Rockwell Automation 1608P-200A480V User Manual

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User Manual

Bulletin 1608P HC-DySC Dynamic Voltage Sag Corrector

1608P-200A480V...-HC and 1608P-200A480V...-GT 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.

Waste batteries should be separated from the normal municipal waste stream and collected for local recycling.

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

You can view or download publications at http:/www.rockwellautomation.com/literature/

Provides general guidelines for installing a Rockwell Automation industrial system.

Provides declarations of conformity, certificates, and other certification details.

. To order paper copies of

technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Table of Contents

Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Ch 1 - Introduction

Ch 2 - Installation

Ch 3 - Communications

Ch 4 - Applying Power and Operation

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

HC-DySC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Ch 5 - Display Screen

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Mechanical Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

System Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Voltage Sag Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Voltage Sag Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Voltage Sag Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Voltage Sag RMS Voltage Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Voltage Sag Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

System Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

System Event Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

System Event Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Run System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Diagnostics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 3

Table of Contents

Ch 6 - Maintenance

Ch 7 - Specifications and Dimensions

Appendix A - HC-DySC with Generator Transfer (GT) Option

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Monthly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Fuse Rating Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Transient Voltage Surge Suppressor (TVSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

GT Option Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

GT Option Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

ATS / Generator Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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 that are found in industry today are susceptible to power disturbances. Momentary sags in line voltage can reset or damage sensitive production equipment. The HC-DySC provides instantaneous and 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 event, the HC-DySC inverter is activated-adding 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. It 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 help ensure that the safety and installation of the HC-DySC are handled with appropriate care.

WARNING: HC-DySC products help protect diagnostic imaging equipment and facilities support systems against voltage sags and momentary power interruptions. HC-DySC products can not be used to protect life-critical patient care equipment.

SHOCK HAZARD: The HC-DySC has high voltage present up to 5 minutes after disconnection from the AC line. If the exposed or disconnected terminals, cables, or parts of the HC-DySC are touched it can lead to serious injuries or even death. Wait for a minimum of 5 minutes before performing any service or test on the HC-DySC after power is removed. High voltage remains if red status indicators above capacitor banks are lighted. Keep the cabinet doors closed and locked to help ensure proper cooling airflow and to help protect personnel from dangerous voltages inside the HC-DySC.

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 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.

• Help ensure all power is disconnected before installation or service.

ATT EN TI ON : Electrostatic discharge (ESD) can damage internal components.

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.

• Help ensure the area around the HC-DySC is clean and uncluttered.

• Observe all DANGER, CAUTION, and WARNING notices that are affixed to the inside and outside of the

equipment.

6 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

Installation

Chapter 2

Installation Check List

Inspecting and Unpacking

Before proceeding, 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 verify 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

Install the HC-DySC 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 HCDySC in an environment where the ambient temperature or humidity is beyond the specified limits that are given in this manual.

The HC-DySC consists of one enclosure with an integral maintenance bypass switch to prevent power disruption during service and maintenance.

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 7

Chapter 2 Installation

1.38 35

1.00 25

1.20 31

.625

2.01 51

9.00 229

11.00 279

3.58 91

37.25 946

28.00 711

37.25 946

18.75 476

Removable Plate for Bottom Conduit Entry

Floor Mounting

Secure the HC-DySC to the floor using fasteners and fittings appropriate for the type of floor. Holes are provided in the base channels; see Figure 1

for mounting

dimensions.

Note: Top or bottom cable entry is allowed. See Figure 1

Figure 1 - Bottom View Floor Mount Dimensions

and Figure 2 on page 9.

Clearance

Circuit Breaker Recommendations

8 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

HC-DySC doors hinge on both right and left. See Figure 30 on page 40 for dimensions including door swing. Leave required clearances:

• Door swing must allow doors to open at least 90°

• 3”[75 mm] on right side for air filter clearance when the door is open

• Left side clearance is required for bottom entry cable installation

Branch circuit protection upstream of the HC-DySC is required. Maximum allowed circuit breaker ratings are listed in Ta b l e 1 is rated less than the HC-DySC current rating may result in nuisance tripping.

