Bulletin 1608P - ProDySC User Manual
Contents
1. 75 f 19 p Al 1 50 7 10 8 DETAIL A 4 PLACES 8 Rockwell Automation Publication 1608P UM001A EN P July 2013 Installation Chapter2 Figure 2 50A Mounting dimensions in mm 37 36 949 36 00 914 34 50 m TYP 5 14 i Q 75 19 Al 1 50 10 38 DETAIL A 4 PLACES Rockwell Automation Publication 1608P UM001A EN P July 2013 9 Chapter2 Installation Bypass Switch Installation of the ProDySC with an external maintenance bypass is required to avoid power interruptions to the criticalloads during maintenance service or testing Mount the bypass close to the ProDySC to provide quick access and visual coordination when testing or providing service The 1608P bypass is a wall mounted enclosure with 3 position rotary switch Its dimensions and mounting locations are shown in Figure 3 Figure 3 25A and 50A bypass mounting dimensions 14 00 356 Bypass Switch Modes The 1608P bypass switch has three modes of operation and is configured as shown in Figure 4 Figure 4 Bypass switch and mode operation NORMAL Mode Power flows from the utility source through the ProDySC to the load TEST Mode Power flows2. Table 11 Model Information Description Function odel Number System Model number Model Details 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 Unit Details Rockwell Automation Publication 1608P UM001A EN P July 2013 Display Screen Chapter 5 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 27 Figure 27 System Tests System Tests Fan Tests Diagnostics Mode This is not a user function It is numerical code protected for authorized service personnel Rockwell Automation Publication 1608P UM001A EN P July 2013 29 Chapter5 Display Screen Notes 30 Rockwell Automation Publication 1608P UM001A EN P July 2013 Preventative Maintenance Chapter 6 Maintenance The ProDySC requires very little preventative maintenance The ProDySC 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
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5. 21 00 533 1 31 13 791 1 30 00 762 d e All n Bradisy 05 99 21 00 533 AL 60 572 Alle Nc 57 75 f 4 Ma u m TYP 10 DETAIL A 4 PLACES Rockwell Automation Publication 1608P UM001A EN P July 2013 Specifications and Dimensions 13 21 336 12 80 325 Chapter 7 37 Chapter 7 38 Specifications and Dimensions Figure 29 50A Standard Extended Run 37 36 949 747 36 00 914 34 50 876 33 00 838 37 13 943 36 00 914 33 00 838 34 50 876 10 DETAIL A 4 PLACES Rockwell Automation Publication 1608 July 2013 13 21 336 12 80 325 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information
6. Rockwell Automation Publication 1608P UM001A EN P July 2013 21 Chapter5 Display Screen Voltage Sag Events 22 Table 5 System Status Description Description Function verall system status including current operational status availability to correct sags an System Status internal cabinet temperature Voltage current frequency and static switch temperature are displayed for all phases The Phase Status percentage displayed following the voltage and current is the percent of nominal value for the ProDySC Nominal values are listed on the View Model Information screen sample of a 4 cycle waveform that includes real time Tine voltage load voltage or load Waveforms current can be selected for display 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 ProDySC protection are captured and saved to the voltage sag log Voltage Sag Log The Voltage Sag Log screen See Figure 17 displays a list of the last 61 voltage sags Reach this screen by pressing VOLTAGE SAGS button on the HOME screen Figure 17 Voltage Sag Log 04 21 2009 15 19 25 04 21 2009 08 22 45 04 21 2009 01 26 05 04 20 2009 11 32 4 04 20 2009 04 36 05 04 19 2009 21 39 25 04 19 2009 14 42 45 04 19 2009 07 46 05 04 19 2009 00 49 25 04 21 2009 16 18 Table 6 Voltage Sag Log Description Description Functio
