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'('
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6+2:1:,7+287
&29(5
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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
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.
For access, remove the small metal cover from the top of the HC-DySC
(See Figure 6
• All wiring is to be Class 2, limited to 24 Volts, AC or DC.
• Acceptable wire gauges range from 24AWG to 12AWG (0.205-2.5mm2).
• Torque connections to 5.0 lb-in (0.6 N-m).
• For permanent installation of communications conductors, a standard
Figure 6 - Access Cover Location
).
conduit knockout is located on the cabinet top (See Figure 2
).
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 13
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).
• Data accessible through this port includes load voltages, load currents,
status, and event and diagnostic logs.
• Consult Rockwell Automation technical support for specifications to the
HC-DySC SLIP protocol.
Figure 7 - Serial Communications Port
14 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Applying Power and Operation
Chapter 4
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.
• Ensure all input/output wiring including grounding has been completed
and properly tightened.
• Verify CBA circuit breaker is in the ON position before replacing covers.
Replace all covers. Close and lock cabinet doors.
• Put bypass switch in the “BYPASS” position.
• Put CBI circuit breaker in the ON position.
• Apply power from the upstream branch protection device. Power will flow
directly to the load through the bypass switch. The HC-DySC
touchscreen will become active and display “System Offline” in the upper
left corner.
• Veri f y o ut p ut (lo ad ) vo lt age i s pres en t
• Put bypass switch in the “TEST” position. The HC-DySC system will
become energized in this mode but the load will still be powered through
the bypass switch.
• Ensure that the touchscreen displays “OK” in the upper left corner, with a
bar above that states “Sag Prot. Bypassed.” Ensure that the voltage, current,
and frequency readings in the status display are correct.
• If a “Critical” or “Fatal” system event appears on the touch screen (1) place
the maintenance bypass switch in BYPASS and (2) call for technical
support.
• Put the bypass switch in the “NORMAL” position. The load is now being
protected by the HC-DySC. The display should show “OK” in the upper
left corner.
WARNING: This system is interlocked: Opening HC-DySC doors while the
system is in operation will result in loss of power to protected loads, unless the
bypass switch is in the Bypass mode (see HC-DySC SYSTEM OPERATION)
NOTICE: Cycling HC-DySC input power in the sequence OFF--ON--OFF--ON within a one minute
period will cause a “Limit Cycle Timeout” alarm. In such case sag correction will be inhibited for
one minute, after which the alarm will automatically reset.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 15
Chapter 4 Applying Power and Operation
L1, L2, L3 X1, X2 , X3
DySC
EL EC T RONI C S
OUTPUT TO
PROTECTED LOADS
CBI CIRCUIT
BREAKER
OUTPUT
CONTACTS
INPUT
CONTACTS
BYPASS CONTACT SUTILITY INPUT
CBA CIRCUIT
BREAKER
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.
System Description
The HC-DySC system consists of the DySC dynamic voltage sag correction
electronics together with an integral maintenance bypass switch. In the Normal
mode of operation the raw utility power is routed through the DySC electronics
to protect the loads from voltage sags and momentary interruptions. Figure 8
shows a simplified one-line diagram for the system. Neutral and Ground
connections are passed straight through to the loads.
Figure 8 - One Line Diagram of the HC-DySC System
Maintenance Bypass Operation
The HC-DySC has an integral maintenance bypass switch. The maintenance
bypass switch is used to avoid power interruptions to the critical loads during
maintenance or service. The bypass is a 3 position make-before-break rotary
switch.
16 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Applying Power and Operation Chapter 4
Bypass Switch Modes
Maintenance Bypass Transfer Procedure
The bypass switch has three modes of operation and is configured as shown in
Figure 9
• BYPASS Mode – Only bypass contacts are closed. Power flows directly from
the utility to the load. No power is present on DYSC inputs or outputs. DySC
power electronics are isolated for maintenance or repair.
.
Figure 9 - Bypass Switch and Mode Operations.
• NORMAL Mode – Input and output contacts
are closed. Power flows from the utility source
through the DYSC electronics to the load.
