Rockwell Automation 1608P User Manual
User Manual
Bulletin 1608P ProDySC Dynamic Voltage Sag Corrector
Catalog Numbers 1608P - 25 and 50 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.
ProDySC, 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
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspecting and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location (Environment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting the ProDySC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bypass Switch Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bypass SwitchWiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Circuit Breaker Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Accessing ProDySC Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ProDySC Terminations and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Input: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Output: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Dry Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Serial Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Ch 5 - Display Screen
Ch 6 - Maintenance
Ch 7 - Specifications and Dimensions
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Voltage Sag Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Voltage Sag Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Voltage Sag Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Voltage Sag RMS Voltage Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Voltage Sag Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
System Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
System Event Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System Event Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Run System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Monthly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3-6 Month Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
System Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fuse Rating Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Approximate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013 3
Table of Contents
Notes:
4 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013
Chapter 1
Introduction
The Allen-Bradley Bulletin 1608P ProDySC Dynamic Sag Corrector is
engineered to provide years of trouble-free voltage sag (dip) protection. The
patented ProDySC technology does not use batteries, requires only routine
maintenance, includes three-stage transient voltage surge suppression, and has
unparalleled energy efficiency. Most electronic devices found in industry today
are susceptible to power disturbances. A momentary sag in line voltage can reset
or damage sensitive production equipment. The ProDySC provides
instantaneous dynamic sag correction to help your equipment ride through these
common events. The ProDySC connects normal utility power directly to the
load until a voltage sag occurs. During a sag, the ProDySC 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 ProDySC is
quickly ready to correct the next sag.
The ProDySC 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 ProDySC is designed to operate in industrial applications. Follow these
guidelines to ensure that the safety and installation of the ProDySC are handled
with appropriate care.
SHOCK HAZARD: The ProDySC has high voltage remaining up to 5 minutes
after disconnection from the AC line. Touching exposed or disconnected
terminals, cables or parts of the ProDySC can lead to serious injuries or even
death. Wait for a minimum of 5 minutes before performing any service or
testing on the ProDySC after power is removed.
Keep the cabinet doors closed to ensure proper cooling airflow and to protect
personnel from dangerous voltages inside the ProDySC.
ATTENTION: - To reduce the risk of fire or electric shock, install this ProDySC in
a temperature and humidity controlled, indoor environment, free of conductive
contaminants.
• Avoid installing the ProDySC 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 ProDySC.
• Ensure all power is disconnected before performing installation or service.
Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013 5
Chapter 1 Introduction
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. Use an insulated screw driver when connecting the
lines.
• The ProDySC is not rated to directly power life support equipment.
• Ensure the area around the ProDySC is clean and uncluttered.
• Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the
equipment.
6 Rockwell Automation Publication 1608P-UM001A-EN-P - July 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 ProDySC.
• All packing materials and restraints have been removed.
• The ProDySC is placed in its installed location.
• All conduits and cables are properly routed to the ProDySC.
• All power cables are properly terminated.
• A ground conductor is properly installed and terminated.
• If neutral connection is required that it is properly terminated on the
ProDySC.
• The area around the installed ProDySC is clean and dust-free.
• Adequate work space exists around the ProDySC.
• Adequate lighting is provided around the ProDySC.
• Operational checks have been reviewed and completed.
• 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 ProDySC 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)
Mounting Considerations
The ProDySC must be installed in a protected environment. The location must
provide adequate airflow around the ProDySC in an atmosphere free from
excessive dust, corrosive fumes, or conductive contaminants. Do not operate the
ProDySC in an environment where the ambient temperature or humidity is
beyond the specified limits given in this manual.
The ProDySC must be mounted vertically, as shown in the figures, and may be
mounted inside another enclosure if the ProDySC inlet temperature remains at
or below specified limits. Read this entire user manual to understand the
additional space requirements around the ProDySC for power conductor entry,
communications conductors, and airflow. Refer to Specifications and
Dimensions on page 35 for temperature ratings and heat dissipation.
Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013 7
Chapter 2 Installation
21.00
533
22.50
572
24.00
610
25.35
644
30.00
762
21.00
533
22.50
572
31.13
791
A
12.80
325
13.21
336
13.39
340
.5714 TYP.
.75
19
1.50
38
.4110 TYP.
DETAIL A
4 PLACES
Mounting the ProDySC
Using the 3/8" hardware and four (4) wall mounting brackets supplied, mount
the wall mount brackets to the back of the ProDySC. Mount each bracket to the
back of the ProDySC with a single 3/8"-16 x 1" hex cap head screw. Mount the
brackets so the flat portion of the mounting bracket is against the back of the
ProDySC. Bolt two 2 x 4 pieces of lumber horizontally to the wall using 3/8" by
4" hex-head lag bolts.
Make certain that:
1. The lag bolts line up with the wall studs.
2. The distance between the centers of the pieces of lumber is equal to the
distance between the centers of the mounting holes. Refer to Figure 1
.
3. Bolt unit to the 2 x 4 pieces of lumber with (4) 3/8" by 2" long hex-head lag
bolts.
