User Manual Bulletin 1608P ProDySC Dynamic Voltage Sag Corrector Catalog Numbers 1608P - 25 and 50 Amp 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 Ch 4 - Applying Power Ch 5 - Display Screen Ch 6 - Maintenance Ch 7 - Specifications and Dimensions Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Notes: 4 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013
Chapter 1 Introduction The Allen-Bradley Bulletin 1608P ProDySC Dynamic Sag Corrector is engineered to provide years of trouble-free voltage sag (dip) protection. The patented ProDySC 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 Introduction ATTENTION: Internal components can be easily damaged by electrostatic discharge (ESD). Do not touch circuit boards or electronic components with hands or metal objects. Use an insulated screw driver when connecting the lines. • The ProDySC is not rated to directly power life support equipment. • Ensure the area around the ProDySC is clean and uncluttered. • Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the equipment.
Chapter 2 Installation Installation Check List Inspecting and Unpacking Before proceeding, please take a few minutes to review the necessary steps to install your ProDySC. • All packing materials and restraints have been removed. • The ProDySC is placed in its installed location. • All conduits and cables are properly routed to the ProDySC. • All power cables are properly terminated. • A ground conductor is properly installed and terminated.
Chapter 2 Installation Mounting the ProDySC Using the 3/8" hardware and four (4) wall mounting brackets supplied, mount the wall mount brackets to the back of the ProDySC. Mount each bracket to the back of the ProDySC with a single 3/8"-16 x 1" hex cap head screw. Mount the brackets so the flat portion of the mounting bracket is against the back of the ProDySC. Bolt two 2 x 4 pieces of lumber horizontally to the wall using 3/8" by 4" hex-head lag bolts. Make certain that: 1.
Installation Chapter 2 Figure 2 - 50A Mounting dimensions, in. [mm] 37.36 949 34.50 876 36.00 914 13.21 336 33.00 838 12.80 325 37.13 943 36.00 914 A 33.00 838 34.50 876 13.39 340 .57 TYP. 14 .75 19 1.50 38 .41 TYP.
Chapter 2 Installation Bypass Switch Installation of the ProDySC with an external maintenance bypass is required to avoid power interruptions to the critical loads during maintenance, service, or testing. Mount the bypass close to the ProDySC to provide quick access and visual coordination when testing or providing service. The 1608P bypass is a wall mounted enclosure with a 3 position rotary switch. Its dimensions and mounting locations are shown in Figure 3.
Installation Bypass Switch Wiring Diagram Chapter 2 The maintenance bypass has input and output terminals labeled and located inside the bypass enclosure as shown in Figure 5. The neutral connection is available for 4-wire ProDySC configurations. NOTICE: All electrical connections must be completed by a qualified electrician, in compliance with all local codes and the National Electric Code.
Chapter 2 Installation ProDySC Terminations and Ratings A qualified electrician must install the units. To access the ProDySC Electrical Terminations, turn the two ¼ - turn latches CCW and swing open the door. The unit is furnished with one of the terminal block configurations as shown in Figure 7. For power cable termination specifications see Table 2 for the 25A rated units andTable 3 for the 50A rated units.
Installation Chapter 2 Table 2 - ProDySC 25 Amp Power Cable Terminations 3 Wire with a Ground Terminal Connection AC Input Function Phase A, B, C Terminal Marking L1, L2, L3 Ground AC Output Phase A, B, C Wire Range AWG (mm²) 24- 8 (0.5-6) ¼-20 Stud X1, X2, X3 Ground 24-8 (0.5-6) ¼-20 Stud Torque lb-in (Nm) 7.1- 8.9 (0.8-1) 65 (7.3) 7.1- 8.9 (0.8-1) 65 (7.3) 4 Wire with a Ground AC Input Phase A, B, C L1, L2, L3 Ground AC Output 24- 8 (0.
Chapter 2 Installation Notes: 14 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013
Chapter 3 Communications Both dry contacts (relays) that indicate status and a Serial Communications Port (RS-232) are available for monitoring the ProDySC. Dry Contacts Three relay contacts indicate ProDySC 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 A.
Chapter 3 Communications Serial Communications Port The ProDySC 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.
Chapter 4 Applying Power • Verify that the ProDySC voltage rating matches the source voltage. • Before applying power to the ProDySC, make certain there are no metal filings or any conductive debris in or on any components inside the ProDySC. • Ensure that all input/output wiring including grounding has been completed and that all access doors are closed. • Place the maintenance bypass in “Bypass” mode. • Apply power from the upstream branch protection device.
Chapter 4 Applying Power Notes: 18 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013
Chapter 5 Display Screen Overview The ProDySC® touch screen display is a window to voltage sags and ProDySC 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 ProDySC 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 4.
Chapter 5 Display Screen Table 5 - System Status Description Description System Status Phase Status Waveforms Voltage Sag Events Function Overall system status including current operational status, availability to correct sags, and internal cabinet temperature Voltage, current, frequency, and static switch temperature are displayed for all phases. The percentage displayed following the voltage and current is the percent of nominal value for the ProDySC.
Display Screen Voltage Sag Detail Chapter 5 The "Voltage Sag Detail" screen (See Figure 18)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 7 describes the remaining screen content.