• TEST Mode – Bypass contacts and input
contacts are closed. Power flows directly from the
utility to the load through the bypass contacts.
DYSC outputs are not connected to the load.
DYSC electronics have power provided for testing
by a qualified electrician.
Manual transfer to Bypass (maintenance) mode:
1. Rotate bypass switch to the Test position, then to the Bypass position.
Note: when the bypass switch is in the Bypass position, CBI circuit breaker will open
automatically.
2. Verify the screen on the HC-DySC displays “System Offline” in the upper left-hand corner of the home page.
3. The HC-DySC is now bypassed and isolated for maintenance.
Manual transfer to Normal (sag protection) mode:
1. Rotate CBI handle to the off/reset position then to the on position. Note: HC-DySC prevents re-closure of CBI within 1 minute of opening.
2. Rotate the bypass switch to the Test position. ATTENTION: The bypass
contacts are all timed to make-before-break and will not disrupt power to
the load during any mode transitions. The switch has lockout/tagout
(LOTO) provisions. Delay one second from changing from one position
to the next.
3. Verify the screen on the HC-DySC displays “OK” in the upper left-hand corner of the home page.
4. Rotate the bypass switch to the Normal position.
5. The HC-DySC system is now providing power to the load.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 17
Chapter 4 Applying Power and Operation
Operating and Alarm Modes
Under some conditions the HC-DySC will trip the internal circuit breaker CBI
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.
ATT EN TI ON : reclosing of CBI will be inhibited for one (1) minute after CBI has
opened for any reason. Attempts to close CBI too early will result in immediate
re-tripping.
Table 2 - Operational Conditions and Indications
CONDITION DEFINITION DISPLAY STATUS* INVERTER MODE
Normal: 88.5% < V LINE < 110% Green “OK” Standby Static BP
Sag Event: V
Runtime Exceeded: Cumulative runtime
Normal Mode,
Overload:
Output Over-Current
while inverter running
(I
2t)
Inverter Module
Over-temperature:
HC-DySC cabinet
Over-temperature:
Static Switch Failure: Open SCR(s) Blue, HC-DySC offline Disconnected CBI open
Main Fuse Open Open Fuse(s) Blue, HC-DySC offline Disconnected CBI open
Enclosure Door Open: Door Open Blue, HC-DySC offline Disconnected CBI open
LINE < 88.5% for less
than specified runtime
exceeded
Load current > 110% Red during OL condition,
Load current > 150%
for 3 cycles
Module temperature
limit exceeded
Internal temperature
limit exceeded
Green “OK” Running Inverter
Blinks Red, then Orange for 1
min. Repeats if condition
persists
Orange for 1 min. after OL ends
Blinks Red, then Orange for 1
min. Repeats if condition
persists
Blue, HC-DySC offline Disconnected CBI open
Blue, HC-DySC offline Disconnected CBI open
Inhibited Static BP
Inhibited Static BP
Inhibited Static BP
* The touchscreen will power down if both input and output voltages fall below 75% of nominal.
An error message will be displayed while the red or orange text box is displayed. Refer to
Chapter 5
for further information on accessing fault codes and status history.
18 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
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.
Note: The touch screen is optimized for use with a plastic stylus or bare finger.
At installation time perform the following steps to configure your system:
Step 1: Press the “CONFIG” button
at the bottom of the “HOME” screen
(See Figure 10
).
Step 2: Begin calibration by pressing
“CALIBRATE TOUCH SENSOR”
(See Figure 11
).
Figure 10 - Home Screen
Figure 11 - System Configuration
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 19
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
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.
Step 4: The screen uses the new
calibration configuration. You can test
the calibration before saving by
pressing anywhere on the screen to
ensure the touch target appears where
you press. After testing, press the
“SAVE” button. Press the “BACK”
button to return to the “System
Configuration” screen.
Step 5: Set date and time by pressing
“SET SYSTEM CLOCK” in “System
Configuration.” Press “SAVE” when
completed.