7. inside the enclosure as this can result in electrical damage The system is not intended for outdoor use The operating environment should be maintained within the parameters stated in this manual Only authorized service personnel should perform service on the ProDySC Ensure all power is disconnected before performing installation or service ATTENTION To reduce the risk of fire or electric shock install this ProDySC in Rockwell Automation Publication 1608P UM001A EN P July 2013 Chapter 1 Introduction discharge ESD Do not touch circuit boards or electronic components with hands or metal objects Use an insulated screw driver when connecting the lines ProDySC is not rated to directly power life support equipment Ensure the area around the ProDySC is clean and uncluttered Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of the equipment ATTENTION Internal components can be easily damaged by electrostatic Rockwell Automation Publication 1608 July 2013 Installation Check List Inspecting and Unpacking Location Environment Mounting Considerations Rockwell Automation Publication 1608P UM001A EN P July 2013 Chapter 2 Installation Before proceeding please take a few minutes to review the necessary steps to install your ProDySC All packing materials and restraints have been removed The ProDySC is placed i
8. 8 System Event Description Description Function Informational Purely informational No action is required Auto Resetting The PRODySC will reset within 60 seconds No user action is required User Attention User action may be required to correct a problem The PRODySC will reset 60 seconds after the error condition is corrected For system events that force an automatic transfer to mechanical bypass a Manual Reset manual reset of the DySC system will be required For events classified as Call Service factory trained service support will be Call Service required Contact SoftSwitching Technologies support System Event Log The System Event Log screen displays a list of the last 40 system events in chronological order See Figure 21 Reach this screen by pressing SYSTEM EVENTS on the HOME screen Figure 21 System Event Log System Event Log Severity 65 69 2613 17 55 22 SLAVE_2 Auto Resetting 65 69 2613 10 58 42 SLAVE_1 Auto Resetting 65 69 2613 04 82 02 SYNC ERR Call Service 05 08 2013 21 05 22 GATE_ERR Call Service 05 08 2013 14 08 42 STAT Call Service 05 08 2013 87 12 82 IGBT User Attention 65 68 2613 88 15 22 ULL OU Call Servic 65 67 2613 17 18 42 OUTPUT OU Call Service 65 67 2613 10 22 02 DC UU User Attention 65 67 2613 63 25 22 INV_OC User Attention 65 66 2613 20 28 42 OUTPUT lU User Attention 05 13 2013 13 41 Table 9 System Event Log Description Description Function Uni
9. Before applying power to the ProDySC make certain there are no metal filings or any conductive debris in or on any components inside the ProDySC Ensure that all input output wiring including grounding has been completed and that all access doors are closed Place the maintenance bypass in Bypass mode Apply power from the upstream branch protection device Power will flow through the maintenance bypass directly to the load Place the maintenance bypass in Test mode The ProDySC touchscreen will become active but the load will still be powered through the bypass Ensure that the touchscreen displays OK in the upper left corner and that the nominal voltage current and frequency in the status display are correct Ifa Critical or Fatal system event appears on the touch screen 1 place the maintenance bypass switch in BYPASS and 2 call for technical support Place the maintenance bypass in Normal mode Verify that the output load voltage is present and within its nominal rating Ifa Critical or Fatal system event appears on the touch screen 1 place the maintenance bypass switch in BYPASS and 2 call for technical support Rockwell Automation Publication 1608P UM001A EN P July 2013 17 Chapter4 Applying Power Notes 18 Rockwell Automation Publication 1608P UM001A EN P July 2013 Chapter 5 Display Screen Overview The ProDySC touch
