Rockwell Automation 1608M User Manual
User Manual
Bulletin 1608M MegaDySC Dynamic Voltage Sag Corrector
1608M—400 Amp 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.
MegaDySC, Allen-Bradley, Rockwell Software, Rockwell 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
Ch 5 - Operation
Ch 6 - Display Screen
Table of Contents
Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Instructions for energizing loads before commissioning . . . . . . . . . . . . . . . . 12
MegaDySC System Installation Connections Checklist . . . . . . . . . . . . . . . . 14
MegaDySC System Interconnections Checklist . . . . . . . . . . . . . . . . . . . . . . . 14
Remote Diagnostics and Remote Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CBB Contacts (Bypass Circuit Breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CBI Contacts (Input Circuit Breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remote Seamless Bypass Command-EPO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Contact Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MegaDySC Status Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
RS-232 Serial communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
i-Sense Voltage Monitor Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MegaDySC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Automatic Bypass Switchboard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Automatic Bypass Switchboard Operating Instructions . . . . . . . . . . . . . . . . . . . . 23
Automatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Manual Transfer to Maintenance Bypass (Bypass Mode) . . . . . . . . . . . . . . . 23
Manual Transfer to MegaDySC (Normal Mode) . . . . . . . . . . . . . . . . . . . . . . 23
Transient Voltage Surge Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagnostic Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mechanical Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
System Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Voltage Sag Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Voltage Sag Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Voltage Sag Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Voltage Sag RMS Voltage Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Voltage Sag Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
System Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
System Event Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
System Event Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Run System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Diagnostics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013 3
Table of Contents
Ch 7 - Maintenance
Ch 8 - Specifications
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Monthly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3-6 Month Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Automatic Circuit Breakers, Safety Interlocks and Stored Energy . . . . . . . 42
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Automatic Bypass Switchboard Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
MegaDySC and ER Cabinet Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4 Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013
Chapter 1
Introduction
The Allen-Bradley Bulletin 1608M MegaDySC Dynamic Sag Corrector is
engineered to provide years of trouble-free voltage sag (dip) protection. The
patented DySC technology does not use batteries, requires only routine
maintenance, includes three-stage transient voltage surge suppression, and has
unparalleled energy efficiency. Most electronic devices found in industry today
are susceptible to power disturbances. A momentary sag in line voltage can reset
or damage sensitive production equipment. The MegaDySC provides
instantaneous dynamic sag correction to help your equipment ride through these
common events. The MegaDySC connects normal utility power directly to the
load until a voltage sag occurs. During a sag, the MegaDySC 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 MegaDySC is
quickly ready to correct the next sag.
The MegaDySC 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 MegaDySC is designed to operate in industrial applications. Follow these
guidelines to ensure that the safety and installation of the MegaDySC are
handled with appropriate care.
SHOCK HAZARD: The MegaDySC has high voltage remaining up to 5 minutes
after disconnection from the AC line. Touching exposed or disconnected
terminals, cables or parts of the MegaDySC can lead to serious injuries or even
death. Wait for a minimum of 5 minutes before performing any service or
testing on the MegaDySC 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 MegaDySC.
ATTENTION: - To reduce the risk of fire or electric shock, install this MegaDySC
in a temperature and humidity controlled, indoor environment, free of
conductive contaminants.
• Avoid installing the MegaDySC 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 ser vice on the MegaDySC.
• Ensure all power is disconnected before performing installation or service.
Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013 5
Chapter 1
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 MegaDySC is not rated to directly power life
support equipment.
• Ensure the area around the MegaDySC is clean and uncluttered.
• Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the
equipment.
6 Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013
Installation
Chapter 2
System Components
The MegaDySC system consists of two enclosures including one “DySC 400 A
Module” MegaDySC section and one Automatic Bypass Switchboard, which are
shipped separately and must be mechanically and electrically interconnected at
the time of installation. The MegaDySC section houses the static bypass and
voltage sag-correction electronics as well as the optional extended-run (ER)
module. The Automatic Bypass Switchboard houses the maintenance bypass
circuit breaker (CBB), the MegaDySC input (CBI) and output (CBO) circuit
breakers, automatic controls, and the i-Sense® voltage-monitoring sensor.