Figure 12 - Touch Screen Calibration
Figure 13 - Set System Date and Time
20 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Display Screen Chapter 5
Home Screen The “HOME” screen of the display provides a snapshot view of the status of the
entire system (See Figure 14
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 inTa b l e 3
Figure 14 - Home Screen
). You can return to this screen from any other screen
.
Table 3 - Home Screen Description
Description Function
Status
Last Voltage Sag Rotating information about the last voltage sag: event start time, event duration, and sag depth
Statistics
Main Menu
Real-time system operation: available runtime, output line-to-neutral (L-N) or line-to-line (L-L) voltage (model dependent), load current, and
frequency
Summary view of HC-DySC performance based on sags detected, plus a rotating display of last power-up date, elapsed time (since power up), and total
up-time
The menu buttons at the bottom of the screen navigate through:
VOLTAGE SAGS: Displays the “Voltage Sag Log” screen
CONFIG: Displays the “System Configuration” screen
STATUS: Displays the “System Status” screen
SYSTEM EVENTS: Displays the “System Event Log” screen
Mechanical Bypass
Some systems equipped with a mechanical bypass display the bypass status in the
System Status panel on the Home Screen. When the mechanical bypass is closed,
the DySC unit is bypassed and voltage sags on the line will NOT be corrected.
Figure 15 - Home Screen Mechanical Bypass
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 21
Chapter 5 Display Screen
System Status The “System Status” screen displays the real-time overall system status. Reach this
screen by pressing “STATUS” on the “HOME” screen or the “Status” area at the
top of the “HOME” screen
Figure 16 - System Status Summary Figure 17 - - System Status Waveforms
Table 4 - System Status Description
Description Function
System Status Overall system status including current operational status, availability to correc t sags, and internal cabinet temperature
Phase Status
Waveforms A sample of a 4 cycle waveform that includes real-time line voltage, load voltage, or load current can be selected for display
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 HC-DySC. Nominal values are listed on the “View Model Information” screen.
Mechanical Bypass
Some systems equipped with a mechanical bypass will display the bypass status in
the System Status panel on the Status Screen. When the mechanical bypass is
closed, the DySC unit is bypassed and voltage sags on the line will NOT be
corrected.
Figure 18 - Status Screen Bypass Status
22 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Display Screen Chapter 5
Voltage Sag Events 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 Fig ure 19) displays a list of the last 61 voltage
sags. Reach this screen by pressing “VOLTAGE SAGS” button on the “HOME”
screen.
Figure 19 - Voltage Sag Log
Table 5 - Voltage Sag Log Description
Description Function
# Unique ID within the list (0-60) to identify the voltage sag
Time Start time and date of the voltage sag
Check Mark Denotes the HC-DySC protected the voltage sag
RMS% Worst-case RMS voltage (percent of nominal) across all phases
Duration Duration of the voltage sag
Note: Use the up/down arrows to navigate through the list. Press the “SELECT” button to view additional details about
the voltage sag
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 23
Chapter 5 Display Screen
Voltage Sag Detail Vo lt age Sa g De t ail” s cr een (S ee 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.
Ta b l e 6
Figure 20 - Voltage Sag Detail
describes the remaining screen content.
Table 6 - Voltage Sag Detail Description
Description Function
ID: Unique ID within the list (0-60) to identify the voltage sag
Time: Start time of the voltage sag
Sag Summary
Sag Magnitude
Correction Result
Note: The “Voltage Sag Detail” for the most recent event can also be accessed by pressing the “Last Voltage Sag” area of the “HOME”
screen.
RMS: Worst-case RMS voltage (L-N) and percent of rated voltage across all phases
Duration: Duration of the voltage sag
Frequency: Frequency of the line prior to the start of the voltage sag
Tem per at ure : Internal temperature of the HC-DySC prior to the start of the voltage sag
Line Voltage: Line RMS voltage and percent of rated (L-N). Voltages ≤ 80% of nominal are
displayed in red.
Load Voltage: Load RMS voltage and percent of nominal (L-N).