Chapter 5 Display Screen Voltage Sag RMS Voltage Charts 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 19). Reach this screen by pressing "CHARTS" on the "Voltage Sag Detail" screen as shown in Figure 18 on page 23. Figure 19 - - RMS Voltage Charts Line voltage is shown in red and load voltage is shown in green.
Display Screen System Events Chapter 5 The ProDySC tracks all operational events which are classified into five groups based on severity. Table 8 - System Event Description Description Function Informational Purely informational. No action is required. Auto-Resetting The PRODySC will reset within 60 seconds. No user action is required. User Attention User action may be required to correct a problem. The PRODySC will reset 60 seconds after the error condition is corrected.
Chapter 5 Display Screen System Event Detail 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 21 on page 25). It provides detailed information that was recorded during the event (See Figure 22). Figure 22 - System Event Detail Table 10 - System Event Detail Description Time/Duration 26 Function Time: Date and start time of the system event Duration: The amount of time the event lasted.
Display Screen Chapter 5 System Event Notification When the ProDySC system first detects an event condition, the "System Fault Detection" dialog box will be displayed (See Figure 23). Within the "System Fault Detection" box, the name, severity, and location of the event will be displayed. Figure 23 - 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.
Chapter 5 Display Screen System Configuration Press the "CONFIG" button at the bottom of the “HOME” screen to enter the “System Configuration” screen (See Figure 25). The “SET SYSTEM CLOCK” and “CALIBRATE TOUCH SENSOR” functions are described at the start of this chapter. Figure 25 - System Configuration Model Information Touch “VIEW MODEL INFORMATION” to go to the “Model Information” screen. (See Figure 26).
Display Screen Chapter 5 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 27). Figure 27 - System Tests Diagnostics Mode This is not a user function. It is numerical code protected for authorized service personnel.
Chapter 5 Display Screen Notes: 30 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013
Chapter 6 Maintenance Preventative Maintenance The ProDySC requires very little preventative maintenance. The ProDySC 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. • Update system time, if needed, Figure 13 on page 20 • Use a soft cloth to clean the touch display. DO NOT USE harsh detergent, abrasive sponges, alcohol, ammonia, toluene, or acetone on the touch display.
Static Switch Over-Temperature Overload Controller Power Under-Voltage Output Under-Voltage Inverter Over-Current DC Bus Under-Voltage STAT_OT OVERLOAD DC_OV CNTRL_UV OUTPUT_UV INV_OC 13 14 15 16 17 18 Start-Up Test: DC Bus Unbalance Start-Up Test: AC Voltage Check Call Service Start-Up Test: Controller Roll Call Call Service Timeout Start-Up Test: Communication Call Service Compatibility Mismatch Start-Up Test: Controller Configuration Call Service Timeout Start-Up Test: Controller C
Maintenance Fuse Replacement Chapter 6 Fast-acting fuses are included to protect the ProDySC in the event of a load short circuit. If the screen is dark when power is applied, it may indicate a blown fuse. Check the fuse(s) for continuity. WARNING: Turn the power to the ProDySC off by placing the Bypass Switch into “BYPASS” or opening the branch circuit breaker before replacing the fuse. Failure to comply with this warning can result in injury or death.
Chapter 6 Maintenance Fuse Rating Charts Replace fuse with the same type or equivalent cross-referenced rating. You may order these fuses through Rockwell Automation or the manufacturer listed. Table 13 - DySC Fuse Ratings for 25A Unit Fuse Reference Fuse Location Fuse Rating Manufacturer Part Number F1, F2, F3 Main Power Input 60A/500V Mersen A50QS60-4 F7 Input Control Transformer 0.
Chapter 7 Specifications and Dimensions Table 16 - Technical Specifications 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 Voltages 3 : 208, 380, 400, 415, 480V1 Voltage Range ± 10% Current Overload (Static Switch) 150% @ 30Sec., 400% @ 5 Sec., 600% @ 0.5 Sec.
Chapter 7 Specifications and Dimensions Heat Dissipation Rating (A) 25 50 Heat Loss (J) Heat Loss (Btu/h) Standard Run-time (SR) 957 1196 280 350 Efficiency (%) 97.8% 97.2% Extended Run-time (ER) 25 50 420 560 1435 1913 98.2% 97.7% Approximate Dimensions Rating (A) 25 50 HxWxD in. [mm] Standard Run-time (SR) 32 x 26 x 14 [813 x 660 x 356] 38 x 38 x 14 [965 x 965 x 356] Extended Run-time (ER) Weight lbs.
Specifications and Dimensions Chapter 7 Figure 28 - 25AStandard/Extended Run 25.35 644 22.50 572 24.00 610 13.21 336 21.00 533 12.80 325 31.13 791 30.00 762 21.00 533 A 22.50 572 13.39 340 .57 TYP. 14 .75 19 1.50 38 .41 TYP.
Chapter 7 Specifications and Dimensions Figure 29 - 50A Standard/Extended Run 37.36 949 34.50 876 36.00 914 13.21 336 33.00 838 12.80 325 37.13 943 36.00 914 A 33.00 838 34.50 876 .57 TYP. 14 .75 19 1.50 38 .41 TYP. 10 DETAIL A 4 PLACES 38 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013 13.
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