. Branch circuit protection that

Table 1 - Branch Circuit Protection Ratings

HC-DySC Rating Max. MCCB Rating

200 A 250 A

WARNING: To reduce the risk of fire, use only on circuits that are provided with 250 ampere maximum branch circuit protection in accordance with the National Electric Code ANSI/NFPA 70.

Installation Chapter 2

3.00 76

11.00 279

2.00 51

9.00 229

20.75 527

51.07 1297

Area

Recommended

For Top

Conduit Entry

(Shown Without

Cover)

I/O Knockouts

Electrical Terminations

Accessing Terminations

Use a qualified electrician to install the HC-DySC in compliance with all local, and national electric codes. The HC-DySC input (line) and output (load) terminals are located behind the left door. Terminal details are shown in Figure 5

on page 12.

For top entry, remove the top gland plate, which is 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 shown in Figure 6 on page 13 entry of communications conductors, as shown in Figure 2

. Access to the communications port is above the front doors, as

. A separate conduit knock-out is provided for top

Note: When punching or drilling holes for conduit fittings, take care to avoid

dropping metallic particles inside the enclosure. Metallic contamination voids the product warranty.

Figure 2 - Top Conductor Entry

WARNING: Metallic Particles inside the Enclosure Void the Warranty

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 9

Chapter 2 Installation

L3 X3

X2L2

Customer supplied

circuit breaker

GND GND

CBB

CBOCBI

HC-DySC

Electronics

3-WIRE SOURCE

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 maintenance bypass switch

Figure 3 shows the 3-wire HC-DySC system wiring schematically,

Figure 3 - HC-DySC 3-Wire Configuration

Note for Canadian Users: The 200 A HC-DySC models rated greater than 440V have not been evaluated for compliance with CSA 22.2 No. 107.1-01 when connected to corner-grounded or ungrounded delta power sources. Contact Rockwell Automation Technical Support for assistance.

10 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

Installation Chapter 2

L3 X3

X2L2

Customer supplied

circuit breaker

GND GND

CBB

CBOCBI

HC-DySC

Electronics

N N

4-WIRE SOURCE

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 maintenance bypass switch.

Figure 4 - HC-DySC 4-Wire Configuration.

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 11

Chapter 2 Installation

Neutral Bus

Ground Bus

AC Input Connections

AC Output Connections

SHOWN WITH DOOR OPEN

Electrical Terminations and Ratings

Input connections are marked L1, L2, and L3 for the source connections. Output connections 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

12 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

• Input/Output mechanical lugs accept AWG 6 to 350 kcmil [16 to 150 mm2] conductors. Tig hten lugs to

275 lb-in [31 N-m]. Lugs require 5/16” hex key tool for installation.

• Input/Output mechanical lugs may be removed and replaced with pressure (crimp) lugs. Two 1/2” holes (1.75”

spacing) are provided.

• 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 and accident prevention regulations must be strictly observed

Chapter 3

I/O

COMM

PORT

ACCESS

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

conduit knockout is located on the cabinet top (See Figure 2

Figure 6 - Access Cover Location

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 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-UM005A-EN-P - November 2014

Applying Power and Operation

IMPORTANT

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.

• Verify all input/output wiring including grounding has been completed

and properly tightened.

• Replace all covers. Close all cabinet doors.

• Put CBI circuit breaker and CBO circuit breaker in the OFF position.

CBB circuit breaker closes automatically when upstream power is applied.

• Apply power from the upstream branch protection device. Power flows directly to the load through the CBB circuit breaker. The HC-DySC touch screen becomes active and displays "System Offline" in the upper left corner.

• Veri f y o ut p ut (lo ad ) vo lt age i s pres en t.