The “Correction Result” is displayed in a box in the upper-right-hand corner of the “Event
Summary” section. The “Correction Result” conveys how the HC-DySC performed correcting
the voltage sag. The possible values are:
Protected: The output RMS voltage on all phases is ≥ 85 percent of nominal and the HC-DySC
correction was active for the duration of the voltage sag (will be displayed in green).
Run Error: An unexpected system event occurred during the sag (will be displayed in orange)
Run Inhibited: The HC-DySC system was inhibited when the sag occurred (will be displayed in
orange).
24 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Display Screen Chapter 5
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 21
Detail” screen as shown in Figure 20 on page 24
Figure 21 - RMS Voltage Charts
Line voltage is shown in red and load voltage is shown in green. By pressing the
check boxes in the right column, you can toggle each data series Off and On as
well as enable y-axis auto-scaling.
Note: 300 cycles = 5.0 seconds at 60 Hz or 6 seconds at 50 Hz.
). Reach this screen by pressing “CHARTS” on the “Voltage Sag
.
Voltage Sag Notification While the voltage sag is in-progress, a flashing red box in the upper left-hand
corner will display “SAG-IN-PROGRESS.” This box will appear on every screen
until the voltage sag ends. See Figure 22
Figure 22 - Voltage Sag Detected
.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 25
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
Manual-Reset
Call Service
User action may be required to correct a problem. The HC-DySC will reset 60
seconds after the error condition is corrected.
For system events that cause circuit breaker CBI to open a manual reset of the
DySC system will be required.
For events classified as Call Service, factory trained service support will be
required. Contact Rockwell Automation technical suppor t.
System Event Log
The “System Event Log” screen displays a list of the last 40 system events in
chronological order (See Figure 23
EVENTS” on the “HOME” screen.
Figure 23 - System Event Log
). Reach this screen by pressing “SYSTEM
Table 8 - System Event Log Description
Description Function
# Unique ID (0-39) to identify the system event (unique within the list)
Time Start time of the system event
Name Short name of the system event.
Severity Severity of the system event
Note: Use the up/down arrows to navigate through the list. Press the “SELECT” button to view additional detail about the system event.
26 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Display Screen Chapter 5
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 23 on page 26
recorded during the event (See Figure 24
Figure 24 - System Event Detail
). It provides detailed information that was
).
Table 9 - System Event Detail
Description Function
Time/Duration
Type
Component
Time: Date and start time of the system event
Duration: The amount of time the event lasted.
Event ID: Unique ID within the list (0-39) to identify the event.
Code: Abbreviation of the event followed by a numeric event code in parentheses. (For a
list of codes and abbreviations see Table 11 on page 32
Severity: Severity of the event
Description: Name of the event see Table 11 on page 32
Location: The location in the system where the event originated (i.e. Phase A, Phase B,
Phase C, etc.).
Area: The specific area within the location where the event originated (i.e. Inverter, etc.).
Reading: a data value relevant to the System Event may be recorded in some cases, e.g.,
detail for an “Inverter Over-Current” alarm would include a reading of the causal high
current value. The reading “N.A.” is displayed if no appropriate data value exists.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 27
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
Fault Detection” box, the name, severity, and location of the event will be
displayed.
Figure 25 - System Fault Detection
). Within the “System
Pressing the “OK” button will open the “System Event Detail” screen. The event
will appear in the event list after the event is over. The window can be closed by
pressing the “CANCEL” button or waiting 15 seconds.
When the event condition clears, a new dialog box will be displayed. Press “OK”
to view the complete event detail, or “CANCEL” to close the dialog box (See
Figure 26
Figure 26 - System Fault Detection - Cleared
).
If a “Call Service” severity event is detected, record the event details including:
name, description, location, and reading. Contact product support immediately.
If the event clears, the touch screen will automatically go back to normal
operation.
28 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Display Screen Chapter 5
System Configuration Press the “CONFIG” button at the bottom of the “HOME” screen to enter the
“System Configuration” screen (See Figure 27
and “CALIBRATE TOUCH SENSOR” functions are described at the start of
this chapter.
