 - Maintenance Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Monthly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fuse Rating Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 Introduction The Allen-Bradley Bulletin 1608P HC-DySC 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 that are found in industry today are susceptible to power disturbances.
Chapter 1 ATTENTION: - To reduce the risk of fire or electric shock, install this HC-DySC in a temperature and humidity controlled, indoor environment, free of conductive contaminants. • Avoid installing the HC-DySC directly near heat-emitting equipment such as ovens, heaters, or furnaces. • Ambient temperature must not exceed 40°C (104°F). • Do not operate near water or excessive humidity (95% max).
Chapter 2 Installation Installation Check List Inspecting and Unpacking Before proceeding, take a few minutes to review the necessary steps to install your HC-DySC. • All packing materials and restraints have been removed. • The HC-DySC is placed in its installed location. • All conduits and cables are properly routed to the HC-DySC. • All power cables are properly terminated. • A ground conductor is properly installed and terminated.
Chapter 2 Installation Floor Mounting Secure the HC-DySC to the floor using fasteners and fittings appropriate for the type of floor. Holes are provided in the base channels; see Figure 1 for mounting dimensions. Note: Top or bottom cable entry is allowed. See Figure 1 and Figure 2 on page 9. Figure 1 - Bottom View Floor Mount Dimensions 37.25 946 18.75 476 3.58 91 6X 11.00 279 .625 16 28.00 711 9.00 229 2.01 51 1.00 25 37.25 946 1.20 31 1.
Installation Chapter 2 Electrical Terminations Use a qualified electrician to install the HC-DySC in compliance with all local, and national electric codes. The HC-DySC input (line) and output (load) terminals are located behind the left door. Terminal details are shown in Figure 5 on page 12. Accessing Terminations For top entry, remove the top gland plate, which is shown in Figure 2, to access input and output terminals. This plate may be removed for drilling or punching holes for conduit.
Chapter 2 Installation 3-Wire vs. 4-Wire Configurations HC-DySC models are available for use with either 3-wire (L1, L2, L3) or 4-wire (L1, L2, L3, N) sources. The input N conductor must be connected to 4-wire models for proper operation. Do not connect a N conductor to 3-wire models. 3- Wire Models Bulletin 1608P part numbers containing V3 are configured for 3-wire source (L1, L2, L3) and 3-wire loads (X1, X2, X3). Do not connect a N conductor to 3-wire models.
Installation Chapter 2 Bulletin 1608P part numbers containing V4 are configured for 4-wire source (L1, L2, L3, N) and either 3-wire or 4-wire loads. The source N conductor must be connected for proper operation of these models. Connect both input and output N conductors to the bus bar labeled NEUTRAL (See Figure 5). Figure 4 shows the 4-wire HC-DySC system wiring schematically, including the internal maintenance bypass switch. 4- Wire Models Figure 4 - HC-DySC 4-Wire Configuration.
Chapter 2 Installation Electrical Terminations and Ratings Input connections are marked L1, L2, and L3 for the source connections. Output connections are marked X1, X2, and X3 for the load connections (See Figure 5). In 4-wire models only, connect both input and output N conductors to the NEUTRAL bus bar. Do not connect to the NEUTRAL bus bar in 3-wire models. Replace all shields and covers when wiring is completed. The doors must be closed and latched securely.
Chapter 3 Communications Both dry contacts (relays) that indicate status and a Serial Communications Port (RS-232) are available for monitoring the HC-DySC. Dry Contacts Three relay contacts indicate HC-DySC status. The contacts are form A and close upon occurrence of the named event: (a) any SAG EVENT, when rms input voltage drops below 88.5% of rated value; (b) OUTPUT OK, when output voltage remains between 87% and 110%; and (c) a system ALARM event. The relay contact ratings are 24V at 1A.
Chapter 3 Communications Serial Communications Port The HC-DySC serial port is a DE-9 female connector. The pin-out follows standard RS-232 protocol: pin 2 is RxD, pin 3 is TxD and pin 5 is common (return). All other pins are unused. Contacts are galvanically isolated from the system power and grounds. • Protection: The RS-232 port is ESD-protected to 15kV. • Protocol: 57.6k bps, 8 data bits, one stop bit, no parity, flow control off • Data packets are SLIP encoded (with 2 byte length field).
Chapter 4 Applying Power and Operation Applying Power • Before applying power to the HC-DySC, make certain there are no metal filings or any conductive debris in or on any components inside the cabinet. • Verify HC-DySC voltage rating matches ac source voltage. • Verify all input/output wiring including grounding has been completed and properly tightened. • Replace all covers. Close all cabinet doors. • Put CBI circuit breaker and CBO circuit breaker in the OFF position.