10. Checks a E a 31 3 6 Month Checks 31 System Event cese sasana piq eter RSV A eI RR aqa Papp aa ns 32 Buse Replacement u yaaa kunqa 33 Fuse Rating ei iue eR vases d ee KEE kaha 34 Technical Specifications zudem p E EL edet CHE 35 Heat Dissipation rererere rrr eceran Cuna n ES 36 Approximate Dimensions oes ELCHE E RE e a 36 Rockwell Automation Publication 1608 July 2013 3 Table of Contents Notes 4 Rockwell Automation Publication 1608P UM001A EN P July 2013 Safety Considerations Chapter 1 Introduction The Allen Bradley Bulletin 1608P ProDySC Dynamic Sag Corrector is engineered to provide years of trouble free voltage sag dip protection The patented ProDySC technology does not use batteries requires only routine maintenance includes three stage transient voltage surge suppression and has unparalleled energy efficiency Most electronic devices found in industry today are susceptible to power disturbances A momentary sag in line voltage can reset or damage sensitive production equipment The ProDySC provides instantaneous dynamic sag correction to help your equipment ride through these common events The ProDySC connects normal utility power directly to the load until a voltage sag occurs During a sag the ProDySC inverter is activated adding missing voltage to keep the load voltage within
11. Configuration only 4 Wire Configuration only p a 5 GND GND GND GND 2 13 2 13 2 13 Circuit Breaker Recommendations Accessing ProDySC Terminations Branch circuit protection upstream of the ProDySC is required Recommended circuit breakers and maximum allowed circuit breaker ratings are listed in Table 1 Branch circuit protection rated less than the ProDySC current rating may result in nuisance tripping Table 1 Recommended Branch Circuit Protection Recommended Cat No ProDySC Rating Max MCCB Rating 25A 50A 1400U H3C3 C35 35A 140U H6C3 C70 70A Two holes are provided for punch out locations to provide the appropriate hole size for conduit fittings in the ProDySC Take care to avoid dropping any metal filings inside the enclosure Metallic contamination will void the product warranty See Figure 6 for preferred Input Output wiring locations Figure 6 Knockout Hole Locations TOP VIEW Rockwell Automation Publication 1608P UM001A EN P July 2013 11 Chapter2 Installation Pro DySC Terminations and A qualified electrician must install the units To access the ProDySC Electrical Ratin gs Terminations turn the two turn latches CCW and swing open the door The unit is furnished with one of the terminal block configurations as shown in Figure 7 For power cable termination specifications see Table 2 for the 25A rated units and Table 3 for the 50A
12. Ve eta eee ee es reru 11 Circuit Breaker Recommendations 11 Accessing ProDySC Terminations 11 ProDySC Terminations and Ratings 12 IG ds kuqa uad uetus da e 12 NI Med UP ER PRAES 12 Dry Contacts ura ua aka aa aasawa 15 Serial Communications Ports thier rt er ORO eoe 16 rcu ET 19 Home Ip o eed anu M eti ai oo aU d EA 21 e atii tee celu c aote als S 21 Voltage Sag Events sua epee ane edad a 22 Voltage Sag Los RERO ob Yes RE qu mem paspa ses 22 Voltage Sag Detail asa anal ol chew e mo Rees Bek AVE 23 Voltage Sag RMS Voltage Charts sese 24 Voltage Sag Notification phi stents wit ae ted etus ene d dotada 24 Systemi De cod oe pU bapa aunt 25 System Brent Log 1209165 sd ose ERAS apa ae ua 25 System Event Detail 45152259222 3333 S0 P259 26 System Event Notification 27 System Configuration etse E V rrr ee beta etn 28 Model Information ud eer CIR RR e cH 28 R n System 29 Diagnostics Mode aa ab phu 29 Preventative Maintenance 31 Monthly