Figure 27 - System Configuration
). The “SET SYSTEM CLOCK”
Model Information Touch “VIEW MODEL INFORMATION” to go to the “Model Information”
screen. (See Figure 28
Figure 28 - Model Information
Table 10 - Model Information
Description Function
Model Details
Unit Details
).
Model Number: System Model number
Serial Number: System serial number
System Rating: System voltage and current ratings
Node: The location index for the details listed to the right
Firm: The firmware version for the location indexed.
Type: Unique code specifying firmware part number for the location indexed.
Serial: The serial number for the location indexed
Volts: The rated voltage for the locations
Amps: The rated current for the location indexed
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 29
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.
30 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Maintenance
Chapter 6
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 bypass switch is in the NORMAL mode.
• 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.
• Ensure air intake and exhaust filters are not covered or obstructed.
.
3-6 Month Checks
• Check air filters and clean when necessary.
– Air filters for the HC-DySC will require periodic cleaning, with the
frequency depending on the environment. Filters are located on the
front side of the HC-DySC, and can be accessed with the door closed.
The HC-DySC need not have power removed for this operation.
Remove the grill covers by unscrewing the knurled nuts; the washable
foam filter pads are behind the grill cover. Gently wash the foam filter
pads as needed with a light non-abrasive soap and water mixture.
Towel-dry; do not wring-out. Place the filter and grill cover back into
their location and replace the screw caps by rotating clockwise until
finger tight. Replace filter if damaged. Consult Rockwell Automation
technical support for replacement filters. Replacement filters must be
no more restrictive to air flow than the original equipment filters.
• Check fan for proper operation.
– Tap on “CONFIG” on the touch screen display. Tap on “Run System
Test”. This will bring up a “System Test” screen to test the fans. After
tapping the “Fan Test” button, you should hear the fans run for two
minutes.
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 31
Chapter 6 Maintenance
Table 11 - System Event Table
Event
Code Name Full Name Severity Area Event Description Event Resolution
Code
POWER_ON DySC Power On Informational Unit Power re-applied to the DySC. No action needed.
1
T_FAN_ST Fan Test Start Informational Unit Start acknowledgment of DySC fan test. No action needed.
4
T_IN_ST_1 Inverter Test (.5 cycles) Start Informational Unit Start acknowledgment of DySC 0.5 cycle inverter test. No action needed.
5
T_IN_ST_2 Inverter Test (3 cycles) Start Informational Unit Start acknowledgment of DySC 3 cycle inverter test. No action needed.
6
T_IN_ST_3 Inverter Test (5.5 seconds) Start Informational Unit Start acknowledgment of DySC 5.5 second inverter test. No action needed.
7
EXTERNAL External Inhibit Auto-Resetting Inverter Controller is inhibited by another phase controller. Review event details from other phase controllers.
9
11
12
13
14
15
16
17
18
19
20
25
31
32
33
RUN_TO Inverter Run Time out Auto-Resetting Inverter DySC inverter had a total cumulative runtime of more than rated. No action needed.
LIM_CYCLE Inverter Limit Cycle Timeout Auto-Resetting Inverter Power was re-applied more than once within a 58 second period. No ac tion needed.
STAT_OT Static Switch Over-Temperature User Attention Static Switch Static switch heatsink temperature was greater than maximum rating.
OVERLOAD Overload User Attention Unit Inverter inhibited because load current exceeded maximum rating.
DC_OV DC Bus Over-Voltage User Attention Inverter Positive or negative half of DC bus voltage exceeded maximum rating.
CNTRL_UV Controller Power Under-Voltage User Attention Inverter DySC control power supply is out of tolerance.
OUTPUT_UV Output Under-Voltage User Attention Inverter
INV_OC Inverter Over-Current User Attention Inverter Inverter current exceeded maximum rating during sag correction.
DC_UV DC Bus Under-Voltage User Attention Inverter DC bus voltage below operational range.
