Rockwell Automation 1608 User Manual
User Manual
Bulletin 1608P HC-DySC Dynamic Voltage Sag Corrector
1608P-200A480V...-HC Models
Important User Information
IMPORTANT
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
office or online at http://www.rockwellautomation.com/literature/
hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all
persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application
of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements
associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the
examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in
this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
) describes some important differences between solid-state equipment and
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
available from your local Rockwell Automation sales
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
Identifies information that is critical for successful application and understanding of the product.
HC-DySC, Allen-Bradley, Rockwell Software, Ro ckwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of
their respecti ve companies.
Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
Resource Description
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website, http://www.ab.com
Provides general guidelines for installing a Rockwell
Automation industrial system.
Provides declarations of conformity, certificates, and
other certification details.
You can view or download publications at http:/www.rockwellautomation.com/literature/
. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.
Ch 1 - Introduction
Ch 2 - Installation
Ch 3 - Communications
Ch 4 - Applying Power and Operation
Ch 5 - Display Screen
Table of Contents
Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspecting and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location (Environment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Floor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Circuit Breaker Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Accessing Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-Wire vs. 4-Wire Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3- Wire Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4- Wire Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Terminations and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dry Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Serial Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HC-DySC System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bypass Switch Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance Bypass Transfer Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manual transfer to Bypass (maintenance) mode:. . . . . . . . . . . . . . . . . . . . . . . 17
Manual transfer to Normal (sag protection) mode: . . . . . . . . . . . . . . . . . . . . 17
Operating and Alarm Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mechanical Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
System Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Voltage Sag Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Voltage Sag Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Voltage Sag Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Voltage Sag RMS Voltage Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Voltage Sag Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System Event Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
System Event Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Run System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diagnostics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 3
Table of Contents
Ch 6 - Maintenance
Ch 7 - Specifications and Dimensions
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Monthly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3-6 Month Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Circuit Breaker CBI, Safety Interlocks and Stored Energy . . . . . . . . . . . . . . 34
Circuit Breaker CBA and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuse Rating Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Transient Voltage Surge Suppressor (TVSS). . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
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 found in industry today
are susceptible to power disturbances. A momentary sag in line voltage can reset
or damage sensitive production equipment. The HC-DySC provides
instantaneous dynamic sag correction to help your equipment ride through these
common events. The HC-DySC connects normal utility power directly to the
load until a voltage sag occurs. During a sag, the HC-DySC inverter is activatedadding missing voltage to keep the load voltage within the normal range. When
utility power returns to normal, the inverter is deactivated and the HC-DySC is
quickly ready to correct the next sag.
The HC-DySC reports these voltage sag events through its integrated touch
screen display and provides system status, voltage sag notification and history,
runtime statistics and system history in a simple and intuitive touch-based user
interface.
Safety Considerations
The HC-DySC is designed to operate in industrial applications. Follow these
guidelines to ensure that the safety and installation of the HC-DySC are handled
with appropriate care.
WARNING: HC-DySC products protect diagnostic imaging equipment and
facilities support systems against voltage sags and momentary power
interruptions. HC-DySC products are not to be used for protection of life-critical
patient care equipment.
SHOCK HAZARD: The HC-DySC has high voltage remaining up to 5 minutes
after disconnection from the AC line. Touching exposed or disconnected
terminals, cables or parts of the HC-DySC can lead to serious injuries or even
death. Wait for a minimum of 5 minutes before performing any service or
testing on the HC-DySC after power is removed. High voltage remains if red LED
indicators above capacitor banks are lighted. Keep the cabinet doors closed and
locked to ensure proper cooling airflow and to protect personnel from
dangerous voltages inside the HC-DySC.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 5
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).
• When punching or drilling holes for conduit fittings, take care to avoid dropping metallic particles
inside the enclosure as this can result in electrical damage.
• The system is not intended for outdoor use.
• The operating environment should be maintained within the parameters stated in this manual.
• Only authorized service personnel should perform service on the HC-DySC.
• Ensure all power is disconnected before performing installation or service.
ATT EN TI ON : Internal components can be easily damaged by electrostatic
discharge (ESD). Do not touch circuit boards or electronic components with
hands or metal objects. The HC-DySC is not rated to directly power life support
equipment.
• Ensure the area around the HC-DySC is clean and uncluttered.
• Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the
equipment.
6 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Installation
Chapter 2
Installation Check List
Inspecting and Unpacking
Before proceeding, please 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.
• If neutral connection is required that it is properly terminated on the
HC-DySC.
• The area around the installed HC-DySC is clean and dust-free.
• Adequate work space exists around the HC-DySC.
• Adequate lighting is provided around the HC-DySC.
• Operational checks have been reviewed and completed.
• Lift only at the base with a fork truck or pallet jack.
• Carefully inspect the outer packaging for evidence of damage during
transit. Do not install a damaged cabinet. Report any damage to the carrier
and contact your local sales or service immediately.