• Wait for the HC-DySC to display "READY TO CLOSE CBI" in the

upper left corner of the touch screen. Rotate CBI circuit breaker to the ON position. The HC-DySC electronics become energized in this mode but the load is still powered through the CBB circuit breaker.

• Verify that the touch screen displays "OK" in the upper left corner, with a bar above that states "Sag Prot. Bypassed." Verify 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) rotate CBI circuit breaker to the off position (2) call for technical support.

• Rotate CBO circuit breaker to the ON position. Press the red "CBB OFF" push button. Verify that the red "CBB CLOSED" lamp is off. The load is now being protected by the HC-DySC. The display shows "OK" in the upper left corner.

Always use red "CBB OFF" pushbutton to open the CBB circuit breaker. Do not use the red "Push OFF" button that is part of the CBB circuit breaker. For proper operation of the HC-DySC, the CBB circuit breaker spring must be charged (displays "Charged Spring") when the CBB circuit breaker is off. If the CBB circuit breaker is off and displays "Discharged Spring", push the "CBB OFF" pushbutton to charge the spring.

NOTICE: If the HC-DySC input power is cycled in the sequence OFF--ON--OFF-ON within one minute, 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-UM005A-EN-P - November 2014 15

Chapter 4 Applying Power and Operation

L3 X3

X2L2

GND GND

CBB

CBOCBI

HC-DySC

Electronics

N N

Breakers

Closed

Function

CBI, CBO CBI, CBB

CBB

Normal

Test

Bypass

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 maintenance bypass switch consists of a bypass circuit breaker (CBB), an input circuit breaker (CBI), and an output circuit breaker (CBO). Under normal operating conditions raw input power is routed through CBI to the input of the HC-DySC. The output of the HC-DySC is routed to the load through CBO. CBB is normally open. CBB connects utility power directly to the load, bypassing the HC-DySC, when operating in the maintenance bypass mode.

WARNING: Dangerous voltages can still exist within the HC-DySC enclosure

16 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

even if the system is in bypass mode. Refer servicing to qualified personnel

Applying Power and Operation Chapter 4

CBB

CIRCUIT

BREAKER

CBI

CIRCUIT

BREAKER

CBO

CIRCUIT

BREAKER

Bypass Switch Modes

The maintenance bypass switch has three modes of operation: Normal Mode, Bypass Mode, and Test Mode. It is configured as shown in Figure 9

Normal Mode

The NORMAL mode for the HC-DySC is the input circuit breaker (CBI) and the output circuit breaker (CBO) closed. The bypass circuit breaker (CBB) must be open or the HC-DySC will not be able to correct voltage sags. There is a red indicator light on the enclosure that is lighted when the bypass circuit breaker is closed. The green "OK" status box should be shown on the touchscreen display. The green "OK" box indicates that the voltage at the output of the HC-DySC is within the +10%, -13% normal window. Refer to Table 2 for operational conditions and indications

Bypass Mode

The BYPASS mode for the HC-DySC is for the input circuit breaker (CBI) and the output circuit breaker (CBO) to be open. The bypass circuit breaker (CBB) must be closed to provide power to the load while the HC-DySC is being serviced.

Refer toMaintenance Bypass Transfer Procedure

on page 18 for instructions on

transferring the system into and out of bypass mode.

Figure 9 - Maintenance Bypass Switch Configuration.

WARNING: Servicing must only be performed by factory authorized and

qualified personnel

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 17

Chapter 4 Applying Power and Operation

IMPORTANT

Test Mode

The TEST mode for the HC-DySC is for the input circuit breaker (CBI) to be closed and the output circuit breaker (CBO) to be open. The bypass circuit breaker (CBB) must be closed to provide power to the load while the HC-DySC is being tested off-line.

WARNING: Testing must only be performed by factor y authorized and qualified personnel

Maintenance Bypass Transfer Procedure

Automatic System

In the event of a fault in the HC-DySC system, bypass circuit breaker (CBB) will close. The system will remain in bypass until manually transferred back to the HC-DySC.