OUTPUT_OV Output Over-Voltage Call Service Inverter
SYNC_ERR Line Synchronization Error Call Service Inverter Inverter not synchronized to line when sag detected. Call service.
CONFIG Configuration Alert Call Service Inverter Controller configuration has changed. Call service.
CNTRL_MEM Controller Memory Busy Auto-Resetting Inverter Controller is loading new data into Flash memory. No action needed.
UNBALANCE Start-Up Test: DC Bus Unbalance Call Ser vice Inver ter
DySC output voltage was less than 80% of nominal during sag correction.
Sag condition likely outside of DySC specification.
DySC output voltage was greater than 115% of nominal during sag
correction.
Positive and negative halves of the DC bus did not charge equally during
power up.
Verify ambient temperature is within DySC specification. Check
for damaged fans. Check for dirty or obstructed air filters.
Reduce load. In parallel DySC systems, verify proper current
sharing among slave cabinets.
Verify line voltage is within ratings. Verify proper DySC
application. Call service.
Verify DySC is online and line voltage is within ratings. Call
service.
Verify line voltage is within ratings. Verify proper DySC
application.
Verify load current is within ratings. Verify mechanical bypass
switch is open. Verify proper DySC application.
Verify line voltage is within ratings.
Call ser vice.
Call ser vice.
Call ser vice.
AC_V_CHK Start-Up Test: AC Voltage Check Call Service Inverter Output voltage was detected out of tolerance during the start-up test. Call service.
34
ROLL_CALL
35
32 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Start-Up Test: Controller Roll Call
Timeout
Call Service Unit Controller communication problem detected during start-up test. Call service.
Chapter 6 Maintenance
Event
Code Name Full Name Severity Area Event Description Event Resolution
Code
36
37
38
39
40
41
COM_V ER
CNFG_TO
CNFG_ERR
FIRM_TO
FIRM_DIFF
SRL_TO
Start-Up Test: Communication
Compatibility Mismatch
Star t-Up Test: Contro ller Configuration
Timeout
Star t-Up Test: Contro ller Configuration
Mismatch
Start-Up Test: Controller Firmware
Check Timeout
Start-Up Test: Controller Firmware
Revision Mismatch
Start-Up Test: Controller Serial Number
Check Timeout
Call Ser vice Unit
Call Service Unit Controller communication problem detected during start-up test. Call service.
Call Service Unit Controller firmware configuration problem detected during start-up test. Call service.
Call Service Unit Controller communication problem detected during start-up test. Call service.
Call Service Unit Controller firmware revision mismatch detected during start-up test. Call service.
Call Service Unit Controller communication problem detected during start-up test. Call service.
Firmware communication compatibility problem detected during start-up
test.
Call ser vice.
42
44
46 DOOR_OPEN DySC Cabinet Door Open Manual Reset Unit DySC door was opened. Mechanical bypass commanded. Close door. Manually reset DySC.
47 CRIT_OT Critical Over-Temperature Manual Reset Unit
48 FUSE_OPEN Fuse Open Call Service Unit One of the DySC fuses was detected open. Mechanical bypass commanded. Call service.
49 OPEN_SCR_A Open SCR Phase A Call Service Static Switch The SCR on the phase A module was detected open. Call service.
50 OPEN_SCR_B Open SCR Phase B Call Ser vice Static Switch The SCR on the phase B module was detected open. Call ser vice.
51 OPEN_SCR_C Open SCR Phase C Call Ser vice Static Switch The SCR on the phase C module was detected open. Call service.
53 DYN_BRAKE Dynamic Brake Error Call Service Unit A problem was detected with the DySC dynamic brake controller. Call service.
58 PLC_ERR Programmable Logic Controller Error Call Service PLC PLC error detected. Call service.
59 PLC_ST_MM
SRL_DIFF Start-Up Test: Serial Number Mismatch Informational Unit Controller serial number mismatch detected during start-up test. No action needed.
T_INV_TO Inverter Test Timeout Call Service Unit Phase control board failed to respond to Comm board's Inverter test. Call service.
Verify ambient temperature is within DySC specification.