NOTICE: Weights and complete mounting dimensions are provided in Chapter 7
Figure 1 - 25 A Mounting dimensions, in. [mm]
8 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013
Figure 2 - 50A Mounting dimensions, in. [mm]
33.00
838
34.50
876
36.00
914
37.36
949
36.00
914
33.00
838
34.50
876
37.13
943
A
12.80
325
13.21
336
13.39
340
.75
19
1.50
38
.5714 TYP.
.4110 TYP.
DETAIL A
4 PLACES
Installation Chapter 2
Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013 9
Chapter 2 Installation
12.00
305
16.75
425
4X
.30
8
14.00
356
8.00
203
17.50
445
Bypass Switch
Installation of the ProDySC with an external maintenance bypass is required to
avoid power interruptions to the critical loads during maintenance, service, or
testing. Mount the bypass close to the ProDySC to provide quick access and
visual coordination when testing or providing service. The 1608P bypass is a wall
mounted enclosure with a 3 position rotary switch. Its dimensions and mounting
locations are shown in Figure 3
Figure 3 - 25A and 50A bypass mounting dimensions
.
Bypass Switch Modes
The 1608P bypass switch has three modes of operation and is configured as
shown in Figure 4
Figure 4 - Bypass switch and mode operation
NORMAL Mode - Power flows from the utility source
through the ProDySC to the load.
TEST Mode - Power flows directly from the utility to
the load. ProDySC outputs are not connected to the
load. ProDySC inputs have power provided for testing
by a qualified technician.
BYPASS Mode - Power flows directly from the utility
to the load. No power is present on ProDySC inputs or
outputs.
NOTICE: The 1608P bypass switch contacts are designed to make-before-break and will not
disrupt power to the load during any mode transitions. The switch has lockout/tagout (LOTO)
provisions.
10 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013
Installation Chapter 2
2X
1.12
28
TOP VIEW
Bypass Switch Wiring Diagram
The maintenance bypass has input and output terminals labeled and located
inside the bypass enclosure as shown in Figure 5
. The neutral connection is
available for 4-wire ProDySC configurations.
NOTICE: All electrical connections must be completed by a qualified electrician, in compliance
with all local codes and the National Electric Code.
Figure 5 - Bypass wiring diagram
Circuit Breaker Recommendations
Accessing ProDySC Terminations
Branch circuit protection upstream of the ProDySC is required. Recommended
circuit breakers and maximum allowed circuit breaker ratings are listed in
Ta bl e 1
. Branch circuit protection rated less than the ProDySC current rating
may result in nuisance tripping.
Table 1 - Recommended Branch Circuit Protection
ProDySC Rating
25 A 140U-H3C3-C35 35 A
50 A 140U-H6C3-C70 70 A
Recommended MCCB
Cat. No.
Max. MCCB Rating
Two holes are provided for punch-out locations to provide the appropriate hole
size for conduit fittings in the ProDySC. Take care to avoid dropping any metal
filings inside the enclosure. Metallic contamination will void the product
warranty. See Figure 6
Figure 6 - Knockout Hole Locations
for preferred Input/Output wiring locations.
Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013 11
Chapter 2 Installation
USER INTERFACE
TOUCHSCREEN DISPLAY
AC INPUT AND LOAD CONNECTIONS
LOCATED BEHIND DOOR ON MAIN
ELECTRICAL PANEL IN THIS AREA.
GROUND STUD LOCATED
BEHIND DOOR ON MAIN
ELECTRICAL PANEL IN THIS AREA.
3-WIRE CONFIGURATION
X1 X2 X3 L1 L2 L3 GR
4-WIRE CONFIGURATION
X1 X2 X3 N N L1 L2 L3 GR
IMPORTANT
IMPORTANT
ProDySC Terminations and Ratings
A qualified electrician must install the units. To access the ProDySC Electrical
Terminations, turn the two ¼ - turn latches CCW and swing open the door. The
unit is furnished with one of the terminal block configurations as shown in
Figure 7
units andTa b l e 3
Figure 7 - Input/Output terminal locations
. For power cable termination specifications see Ta bl e 2 for the 25A rated
for the 50A rated units.
ATT EN TI ON : All electrical connections must be completed by a qualified
electrician, in compliance with all local codes and the National Electric Code
Input:
• Ground (Earth): Connect the safety ground conductor to the ground stud.
• 3-Wire Input: Connect source L1, L2, and L3 to terminals labeled L1, L2, and L3
respectively.
• 4-Wire Input: Connect source L1, L2, L3, and Neutral to terminals labeled L1,
L2, L3, N respectively.
4-wire ProDySCs (units with “… V4” in their part number) must also have a
neutral connected to the neutral terminal block. The neutral terminal block
is labeled “N”. Neutral must be connected for these units to operate properly.
Output:
• Terminal blocks are provided marked X1, X2, X3 and N (if used) as shown
inFigure 7
so that there is only one set of output wires terminated inside the ProDySC
enclosure.
If there are multiple loads, a separate distribution box must be provided
The 480V 3 phase 3W ProDySC has not been evaluated by Underwriter's
Laboratories, Inc.® for connection to a corner-grounded delta power source.
12 Rockwell Automation Publication 1608P-UM001A-EN-P - July 2013
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