13. be mounted vertically as shown in the figures and may be mounted inside another enclosure if the ProDySC inlet temperature remains at or below specified limits Read this entire user manual to understand the additional space requirements around the ProDySC for power conductor entry communications conductors and airflow Refer to Specifications and Dimensions on page 35 for temperature ratings and heat dissipation Chapter2 Installation Mounting the ProDySC Using the 3 8 hardware and four 4 wall mounting brackets supplied mount the wall mount brackets to the back of the ProDySC Mount each bracket to the back of the ProDySC with a single 3 8 16 x 1 hex cap head screw Mount the brackets so the flat portion of the mounting bracket is against the back of the ProDySC Bolt two 2 x 4 pieces of lumber horizontally to the wall using 3 8 by 4 hex head lag bolts Make certain that 1 The lag bolts line up with the wall studs 2 The distance between the centers of the pieces of lumber is equal to the distance between the centers of the mounting holes Refer to Figure 1 3 Bolt unit to the 2 x 4 pieces of lumber with 4 3 8 by 2 long hex head lag bolts NOTICE Weights and complete mounting dimensions are provided in Chapter 7 Figure 1 25 A Mounting dimensions in mm 25 35 644 24 00 md 13 21 336 572 12 80 31 13 791 762
14. directly from the utility to the load ProDySC outputs are not connected to the load ProDySC inputs have power provided for testing by a qualified technician BYPASS Mode Power flows directly from the utility to the load No power is present on ProDySC inputs or outputs NOTICE The 1608P bypass switch contacts are designed to make before break and will not disrupt power to the load during any mode transitions The switch has lockout tagout LOTO provisions 10 Rockwell Automation Publication 1608P UM001A EN P July 2013 Bypass Switch Installation Chapter 2 The maintenance bypass has input and output terminals labeled and located Wiring Diaqram inside the bypass enclosure as shown in Figure 5 The neutral connection is gulag available for 4 wire ProDySC configurations NOTICE All electrical connections must be completed by a qualified electrician in compliance with all local codes and the National Electric Code Figure 5 Bypass wiring diagram TB1 Line Input TB2 Line to DySC TB3 DySC to Load TB4 Output to Load L1 t p NE lo N ol L1 F1 12 2 12 o 2 the lo N ol L2 DySC F2 L3 7 l g p 1 lt ol L3 F3 N Q d N N 4 Wire
15. displayed Update system time if needed Figure 13 on page 20 e 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 e Ensure air intake and exhaust filters are not covered or obstructed 3 6 Month Checks e Check air filters and clean when necessary Air filters for the ProDySC will require periodic cleaning with the frequency depending on the environment Filters are located on the right and left sides of the ProDySC and can be accessed with the door closed The ProDySC need not have power removed for this operation Remove the grill covers by unscrewing the knurled nuts the washable foam filter pads are behind the grill cover Gently wash the foam filter pads as needed with a light non abrasive soap and water mixture Towel dry do not wring out Place the filter and grill cover back into their location and replace the screw caps by rotating clockwise until finger tight Replace filter if damaged Consult Rockwell Automation technical support for replacement filters Replacement filters must be no more restrictive to air flow than the original equipment filters Check fan for proper operation Tap on CONFIG on the touch screen display Tap on Run System Test This will bring up a System Test screen to test the fans After tapping the Fan Test button you should hear the fan run for two minutes E
16. list 0 60 to identify the voltage sag Time Start time of the voltage sag RNS 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 Temperature Internal temperature of the PRODySC prior to the start of the voltage sag Line Voltage Line RMS voltage and percent of rated L N Voltages lt 80 of nominal are displayed in red Load Voltage Load RMS voltage and percent of nominal L N Correction Result 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 PRODySC performed correcting the voltage sag The possible values are Protected The output RMS voltage on all phases is 785 percent of nominal and the PRODySC 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 PRODySC system was inhibited when the sag occurred will be displayed in orange 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 Rockwell Automation Publication 1608P UM001A EN P July 2013 23 Chapter5 Display Screen Voltage Sag RMS Voltage Charts Voltage Sag Notification 24 The lin