Check for damaged fans. Check for dirty or obstructed air filters.
Manually reset DySC.
Programmable Logic Controller State
Mismatch
Internal DySC temperature exceeded maximum rating. Mechanical bypass
commanded.
Call Service Unit PLC feedback error detected. Call service.
33 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Chapter 6 Maintenance
Servicing
ATT EN TI ON : 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 Operation on page 16.
WARNING: The HC-DySC is interlocked. Opening cabinet doors while the
system is in operation will result in loss of power to protected loads, unless the
bypass switch is in the BYPASS position.
Circuit Breaker CBI, Safety Interlocks and Stored Energy
Figure 8 on page 16 shows the arrangement of circuit breakers CBI and CBA and
of the bypass switch contacts INPUT, OUTPUT and BYPASS. If the cabinet
doors are opened while the HC-DySC is operating the circuit breaker CBI will
be automatically opened and load power will be interrupted unless the bypass
switch is first put into the BYPASS position. Doors should be kept locked to
avoid this situation.
The HC-DySC includes a fast-discharge circuit to quickly dissipate stored
energy when the circuit breaker CBI is opened. Placing the bypass switch in
BYPASS will automatically open CBI. CBI may be operated automatically by the
door interlock switches or other protection devices. CBI can also be operated
manually.
If the upstream power is interrupted before CBI is opened the fast-discharge
circuit will not be triggered. In that case wait at least 30 minutes before opening
the HC-DySC doors to avoid exposure to charged capacitors. High voltage
remains on capacitors if the red LED indicators above the power module
capacitor banks are lighted.
Circuit Breaker CBA and Fuses
Fast-acting fuses are included to protect the HC-DySC in the event of a load
short circuit condition. If the system is found to be offline and the display shows
an “Open Fuse” alarm then a load short circuit may have occurred. Verify no load
short circuit condition exists before placing the bypass switch into the BYPASS
position. Circuit breaker CBA will limit current through the bypass switch in
case of a load short circuit condition while in the BYPASS mode. If there is no
output voltage present and the display is off, it is an indication that either the
CBA circuit breaker has opened or an upstream protection device has opened.
34 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Maintenance Chapter 6
IMPORTANT
SHOCK HAZARD: Remove all power supplying the HC-DySC before removing
the protective cover to reset the CBA circuit breaker. Replace all covers and
doors before reapplying power to the HC-DySC.
WARNING: Turn the power to the HC-DySC electronics off by placing the Bypass
Switch into BYPASS or opening the branch circuit breaker before replacing any
fuse. Failure to comply with this warning can result in injury or death.
WARNING: The HC-DySC has high voltage remaining up to 30 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 HCDySC after power is removed. Keep doors closed until all internal LED indicators
are extinguished.
WARNING: Keep the cabinet doors closed to ensure proper cooling airflow and
to protect personnel from dangerous voltages inside the HC-DySC
Fuse locations within the HC-DySC cabinet are shown on a label inside the door.
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
Tec hnic al Sup port.
Fuse Rating Charts
Table 12 - HC-DySC Enclosure Fuses
Fuse Reference Fuse Location Fuse Rating
F1, F2, F3 Cabinet: Main Power Input 600A/500V Mersen A50QS600-4IL
F4, F5, F6 Cabinet: Cross-Coupling Transformer 100A/600V Mersen AJT100
F7, F8, F9
(3 wire models only)
F10, F11 Cabinet: Input Control Transformer 1A/600V Mersen TRS1R
F12, F13 Cabinet: Cross Coupler Auxiliary 2A/600V Mersen ATQR2
F14, F15 Cabinet: Output Control Transformer 4A/600V Mersen TRS4R
F16, F17, F18
F20 (4 wire only)
F19 Cabinet: Input Control Transformer 4A/600V Bussmann FNQ-R-4
Cabinet
Neutral Forming Transformer
Cabinet: TVSS Input 40kA surge / 600V Mersen VSP40-2
4A/600V Mersen TRS4R
Manufacturer
Part Number
F1, F2 Power Module (x3): Voltage Feedback 2A/600V Mersen ATQR2
F3 Power Module (x3) -- Not Field Replaceable
F4, F5, F6, F7 Power Module (x3): Dynamic Brake 20A/600V Mersen ATM20
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 35
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 F20 (present in 4-wire models
only).