This document applies to the following MegaDySC System Models:
Table 1 - MegaDySC System Models
Catalog Number Current Rating Voltage
Rating
1608M-400A380V3S 400A 380V 3 SR
1608M-400A380V3E 400A 380V 3 ER
1608M-400A380V4S 400A 380V 4 SR
1608M-400A380V4E 400A 380V 4 ER
1608M-400A400V3S 400A 400V 3 SR
1608M-400A400V3E 400A 400V 3 ER
1608M-400A400V4S 400A 400V 4 SR
1608M-400A400V4E 400A 400V 4 ER
1608M-400A415V3S 400A 415V 3 SR
1608M-400A415V3E 400A 415V 3 ER
1608M-400A415V4S 400A 415V 4 SR
1608M-400A415V4E 400A 415V 4 ER
1608M-400A460V3S 400A 460V 3 SR
1608M-400A460V3E 400A 460V 3 ER
1608M-400A460V4S 400A 460V 4 SR
1608M-400A460V4E 400A 460V 4 ER
1608M-400A480V3S 400A 480V 3 SR
1608M-400A480V3E 400A 480V 3 ER
1608M-400A480V4S 400A 480V 4 SR
1608M-400A480V4E 400A 480V 4 ER
3 /
4-wire
SR / ER
Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013 7
Chapter 2 Installation
System Layout
Figure 1 - Standard Run (SR) System Layout
8 Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013
Figure 2 - Extended Run (ER) System Layout
Installation Chapter 2
Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013 9
Chapter 2 Installation
Attach the MegaDySC section to the Automatic Bypass
switchboard using the six (6) sets of 3/8” hardware supplied.
• Install three (3) sets along the front door frame and three
(3) sets along the rear frame. Hardware along the rear
frame may be omitted if rear access to the switchboard is
not available: it is necessary to remove the rear panel of the
switchboard to install the rear sets of hardware.
• Install bolts from the switchboard side and thread into the
weld nuts located in the MegaDySC section enclosure.
• Each set consists of one 3/8-16 x 1.0” bolt, one 3/8 split lock
washer and one 3/8” flat washer, assembled as shown.
System Clearance
System Mounting
The MegaDySC doors are hinged on the left, and clearance must be given to
allow the door to swing open 90 degrees to the front of the enclosure.
Clearance for the Automatic Bypass switchboard must allow the front panels to
swing (left side hinged) open 90 degrees to the front of its enclosure.
Either rear (preferred) or left side access to the Automatic Bypass switchboard
will be required during installation wiring and cabinet interconnect wiring.
The MegaDySC system is floor-mounted, and should be secured using the 0.63”
diameter mounting holes provided along the bottom channels. The MegaDySC
section is provided with all necessary interconnect wiring to the Automatic
Bypass switchboard section. Proper line-up is critical: The MegaDySC section
must be located to the right of the Automatic Bypass section when viewed from
the front of the system.
The "DySC 400A Module" MegaDySC section is shipped separately from the
Automatic Bypass switchboard. The MegaDySC section must be secured to the
Automatic Bypass enclosure with the 3/8” hardware supplied. See Figure 3
for
fastening locations and hardware arrangement. The optional ER enclosure is
permanently connected to the MegaDySC section prior to shipment.
Figure 3 - System Mounting
10 Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013
Figure 4 - Floor Mounting Detail
Installation Chapter 2
Electrical Interconnections
WARNING: Equipment must be earth-grounded according to local and
national electrical codes. Failure to supply proper equipment grounding may
result in electrical shock or death. All interconnection wiring will be
installed by a factory-trained technician during system
commissioning.
The MegaDySC cabinet and the Automatic Bypass (ABP) Switchboard are
shipped separately. The customer is responsible for system mounting. All
interconnecting power cables are provided (shipped inside the ABP switchboard)
and will be connected by a factory-trained technician during commissioning. At
installation the loose ends of the main cables will be routed through the bushings
in the side of the ABP switchboard and connected inside the MegaDySC cabinet
to the appropriately labeled terminals. A control wiring harness is also provided
in the ABP and must be connected to the MegaDySC cabinet. This cable harness
is routed through two large holes, one in the ABP cabinet and one in the
MegaDySC cabinet, located at the bottom front of the cabinets. The harness is
plugged into the associated terminal block located in the lower, left corner of the
MegaDySC cabinet. Finally, the incoming electrical service and outgoing load
cables are brought in through the top (or bottom) of the ABP switchboard and
connected to the appropriate bus locations, as shown in Figure 6
connected to the bus bar terminals labeled L1, L2, L3 and the protected load is
connected to the bus bar terminals labeled X1, X2, X3.
. AC input is
Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013 11
Chapter 2 Installation
Instructions for energizing loads before commissioning
Figure 5 - Rear view of Automatic Bypass Switch board
If the MegaDySC system must
be installed and put into
maintenance bypass mode
before commissioning, the
installers should put the
system enclosures in place as
described on page 10
feed the loose ends of intercabinet cables from the
switchboard into the
MegaDySC cabinet:
1. Route the INPUT power cables (labeled L1, L2, L3) through the top bushing in the right-side wall of the switchboard, labeled “Input to DySC”
, then
2. Route the OUTPUT power cables (X1, X2, X3) and Ground cable through the bottom bushing labeled “Output from DySC”
3. Route the control cable harness from the lower front switchboard pan into
the MegaDySC section through the matching holes in the lower front side
panels. Install the 3.5” snap-in grommet so that it protrudes into the
MegaDySC cabinet before routing the harness. Plug the harness header
into connector TB5 on the MegaDySC floor.