Manual Transfer to Normal (Sag Protection)

1. Wait for HC-DySC to display "READY TO CLOSE CBI"

2. Close CBI using the manual operator (Reset if needed)

3. Verif y H C -Dy SC di sp lays “ OK”

4. Close CBO using the manual operator (Reset if needed)

5. Press “CBB OFF” button to open CBB. Red “CBB CLOSED” lamp

should be off

6. Sag protection is now active

Manual Transfer to Maintenance Bypass

1. Press "CBB ON" pushbutton to close CBB. Red "CBB CLOSED" lamp should be on

2. Open CBO using the manual operator

3. Open CBI using the manual operator

4. Sag protection is now bypassed

18 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

Applying Power and Operation Chapter 4

HC-DySC Operation

The HC-DySC section contains three power electronics modules (one module per phase) and controls that continuously monitor the line voltage. The modules are series-connected to the input line, and operate by adding the compensating voltage needed to restore the line to its nominal output. When the utility line voltage is within normal range the ac static switch components remain closed and no compensating voltage is added. When an insufficient line voltage event occurs, the static switches open and the sag-correcting electronics quickly add the balance of voltage necessary to regulate the load voltage.

The HC-DySC accepts line input power over 3 wires into terminals L1, L2, L3 and provides sag compensated three-phase output power at terminals X1, X2, and X3 when not in the Maintenance Bypass mode. In 4-wire systems the input Neutral is connected directly to the output Neutral terminal.

A touchscreen display provides indication of the status of the HC-DySC operation. After power is switched on, the green "OK" box will be displayed in the upper left hand corner of the display, indicating that the output voltage is within a normal range of -13% to +10% of nominal.

A red "FAULT" box is displayed in the upper left hand corner of the display when a fault condition is present on the HC-DySC. During this period sag correction is disabled and the HC-DySC will continue to bypass the utility voltage directly to the load through the static bypass path. An orange "FAULT OVER" box is displayed when the previous fault condition has cleared. Sag correction will remain inhibited until the reset period has expired (approximately 1 minute). A blue "SYSTEM OFFLINE" box is displayed whenever the HC-DySC system is in the maintenance bypass mode (CBB closed and CBI open).

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 19

Chapter 4 Applying Power and Operation

A list of conditions and indications is given in Table 2. Under some conditions the HC-DySC will automatically close the maintenance bypass switch (CBB) and open CBI and CBO 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. Refer to Chapter 5 for further information on system alarms and status display.

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 Mechanical

Main Fuse Open Open Fuse(s) Blue, HC-DySC offline Disconnected Mechanical

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 Mechanical

Inhibited Static BP

Bypass

* 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.

20 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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-UM005A-EN-P - November 2014 21

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

22 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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-UM005A-EN-P - November 2014 23

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 correct 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

24 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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-UM005A-EN-P - November 2014 25

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).

26 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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 26

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-UM005A-EN-P - November 2014 27

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.

28 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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 28 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 34

Severity: Severity of the event Description: Name of the event see Table 11 on page 34

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-UM005A-EN-P - November 2014 29

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.

30 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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-UM005A-EN-P - November 2014 31

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.

32 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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 maintenance bypass switch is in the NORMAL mode.

• Update system time, if needed, Figure 13 on page 22

• 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.

– To remove the grill covers unscrew the captive screw, slide the frame up,

then lift off. 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 tighten the

captive screw.

– 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.

12 Month Check

• Transfer the HC-DySC to BYPASS Mode, then back to NORMAL mode to exercise the circuit breakers in the maintenance bypass switch.

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 33

Chapter 6 Maintenance

Table 11 - System Event Table

Event

Code Code Name Full Name Severity Area Event Description Event Resolution

POWER_ON DySC Power On Informational Unit Power re-applied to the DySC. No action needed.

T_FAN_ST Fan Test Start Informational Unit Start acknowledgment of DySC fan test. No action needed.