36 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
Specifications and Dimensions
Table 13 - Technical Specifications 200 A HC-DySC
Electrical Input/Output (No rmal Mode—Static Switch)
Connection Configuration
Input Voltage
Voltage Range
Available Short Circuit Current
Current Overload (Static Switch)
Frequenc y
Frequency Range
TVSS
Efficiency
Output Voltage
Voltage Regulation
HC-DySC Output Current
Crest Factor (at nameplate rms load)
Volta ge Wavefo rm
3 phase 87% to 50% Voltage Remaining 5 seconds
Series-connected with load. Under normal line condition, the static switch passes utility voltage directly to the load
3-phase: 480V
± 10%
25kA
150% @ 30Sec., 400% @ 5 Sec., 600% @ 0.5 Sec.
50/60 Hz Auto Sensing
48 -62 Hz
Output SPD, 40kA/mode
> 99% @ 480V
Pre-sag rms voltage
± 5% typical, +5% / -13% of nominal max
200 ARMS 2 Not rated for DC loads; max. allowable 2% DC loading
1.45
Sine wave
1
Electrical Output (S ag Correction Mode - Inverter)
Voltage Sag Correction Times
Single Event
Chapter 7
All three phases to zero voltage remaining 78 ms based on nameplate rated load with a power factor of 0.7
Multiple Event
Max Sag Correction Time 5 seconds cumulative usage
Sequential Sag Recovery 0 seconds (assuming cumulative run-time available)
Full Recovery Time Max 5 minutes
Mechanical
Enclosure Ratings
Cable Entry
Cooling
Access
Audible Noise
Weight
NEMA 1 (IP20)
Top or Bo tt om
Filtered Forced Air
Front for servicing and connections
less than 60 dBA at 1m
1408 lb (639 kg)
Environmental
Ambient Temperature 0 to 40°C
Storage Temperature -40°C to 75°C
Relative Humidity 0 to 95% non-condensing
Altitude Rated current available to 1000m (3300ft). De-rate output current 10% per 1000m, from 1000m to 3000m (9900ft).
Safety and Compliance
Agency Approvals cULus Listed (UL 1012)
Standards Compliance Exceeds SEMI F47 Standard; IEEE Std C62.41.1 and UL 1449 3rd Ed. compliant
1. HC-DySC has not been evaluated for use in Corner Grounded or Ungrounded Delta Power Systems in systems rated over 240V.
2. When using HC-DySC with motor drive loads, either insert 3% to 5% line reactance at HC-DySC output or limit motor drive loads to 60% of HC-DySC rating
Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013 37
Chapter 7 Specifications and Dimensions
29(5$//
:,'7+
,2
&200
3257
$&&(66
/&'
',63/$<
$,5
,17$.(6
%<3$66
6:,7&+
$&,1387
6:,7&+
$5($
5(&200(1'('
)25723
&21'8,7(175<
6+2:1:,7+287
&29(5
0,1,080
>@&/($5$1&(
72%(0$,17$,1('
)5206,'($1'%$&.
/289(5('9(176
)253523(5&22/,1*
'2256:,1*
,2.12&.287
29(5$//
+(,*+7
29(5$//
'(37+
Table 14 - Heat Dissipation
Rating (V) Heat Loss (W) Heat Loss (Btu/h) Efficiency (%)
480V 1664 5677 99%
Approximate Dimensions
Dimensions are shown in inches (millimeters). Dimensions are not intended to
be used for manufacturing purposes.
Figure 30 - 200 A HC-DySC Dimensions
38 Rockwell Automation Publication 1608P-UM004A-EN-P - September 2013
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SM
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Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this
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Publication 1608P-UM004A-EN-P - September 2013 Copyright © 2013 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A
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