WARNING: 120VAC is present at several pins of the harness header when the
switchboard is energized.
4. Lockout circuit breakers CBI and CBO in the Automatic Bypass Switchboard.
5. Install utility input and load output conductors.
6. Energize the switchboard.
The MegaDySC touch screen display will be active only if the control
harness has been plugged in on the MegaDySC side. If the screen is active
then 120VAC is present at several points within the MegaDySC enclosure.
7. Push the green CLOSE CBB button to energize loads. The remaining interconnections and commissioning must be completed by factory-trained technicians.
12 Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013
Figure 6 - Switchboard Terminations and Conduit landing areas
Installation Chapter 2
Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013 13
Chapter 2
MegaDySC System Installation Connections Checklist
• Connect the Automatic Bypass Switchboard ground bus to an earth
ground in accordance with the National Electrical Code and local codes.
• Connect the AC input (line) conductors to the terminals labeled "L1",
"L2" and "L3". The set is labeled "UTILITY INPUT". These terminals are
located left of the switchboard. See Figure 6
• Connect the AC output (load) conductors to the terminals labeled "X1",
"X2" and "X3". The set is labeled "OUTPUT TO PROTECTED
LOADS". See Figure 6
• For 4-wire models only: connect input and output Neutral (N)
conductors to the NEUTRAL bus bar. The input N connection is
required for proper operation of 4-wire models. Do not connect to the
NEUTRAL bus bar in 3-wire models.
• Check all electrical terminations for properly torqued connections.
See Figure 6
• For i-Sense communications: connect either an analog telephone line to
RJ11 jack or Ethernet cable to RJ45 jack. The RJ11 and RJ45 jacks are
located in the upper switchboard compartment. They can be accessed
through a 1" conduit knockout in the top of the cabinet. See Figure 6
Refer to i-Sense Voltage Monitor Communications
.
.
.
on page 18.
and
MegaDySC System Interconnections Checklist
(To be completed by factory-trained technician)
• Connect the Automatic Bypass (ABP) Switchboard-to-MegaDySC
ground cable to the ground bus in the MegaDySC.
• Connect line side cables from input circuit breaker (CBI) located in the
ABP Switchboard to the MegaDySC section bus bars labeled RH1-L1,
RH1-L2 and RH1-L3 respectively.
• Connect load side cables from the output circuit breaker (CBO) located in
the ABP Switchboard to the MegaDySC section bus bars labeled RH1X1, RH1-X2 and RH1-X3 respectively.
• Plug the control cable from the ABP Switchboard into the MegaDySC
cabinet.
14 Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013
Communications
K1
5
1362
4
78
CBB
N/C
CBB1
N/O
TB1
terminal block
NC
1
A
C
2
A
NO
3
A
NC
1B
C
2B
NO
3B
NC
4
A
C
5
A
NO
6
A
NC
4B
C
5B
NO
6B
.
7B
.
8B
.
9B
NC
10B
C
11B
NO
12B
unused
7
A
unused
8
A
unused
9
A
NC
10A
C
11A
NO
12A
NC
13B
C
14B
NO
15B
NC
13A
C
14A
NO
15A
Customer-Supplied Contact:
Close to command
Seamless Bypass
Chapter 3
Remote Diagnostics and Remote Bypass
Relay dry contacts are available for remote monitoring of the state of the Bypass
Circuit Breaker CBB and the Input Circuit Breaker CBI shunt-trip condition
(See Figure 7
). In addition, a customer-supplied relay may be used to remotely
command a Seamless Bypass operation, as described in Automatic Bypass
Switchboard Operation on page 22. These functions are available from terminal
block TB1 located in the upper compartment of the bypass switchboard. See
Figure 9
Figure 7 - Schematic Diagram - Status Relay Contacts
and Figure 6 for recommended conduit entry location.
CBB Contacts (Bypass Circuit Breaker)
"Normal" position for the Bypass Breaker is defined as the breaker being OFF, or
Open. As such, the Normally-Open contacts are open when the Breaker is open;
the Normally-Closed contacts will open when the breaker is closed.
Example: Normal run: CBB will be Open; therefore TB1/11B will be electrically
connected to TB1/10B.
Rockwell Automation Publication 1608M-UM001A-EN-P - September 2013 15
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