17. rated units Figure 7 Input Output terminal locations GROUND STUD LOCATED BEHIND DOOR ON MAIN ELECTRICAL PANEL IN THIS AREA 00 00 gt 1 p Al X1 X2 X8 Ll 12 13 GR 3 WIRE CONFIGURATION AC INPUT AND LOAD CONNECTIONS d LOCATED BEHIND DOOR ON MAII ELECTRICAL PANEL IN THIS AREA USER INTERFACE TOUCHSCREEN DISPLAY H 2 9 um lor HO O10 0 o 016 XI X2 X3 N N LI L2 13 GR 4 WIRE CONFIGURATION loof 00 ATTENTION All electrical connections must be completed by a qualified electrician in compliance with all local codes and the National Electric Code Input Ground Earth Connect the safety ground conductor to the ground stud e 3 Wire Input Connect source L1 L2 and L3 to terminals labeled L1 L2 and L3 respectively e 4 Wire Input Connect source L1 L2 L3 and Neutral to terminals labeled 1 1 L2 L3 N respectively IMPORTANT 4 wire ProDySCs units with V4 in their part number must also have a neutral connected to the neutral terminal block The neutral terminal block is labeled N Neutral must be connected for the
18. support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedba
19. the normal range When utility power returns to normal the inverter is deactivated and the ProDySC is quickly ready to correct the next sag The ProDySC reports these voltage sag events through its integrated touch screen display and provides system status voltage sag notification and history runtime statistics and system history in a simple and intuitive touch based user interface The ProDySC is designed to operate in industrial applications Follow these guidelines to ensure that the safety and installation of the ProDySC are handled with appropriate care after disconnection from the AC line Touching exposed or disconnected terminals cables or parts of the ProDySC can lead to serious injuries or even death Wait for a minimum of 5 minutes before performing any service or testing on the ProDySC after power is removed Keep the cabinet doors closed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the ProDySC SHOCK HAZARD The ProDySC has high voltage remaining up to 5 minutes a temperature and humidity controlled indoor environment free of conductive contaminants Avoid installing the ProDySC directly near heat emitting equipment such as ovens heaters or furnaces Ambient temperature must not exceed 40 C 104 F Do not operate near water or excessive humidity 95 max When punching or drilling holes for conduit fittings take care to avoid dropping metallic particles
20. 2 3 10 0 1 35 a AC Input Ground 4 20 Stud 65 7 3 Phase A B 10 0 1 35 mr ACOutput Ground 4 20 Stud 65 73 4Wire with a Ground Phase A B C 24 9 26 7 and Neutral L1 L2 L3 N 10 0 1 35 2 8 3 AC Input Ground D 4 20 Stud 65 7 3 Phase A B C 24 9 26 7 and Neutral X1 X2 X3 N 10 0 1 35 2 8 3 AC Output Ground D 4 20 Stud 65 7 3 A WARNING The ProDySC must be safety grounded according to the National Code In addition all local state and federal regulations applicable to the installation of electrical systems as well as accident prevention regulations must be strictly observed Rockwell Automation Publication 1608P UM001A EN P July 2013 13 Chapter2 Installation Notes 14 Rockwell Automation Publication 1608P UM001A EN P July 2013 Dry Contacts Chapter 3 Communications Both dry contacts relays that indicate status and a Serial Communications Port RS 232 are available for monitoring the ProDySC Three relay contacts indicate ProDySC 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 A For access remove the Communications Port cover SeeFigure 8 A removable connector plug is provided to facilitate wiring All