T_IN_ST_1 Inverter Test (.5 cycles) Start Informational Unit Start acknowledgment of DySC 0.5 cycle inverter test. No action needed.

T_IN_ST_2 Inverter Test (3 cycles) Start Informational Unit Start acknowledgment of DySC 3 cycle inverter test. No action needed.

T_IN_ST_3 Inverter Test (5.5 seconds) Start Informational Unit Start acknowledgment of DySC 5.5 second inverter test. No action needed.

EXTERNAL External Inhibit Auto-Resetting Inverter Controller is inhibited by another phase controller. Review event details from other phase controllers.

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 action 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

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.

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.

SYNC_ERR Line Synchronization Error Call Service Inverter Inverter not synchronized to line when sag detected. Call service.

CONFIG Configuration Alert Call Ser vice 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 Service Inverter

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.

ROLL_CALL

34 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

Start-Up Test: Controller Roll Call Timeout

Call Service Unit Controller communication problem detected during start-up test. Call service.

Positive and negative halves of the DC bus did not charge equally during power up.

Call ser vice.

Chapter 6 Maintenance

Event

Code Code Name Full Name Severity Area Event Description Event Resolution

COM_V ER

CNFG_TO

CNFG_ERR

FIRM_TO

FIRM_DIFF

SRL_TO

SRL_DIFF

T_INV_TO Inverter Test Timeout Call Service Unit Phase control board failed to respond to Comm board's Inverter test. Call service.

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.

Start-Up Test: Communication Compatibility Mismatch

Start-Up Test: Controller Configuration Timeout

Start-Up Test: Controller Configuration Mismatch

Start-Up Test: Controller Firmware Check Timeout

Start-Up Test: Controller Firmware Revision Mismatch

Start-Up Test: Controller Serial Number Check Timeout

Start-Up Test: Serial Number Mismatch

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.

Informational Unit Controller serial number mismatch detected during start-up test. No action needed.

Firmware communication compatibility problem detected during start-up test.

Internal DySC temperature exceeded maximum rating. Mechanical bypass commanded.

Call ser vice.

Verify ambient temperature is within DySC specification. Check for damaged fans. Check for dirty or obstructed air filters.

Manually reset DySC.

50 OPEN_SCR_B Open SCR Phase B Call Service Static Switch The SCR on the phase B module was detected open. Call service.

51 OPEN_SCR_C Open SCR Phase C Call Service Static Switch The SCR on the phase C module was detected open. Call service.

53 DYN_BRAKE D ynamic Brake Error Call Service Unit A problem was detected with the DySC dynamic brake controller. Call service.

58 PLC_ERR

59 PLC_ST_MM

73 INPUT_PS_FAIL Input Control Power Supply Failure Call Service Unit System output control power supply is not operating properly. Call service.

74 OUTPUT_PS_FAIL

35 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

Programmable Logic Controller Error

Programmable Logic Controller State Mismatch

Output Control Power Supply Fai lure

Call Service PLC PLC error detected. Call service.

Call Service Unit PLC feedback error detected. Call service.

Call Service Unit System output control power supply is not operating properly. Call service.

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 Transfer Procedure on page 18.

CBI Circuit Breaker, Safety Interlocks and Stored Energy

The HC-DySC includes a fast-discharge circuit to quickly dissipate stored energy when the CBI circuit breaker is opened. Always follow the Maintenance

Bypass Transfer Procedure on page 18 to close the CBB circuit breaker before

opening the CBI circuit breaker. Failure to follow these instructions may result in load power interruption.

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.

HC-DySC 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. If there is no output voltage present and the display is off, it is an indication that an upstream protection device has opened. If the bypass circuit breaker CBB opens due to an overcurrent condition, it will need to be manually reset. Pump the spring charging handle on the CBB motor operator until it indicates that the spring is charged. CBB may automatically close once it is reset.