• Check the HC-DySC label for correct model number with the packaging
list to ensure you have received the correct voltage, current, and wiring
configurations.
• After removing the packaging material, inspect the contents for any
evidence of physical damage, and compare each item with the Bill of
Lading. If damage has occurred or shortages are evident contact your
carrier immediately.
Location (Environment)
System Components
The HC-DySC must be installed in a protected environment. The location must
provide adequate airflow around the HC-DySC in an atmosphere free from
excessive dust, corrosive fumes, or conductive contaminants. Do not operate the
HC-DySC in an environment where the ambient temperature or humidity is
beyond the specified limits given in this manual.
The HC-DySC consists of a single enclosure with an integral mechanical bypass
to prevent power disruption during service and maintenance.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 7
Chapter 2 Installation
Floor Mounting
The HC-DySC is to be secured to the floor using fasteners and fittings
appropriate for the type of floor. Holes are provided in the base channels; see
Figure 1
Figure 1 - Bottom View Floor Mount Dimensions
for mounting dimensions.
Note: Top or bottom cable entry is allowed. See Figure 1
and Figure 2 on page 9.
Clearance
Circuit Breaker Recommendations
Electrical Terminations
HC-DySC doors hinge on both right and left. See Figure 30 on page 38 for
dimensions including door swing. Leave required clearances:
• Door swing must allow doors to open at least 90 degrees
• 12” [300mm] clearance on left side and rear for cooling airflow
• 4”[100mm] on right side for air filter clearance when right door opens
Branch circuit protection upstream of the HC-DySC is required. Recommended
circuit breakers and maximum allowed circuit breaker ratings are listed in
Ta b l e 1
may result in nuisance tripping.
Table 1 - Recommended Branch Circuit Protection
The HC-DySC must be installed by a qualified electrician, in compliance with
all local and national electric codes. The HC-DySC input (line) and output
(load) terminals are located behind the right door. Terminal details are shown in
Figure 5 on page 12
. Branch circuit protection rated less than the HC-DySC current rating
HC-DySC Rating Max. MCCB Rating
200 A 250 A
.
8 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Installation Chapter 2
$5($
5(&200(1'('
)25723
&21'8,7(175<
6+2:1:,7+287
&29(5
0,1,080
>@&/($5$1&(
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/289(5('9(176
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Accessing Terminations
For top entry remove the top gland plate, shown in Figure 2, to access input and
output terminals. This plate may be removed for drilling or punching holes for
conduit. Alternate bottom entry should utilize the bottom gland plate shown in
Figure 1
Figure 6 on page 13
communications conductors, as shown in Figure 2
. Access to the communications port is above the front doors, as shown in
. A separate conduit knock-out is provided for top entry of
.
Note: When punching or drilling holes for conduit fittings, take care to avoid
dropping metallic particles inside the enclosure. Metallic contamination will void
the product warranty.
Figure 2 - Top Conductor Entry
WARNING: Metallic particles inside the enclosure will void the warranty.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 9
Chapter 2 Installation
HC-DySC
3-Wire vs. 4-Wire Configurations
3- Wire Models
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
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.
including the internal Bypass Switch
Figure 3 - HC-DySC 3-Wire Configuration
Figure 3 shows the 3-wire HC-DySC system wiring schematically,
.
.
Note: The 3-wire HC-DySC models rated greater than 240V have not been evaluated by
Underwriters Laboratories, Inc.® for connection to a corner-grounded or ungrounded delta
power source. Contact Rockwell Automation Technical Support for assistance.
10 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Installation Chapter 2
HC-DySC
4- Wire Models
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 Bypass
Switch.
Figure 4 - HC-DySC 4-Wire Configuration.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 11
Chapter 2 Installation
Electrical Terminations and Ratings
Input terminals (top lugs on CBA) are marked L1, L2, and L3 for the source
connections. Output terminal blocks 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.
Figure 5 - Electrical Terminations
• Input/Output mechanical lugs accept AWG 4 to 350 kcmil [25 to 150 mm2] conductors. Tighten lugs to 250 lb-in [28.2
N-m]. Lugs require 5/16” hex key tool for installation.
• Output lugs are mounted on threaded studs and may be removed if desired. Studs are 3/8” [9.525mm] diameter and
nuts should be torqued to 192 lb-in [21.7 N-m].
• NEUTRAL Bus and Ground Bus are provided with 3/8”-16 threaded studs (9.525mm diameter). Tighten nuts to 25 lb-ft
(300 lb-in) [33.9 N-m].
WARNING: The HC-DySC must be safety-grounded according to the National
Electrical Code. In addition, all local, state, and federal regulations applicable to
the installation of electrical systems as well as accident prevention regulations
must be strictly observed
12 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
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