21. HOME screen is divided into four main areas described in Table 4 Figure 14 Home Screen 90 Voltage Sags Detected Total Up Time 365d Gh 12m Elapsed Time Since Restart 1 9 cycles Table 4 Screen Description Function eal time system operation available runtime output line to neutra Description Status voltage model dependent load current and frequency Last Voltage Sag Rotating information about the last voltage sag event start time event duration and sag depth Statistics Summary view of ProDySC performance based sags detected plus rotating display of last power up date elapsed time since power up and total up time 25 8R 166 6 25 8R 166 6 25 8R 166 6 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 Main Menu The System Status screen displays the real time overall system status Reach this screen by pressing STATUS on the screen or the Status area at the top of the HOME screen Figure 16 System Status Waveforms Line Voltage 04 21 2009 1 DSC Cabinet 290 Suitch 37 5 C 37 5 C 37 5 Freq 68 8Hz 68 8Hz 680 8Hz SUMMARY waverorns
22. PASS or opening the branch circuit breaker before replacing the fuse Failure to comply with this warning can result in injury or death The ProDySC has high voltage remaining up to 5 minutes after disconnection from the AC line Touching exposed or disconnected terminals cables or parts of the ProDySC can lead to serious injuries or even death Wait for a minimum of 5 minutes before performing any service or testing on the DySC after power is removed Keep the cabinet doors closed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the ProDySC IMPORTANT X A qualified electrician must replace the fuse Open the front cabinet door s to access the fuse holders and fuses To maintain protection of the ProDySC be sure to replace the fuse with the same type and rating These fuses are available from the factory Provide the factory with the ProDySC model number located on the outside of the enclosure Rockwell Automation Publication 1608P UM001A EN P July 2013 33 Chapter6 Maintenance Replace fuse with the same type or equivalent cross referenced rating You may Fuse Rating Charts order these fuses through Rockwell Automation the manufacturer listed Table 13 DySC Fuse Ratings for 25A Unit Fuse Reference Manufacturer Part Number F1 F2 Main Power Input 60A 500V Mersen 500560 4 F7 Input Control Transformer 0 5A 600V Mersen 1 2 F4 F5 F6 Cross Cou
23. User Manual Allen Bradley Bulletin 1608P ProDySC Dynamic Voltage Sag Corrector atalog Numbers 1608P 25 and 50 Amp Models Rockwell Allen Bradley Rockwell Software Automation Important User Information 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 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and 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 circui
24. ck Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1608 July 2013 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in the U S A
25. d products from Rockwell Automation Resource Description Provides general guidelines for installing a Rockwell Automation industrial system Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Product Certifications website http www ab com Provides declarations of conformity certificates and other certification details You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative h1 Introduction 12 Installation 13 Communications Ch 4 Applying Power Ch 5 Display Screen Ch 6 Maintenance Ch 7 Specifications and Dimensions Table of Contents Important User Information 2 1 EVI ee qe ys 2 Additional RESOUTCES cora aaa coute remit bale esie eo ar 2 Safety niet anise deen stud serbe tue baee ud cero 5 Installation Check List i du deua ate eu eee dees dod cel els 7 Inspecting and Unpacking Revo ee PETER TAE EARS 7 Location Environment 7 Mounting Considerations Hee PUR SEES IE ERE I 7 Mounting the Peas ele dede e te aaa acd 8 Bypass eres uy dera Geert CC GL e epee sees al 10 Bypass Switch Modes eri aeien tinae e RR E 10 Bypass Switch Wiring Diagram 0 24002 ies