WARNING: Turn the power to the HC-DySC electronics off by placing the HC-DySC 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

36 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

Maintenance Chapter 6

IMPORTANT

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

HC-DySC Enclosure Fuses

Fuse Reference Fuse Location Fuse Rating Manufacturer Part Number

F1, F2, F3

F4, F5, F6

F7, F8

F9, F10 (380V - 480V models)

F9, F10 (200V - 240V models)

F11, F12

F13, F14 (380V - 480V models)

F13, F14 (200V - 240V models)

F15

F16, F17, F18

F19 (4 wire only)

F20, F21, F22 (3 wire models only)

F23 (3 wire models only)

F24, F25, F26 (GT uni ts only)

F27, F28, F29 (GT uni ts only)

Main Cabinet: Main Power Input

Main Cabinet: Cross-Coupling Transformer

Main Cabinet: Cross Coupler Auxiliary

Main Cabinet: Output Control Transformer

Main Cabinet: Input Control Transformer

Main Cabinet: TVSS Input

Main Cabinet: Neutral Forming Transformer

Main Cabinet: GT Contactor

Main Cabinet: GT Input Snubber

HC-DySC Power Module Fuses

400A/500V Mersen A50QS400-4IL

80A/600V Mersen AJT80

2A/600V Mersen ATQR2

7A/600V Mersen AJT7

17.5A/600V Mersen AJT17-1/2

10A/600V Mersen ATQR10

2A/600V Mersen AJT7

4A/600V Mersen AJT4

4A/600V Mersen ATQR4

40KA surge / 600V Mersen VSP40-2

7A/600V Mersen AJT7

15A/600V Mersen ATQR15

200A/500V Mersen A50QS200-4IL

15A/600V Mersen ATMR15

Fuse Reference Fuse Location Fuse Rating Manufacturer Part Number

F1, F2, F3, F4 Power Module (x3): Dynamic Brake 20A/600V Mersen ATM20

F5 Power Module (x3): — Not Field Replaceable

F6 Power Module (x3):Inverter Output 200A/500V Mersen A50QS200-4IL

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 37

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 F19 (present in 4-wire models only).

38 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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...+5%

65 kA

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

Voltage Sag Correction Times (not applicable in GT mode)

Electrical Output (S ag Correction Mode - Inverter)

Single Event

Chapter 7

All three phases to zero voltage remaining 63 ms at 200A load and 0.7 Power Fac tor; 100ms at 95A load and 0.9 Power Factor

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

1550 lb (700 kg)

Environmental

Ambient Temperature 0 to 40°C

Storage Temperature -40°C to 75°C

Relative Humidity 5% 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 compliance with CSA - 22.2 No. 107.1-01 for use in corner grounded or ungrounded delta power systems in systems rated over 440V.

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-UM005A-EN-P - November 2014 39

Chapter 7 Specifications and Dimensions

3.00 76

11.00 279

2.00 51

9.00 229

20.75 527

51.07 1297

Area

Recommended

For Top

Conduit Entry

(Shown Without

Cover)

I/O Knockouts

DOOR SWING

42.08 1069

OVERALL

WIDTH

I/O

COMM

PORT

ACCESS

LCD

DISPLAY

CBB

CIRCUIT

BREAKER

CBI

CIRCUIT

BREAKER

CBO

CIRCUIT

BREAKER

AIR INTAKE

AIR EXHAUST

77.89 1978

OVERALL

HEIGHT

33.09 840

OVERALL

DEPTH

Table 14 - Heat Dissipation

Rating (V) Heat Loss (W) Heat Loss (Btu/h) Efficiency (%)

480 1250 4265 > 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

40 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

Appendix A

HC-DySC with Generator Transfer (GT) Option

GT Option Description

GT Option Operation

HC-DySC model numbers that end with "-GT" include the generator transfer option. The HC-DySC with Generator Transfer (GT) option is able to switch between two modes of operation: series connected mode and shunt connected mode. The GT model operates identically to the HC model when in the normal series-connected mode; this mode provides excellent voltage sag correction performance. When transferred to the shunt-connected mode the GT model can provide regulated voltage to connected loads during brief, input voltage outages. This includes open-circuit transfer periods typical of a back-up power system that is connected through an Automatic Transfer Switch (ATS).

