Rockwell Automation 1608P-200A480V User Manual
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
6X
.625
16
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
X1
X2L2
CB
CB
CB
Customer supplied
circuit breaker
GND GND
CBB
CBOCBI
G
X1
X2
X3
L1
L2
L3
L1
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
X1
X2L2
CB
CB
CB
Customer supplied
circuit breaker
GND GND
CBB
CBOCBI
G
X1
X2
X3
L1
L2
L3
L1
HC-DySC
Electronics
N 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
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