26. e 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 19 Reach this screen by pressing CHARTS on the Voltage Sag Detail screen as shown in Figure 18 on page 23 Figure 19 RMS Voltage Charts RMS Voltage Charts LINE LOAD VOLTAGE 120 AUTO au 68 128 186 388 Cycles SUMMARY carrs J HOME 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 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 20 Figure 20 Voltage Sag Detected SRG IN PROGRESS Availability Ucitage 207 90 207 90 207 90 Eurrem 2500 2508 2508 600 coon Last Voltage Sag Statistics 1 9 cycles 90 Uoltage Sags O Detected Total Up Time 365d Gh 25m Last Power Up Date 65 68 2613 89 18 Rockwell Automation Publication 1608P UM001A EN P July 2013 System Events Display Screen Chapter 5 ProDySC tracks all operational events which classified into five groups based on severity Table
27. ion the static switch passes utility voltage directly to the load Standard Input Voltages 3 208 380 400 415 480V Voltage Range 10 Current Overload Static Switch 150 30Sec 400 5 Sec 600 0 5 Sec Frequency 50 60 Hz Auto Sensing Frequency Range 45 to 65 Hz TVSS Built in 3 Layers consisting of MOVs amp Capacitors Efficiency gt 9996 480V Electrical Output Sag Correction Mode Inverter Output Voltage Pre sag rms voltage Voltage Regulation 5 13 of nominal Output Current Rated RMS 25A or 50A Not rated for DC loads max allowable 296 DC loading Crest Factor at nameplate rms load 1 45 Voltage Waveform Sine wave Voltage Sag Correction Times Single Event 3 phase 87 to 50 Voltage Remaining 5 seconds All three phases to zero voltage remaining 50ms or 200ms SR or ER Based on load at nameplate ratings with a power factor of 0 7 Multiple Event Max Sag Correction Time 5 seconds cumulative usage Sequential Sag Recovery 0 seconds assuming cumulative run time available Full Recovery Time Max 5 minutes Mechanical Enclosure Ratings NEMA 1 IP20 Cable Entry Top Cooling Filtered Forced Air Access Front for servicing and connections Bypass External Panel mounted for PM or servicing ProDySC Environmental Ambient Temperature 0 to 40 C Storage Temperature 40 C to 75 C Relative Humidity 0 to 95 non c
28. n 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 ProDySC protected the voltage sag RMS 96 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 UM001A EN P July 2013 Display Screen Chapter 5 Voltage Sag Detail The Voltage Sag Detail screen See Figure 18 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 Table 7 describes the remaining screen content Figure 18 Voltage Sag Detail Voltage Sag Detail 6 00 L N 5 for 1 9 cycles Sag Summary ID Protected Time 85 23 2011 15 63 56 RMS 6 8U L N 5 Frequency 60 8 Hz Duration 1 9 cycles Temperature 29 0 C Line L H Load L N 6 90 5 6 122 4U 162 6 24 00 20 0 122 40 182 85 30900 25 0 122 40 162 6 Table 7 Voltage Sag Detail Description Description Function Sag Summary Sag Magnitude ID Unique ID within the
29. n its installed location All conduits and cables are properly routed to the ProDySC All power cables are properly terminated A ground conductor is properly installed and terminated e Ifneutral connection is required that it is properly terminated on the ProDySC The area around the installed ProDySC is clean and dust free e Adequate work space exists around the ProDySC e Adequate lighting is provided around the ProDySC e Operational checks have been reviewed and completed Carefully inspect the outer packaging for evidence of damage during transit Do not install a damaged cabinet Report any damage to the carrier and contact your local sales or service immediately e Check the ProDySC label for correct model number with the packaging list to ensure you have received the correct voltage current and wiring configurations After removing the packaging material inspect the contents for any evidence of physical damage and compare each item with the Bill of Lading If damage has occurred or shortages are evident contact your carrier immediately The ProDySC must be installed in a protected environment The location must provide adequate airflow around the ProDySC in an atmosphere free from excessive dust corrosive fumes or conductive contaminants Do not operate the ProDySC in an environment where the ambient temperature or humidity is beyond the specified limits given in this manual The ProDySC must