Chapter 4 Applying Power and Operation HC-DySC System Operation SHOCK HAZARD: Dangerous voltages are present within the HC-DySC System. The unit should never be operated with the enclosure door open except by qualified and authorized personnel who are trained and familiar with the operation of the unit and the location of components and voltages. Failure to comply with this warning could result in injury or death.
Applying Power and Operation Bypass Switch Modes Chapter 4 The maintenance bypass switch has three modes of operation: Normal Mode, Bypass Mode, and Test Mode. It is configured as shown in Figure 9. Normal Mode The NORMAL mode for the HC-DySC is the input circuit breaker (CBI) and the output circuit breaker (CBO) closed. The bypass circuit breaker (CBB) must be open or the HC-DySC will not be able to correct voltage sags.
Chapter 4 Applying Power and Operation Test Mode The TEST mode for the HC-DySC is for the input circuit breaker (CBI) to be closed and the output circuit breaker (CBO) to be open. The bypass circuit breaker (CBB) must be closed to provide power to the load while the HC-DySC is being tested off-line.
Applying Power and Operation HC-DySC Operation Chapter 4 The HC-DySC section contains three power electronics modules (one module per phase) and controls that continuously monitor the line voltage. The modules are series-connected to the input line, and operate by adding the compensating voltage needed to restore the line to its nominal output. When the utility line voltage is within normal range the ac static switch components remain closed and no compensating voltage is added.
Chapter 4 Applying Power and Operation A list of conditions and indications is given in Table 2. Under some conditions the HC-DySC will automatically close the maintenance bypass switch (CBB) and open CBI and CBO to prevent damage to the HC-DySC or to protect loads from severe voltage unbalance. Those conditions are the last four listed in the table below. Refer to Chapter 5 for further information on system alarms and status display.
Chapter 5 Display Screen Overview The HC-DySC® touch screen display is a window to voltage sags and HC-DySC protection. The display provides system status, voltage sag notification and history, runtime statistics and system history in a simple and intuitive touchbased user interface. When the system first starts, a welcome screen displaying the HC-DySC product logo appears. This screen disappears after 5 seconds, when the “Home” screen appears.
Chapter 5 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 12 - Touch Screen Calibration Calibration” screen will then appear (See Figure 12). 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 5 The “HOME” screen of the display provides a snapshot view of the status of the entire system (See Figure 14). 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 3.
Chapter 5 Display Screen System Status The “System Status” screen displays the real-time overall system status.
Display Screen Voltage Sag Events Chapter 5 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 HC-DySC protection are captured and saved to the voltage sag log. Voltage Sag Log The “Voltage Sag Log” screen (See Figure 19) displays a list of the last 61 voltage sags. Reach this screen by pressing “VOLTAGE SAGS” button on the “HOME” screen.
Chapter 5 Display Screen Voltage Sag Detail Voltage Sag Detail” screen (See Figure 20) 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 6 describes the remaining screen content.
Display Screen Voltage Sag RMS Voltage Charts Chapter 5 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 21). Reach this screen by pressing “CHARTS” on the “Voltage Sag Detail” screen as shown in Figure 20 on page 26. Figure 21 - RMS Voltage Charts Line voltage is shown in red and load voltage is shown in green.
Chapter 5 Display Screen System Events The HC-DySC tracks all operational events which are classified into five groups based on severity. Table 7 - System Event Description Description Function Informational Purely informational. No action is required. Auto-Resetting The HC-DySC will reset within 60 seconds. No user action is required. User Attention User action may be required to correct a problem. The HC-DySC will reset 60 seconds after the error condition is corrected.
Display Screen System Event Detail Chapter 5 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 23 on page 28). It provides detailed information that was recorded during the event (See Figure 24). Figure 24 - System Event Detail Table 9 - 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 5 Display Screen System Event Notification When the HC-DySC system first detects an event condition, the “System Fault Detection” dialog box will be displayed (See Figure 25). Within the “System Fault Detection” box, the name, severity, and location of the event will be displayed. Figure 25 - 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 5 Press the “CONFIG” button at the bottom of the “HOME” screen to enter the “System Configuration” screen (See Figure 27). The “SET SYSTEM CLOCK” and “CALIBRATE TOUCH SENSOR” functions are described at the start of this chapter. Figure 27 - System Configuration Model Information Touch “VIEW MODEL INFORMATION” to go to the “Model Information” screen. (See Figure 28).
Chapter 5 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 29). Figure 29 - System Tests Diagnostics Mode This is not a user function. It is numerical code protected for authorized service personnel.