A Generator Transfer Command signal from the facility is required. The HCDySC with Generator Transfer (GT) option is able to provide open transition ride through protection only if these communications are properly installed. Rockwell Automation or other qualified applications engineers, must specify the connection requirements in consultation with the end user.

The generator transfer command signal is a dry relay contact that opens before the facility ATS transfers the HC-DySC power source from grid power to emergency power. The generator transfer command signal must be received by the HC-DySC at least 1s before the ATS transfer. When the HC-DySC receives the generator transfer command signal, it transitions from the series connection mode to the shunt connection mode in preparation for the ATS transition. When the HC-DySC is in the shunt connection mode, "GEN TRNS MODE" displays in a blue bar in the upper right corner of the screen. See Figure 31 the ATS transitions back to grid power, the generator transfer command signal can be removed and the HC-DySC will transition back to the series connection mode.

. After

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 41

Appendix A HC-DySC with Generator Transfer (GT) Option

SHOWN WITH

DOOR OPEN

TB2 LOCATION

Figure 31 - Home Screen GT Mode

ATS / Generator Contacts

The generator transfer command dry relay contact provided by the user must be rated for at least 24 VDC and 20 mA continuous current. User connections to the HC-DySC are made at terminal block TB2. The location of TB2 is shown in

Figure 32

in the top left of the HC-DySC cabinet as shown in Figure 2 on page 9

Figure 32 - TB2 Location

. For access to the TB2 screw terminal block, remove the I/O knockout

42 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

HC-DySC with Generator Transfer (GT) Option Appendix A

USER

PROVIDED

Located at ATS

Optional

+24VDC GT Command

Ready Indicator

GT Ready

TEST

Optional

Note: Contact K must open at least 1s before

ATS transfers to emergency power

HC-DySC

+24VDC GT Command

24VDC Return

Closes in GT Mode

EARTH GROUND

TB2

USER

PROVIDED

Located at ATS

Optional

+24VDC

Ready Indicator

GT Ready

TEST

GT Ready

Chain

Chain 24VDC Return

GT Command

HC-DySC 1

+24VDC GT Command

24VDC Return

Closes in GT Mode

EARTH GROUND

TB2

HC-DySC 2

+24VDC GT Command

24VDC Return

Closes in GT Mode

EARTH GROUND

TB2

Note: Contact K must open at least 1s before

ATS transfers to emergency power

Typical TB2 connections for a hardwired generator transfer command contact signal are shown in Figure 33

. The signal is connected between positions 1 and 2. Position 1 provides 24VDC to a (normally closed) auxiliary contact on the ATS or generator circuit, which is fed back to terminal 2. Open the external contact to put the HC-DySC in GT mode. An internal contact between Positions 3 and 4 closes whenever the HC-DySC is in the GT mode. This is a remote indicator that the HC-DySC is in GT Mode. This contact is rated for 2A and 24V. Note: if the HC-DySC 24V supply is used to power a remote indication device the device must not exceed 15 W. To place the HC-DySC permanently in GT mode: open the connection between TB2 positions 1 and 2.

Position 5 provides the 24V return, which is internally connected to chassis ground. If an optional READY indicator is installed, connect all 24V returns together when multiple HC-DySC units are installed, as shown in Figure 34

ATTENTION: TB2 Recommended torque is 8 lb.-in. (0.9 N-m). Acceptable wire sizes are 22...8 AWG .

Figure 33 - Typical TB2 ATS / Generator Communication Connections

Figure 34 - Typical TB2 ATS/Generator Communication Connections (Multiple HC-DySC Units)

Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014 43

Appendix A HC-DySC with Generator Transfer (GT) Option

Notes:

44 Rockwell Automation Publication 1608P-UM005A-EN-P - November 2014

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