Chapter 6 Maintenance Preventative Maintenance The HC-DySC requires very little preventative maintenance. The HC-DySC 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 maintenance bypass switch is in the NORMAL mode. • Update system time, if needed, Figure 13 on page 22. • Use a soft cloth to clean the touch display.
Chapter 6 Maintenance Table 11 - 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 Start acknowledgment of DySC 0.5 cycle inverter test. No action needed.
Chapter 6 Event Code Maintenance Code Name 36 COM_VER 37 CNFG_TO 38 CNFG_ERR 39 FIRM_TO 40 FIRM_DIFF 41 SRL_TO 42 SRL_DIFF Full Name Start-Up Test: Communication Compatibility Mismatch Start-Up Test: Controller Configuration Timeout Start-Up Test: Controller Configuration Mismatch Start-Up Test: Controller Firmware Check Timeout Start-Up Test: Controller Firmware Revision Mismatch Start-Up Test: Controller Serial Number Check Timeout Start-Up Test: Serial Number Mismatch 44 T_INV_TO Inve
Chapter 6 Maintenance Servicing ATTENTION: Service must be performed by qualified personnel only. Before attempting any servicing that requires opening the HC-DySC doors first put the system into Bypass (maintenance) mode as described in Maintenance Bypass Transfer Procedure on page 18. CBI Circuit Breaker, Safety Interlocks and Stored Energy The HC-DySC includes a fast-discharge circuit to quickly dissipate stored energy when the CBI circuit breaker is opened.
Maintenance Chapter 6 Fuse locations within the HC-DySC cabinet are shown on a label inside the door. IMPORTANT A qualified electrician must replace the fuses. Open the front cabinet door(s) to access the fuse holders and fuses. To maintain protection of the HC-DySC, be sure to replace the fuse with the same type and rating. These fuses are available through Rockwell Automation Technical Support.
Chapter 6 Maintenance Transient Voltage Surge Suppressor (TVSS) The HC-DySC includes an internal TVSS device (or SPD), protecting the output (load). Indicator lights on the TVSS show if surge protection is not active (internally disconnected). Power to the TVSS module may be removed by opening the block of fuses F16-F17-F18 and F19 (present in 4-wire models only).
Chapter 7 Specifications and Dimensions Table 13 - Technical Specifications 200 A HC-DySC 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 Input Voltage 3-phase: 480V1 Voltage Range -10...+5% Available Short Circuit Current 65 kA Current Overload (Static Switch) 150% @ 30Sec., 400% @ 5 Sec., 600% @ 0.5 Sec.
Chapter 7 Specifications and Dimensions Table 14 - Heat Dissipation Rating (V) 480 Heat Loss (W) 1250 Heat Loss (Btu/h) 4265 Efficiency (%) > 99% Dimensions are shown in inches (millimeters). Dimensions are not intended to be used for manufacturing purposes. Approximate Dimensions Figure 30 - 200 A HC-DySC Dimensions 2.00 51 3.00 76 Area Recommended For Top Conduit Entry (Shown Without Cover) 11.00 279 9.00 229 I/O Knockouts 51.07 1297 20.
Appendix A HC-DySC with Generator Transfer (GT) Option GT Option Description HC-DySC model numbers that end with "-GT" include the generator transfer option. The HC-DySC with Generator Transfer (GT) option is able to switch between two modes of operation: series connected mode and shunt connected mode. The GT model operates identically to the HC model when in the normal series-connected mode; this mode provides excellent voltage sag correction performance.
Appendix A HC-DySC with Generator Transfer (GT) Option Figure 31 - Home Screen GT Mode ATS / Generator Contacts The generator transfer command dry relay contact provided by the user must be rated for at least 24 VDC and 20 mA continuous current. User connections to the HC-DySC are made at terminal block TB2. The location of TB2 is shown in Figure 32. For access to the TB2 screw terminal block, remove the I/O knockout in the top left of the HC-DySC cabinet as shown in Figure 2 on page 9.
HC-DySC with Generator Transfer (GT) Option Appendix A Typical TB2 connections for a hardwired generator transfer command contact signal are shown in Figure 33. The signal is connected between positions 1 and 2. Position 1 provides 24VDC to a (normally closed) auxiliary contact on the ATS or generator circuit, which is fed back to terminal 2. Open the external contact to put the HC-DySC in GT mode. An internal contact between Positions 3 and 4 closes whenever the HC-DySC is in the GT mode.
Appendix A HC-DySC with Generator Transfer (GT) Option Notes: 44 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014
Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.