30. nsure that the optional bypass switch is in Normal mode so that the ProDySC is protecting the load Rockwell Automation Publication 1608P UM001A EN P July 2013 31 6100 Aine d NI VLOOWN d8091 uonexijqng owopog BAS 159 Ja J2AU S 0 5 0 011u02 aseyg yun DIAS 159 19M9AU OL ANT 1 144 uoe ON 159 5 yews eras 0300 uun Jeuoneuuoju yews Jaquiny 40 45 4414 185 DIAS 159 5 payajap uu qo1d Jaj 0 U0 uun aquiny asian OL 185 DIAS 159 5 p 129 p uolsiAaJ 1 011u0 uun JIAJ aped 34Iq Wild 5 _ 1noeull E JIAJ S e 1594 dn 1e1s uone runuiuJo Ja 0 3u0 uun JIAJ9 emua J l onuo 352 41 1201 OL Wild DIAS 159 dn uejs payajap Wajqoid 0 1U0 uun DIAS D4N 8E DIAS 159 dn ye s payajap Jaj 0 U0 uun 25 uopeunbi
31. ondensing Altitude Rated current available to 1000m 3300ft De rate output current 10 per 1000m from 1000m to 3000m 9900ft Safety Agency Approvals cULus Listed 1 ProDySC has not been evaluated for use in Corner Grounded or Ungrounded Delta Power Systems 2 When using ProDySC with motor drive loads either insert 3 to 5 line reactance at ProDySC output or limit motor drive loads to 60 of ProDySC rating Rockwell Automation Publication 1608P UM001A EN P July 2013 35 Chapter7 Specifications and Dimensions Heat Dissipation Rating Heat Loss J Heat Loss Btu h Efficiency 96 Standard Run time SR 25 280 957 97 8 50 350 1196 97 2 Extended Run time ER 25 420 1435 98 2 50 560 1913 97 7 Approximate Dimensions Rating Weight A Ibs kg Standard Run time SR 25 32 26 x 14 813 x 660 x 356 277 126 50 38x38x 14 965 x 965 x 356 330 150 Extended Run time ER Voltage independent may be either 3 or 4 wire 25 32x26x 14 813 x 660 x 356 307 140 50 38x38x 14 965 x 965 x 356 398 181 Dimensions are shown in inches millimeters Dimensions are not intended to be used for manufacturing purposes 36 Rockwell Automation Publication 1608P UM001A EN P July 2013 Figure 28 25AStandard Extended Run 25 35 1644 24 00 610 22 50 572
32. pling Transformer 15A 600V Mersen TRS15R F8 vine Neutral Forming Transformer 0 75A 600V Mersen 4 3 wire models only F17 F18 Output Control Transformer 2A 600V Mersen ATQR2 F1 F2 Extended Run Module PCB x3 25A 600V Mersen A60Q25 2 ER models only Table 14 DySC Fuse Ratings for 50A Units Fuse Reference Manufacturer Part Number F1 F2 Main Power Input 150A 500V Mersen 5005150 4 F7 Input Control Transformer 0 5A 600V Mersen ATQR1 2 F4 F5 F6 Cross Coupling Transformer 30A 600V Mersen TRS30R F8 Frid Neutral Forming Transformer 0 75A 600V Mersen 4 3 wire models only F17 F18 Output Control Transformer 2A 600V Mersen 2 F1 F2 Extended Run Module PCB x6 25A 600V Mersen 60025 2 ER models only WARNING De energize the Bypass Switch by opening the upstream branch AN circuit breaker before replacing a Bypass Switch fuse Failure to comply with this warning can result in injury or death Table 15 Bypass Switch Fuse Ratings Bypass Cat No Manufacturer Part Number 1608P BP025A480V3 35A 600V Bussmann LPJ 35SP 100A 600V Bussmann DFJ 100 1608P BP050A480V3 34 Rockwell Automation Publication 1608P UM001A EN P July 2013 Connection Configuration Chapter 7 Specifications and Dimensions Table 16 Technical Specifications Electrical Input Output Normal Mode Static Switch Series connected with load Under normal line condit
33. que 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 Rockwell Automation Publication 1608P UM001A EN P July 2013 25 Chapter5 Display Screen 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 21 on page 25 It provides detailed information that was recorded during the event See Figure 22 Figure 22 System Event Detail System Event Detail Time Duration Time 87 02 2013 06 09 27 Duration 32 sec Type Event ID 14 Description Code DC OU 15 DC Bus Over Voltage Severity User Attention Component Location Phase C Area Inverter Reading 1237888 0 Table 10 System Event Detail Description Function Time Date and start time of the system event Time Duration Duration The amount of 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 Type list of codes and abbreviations Refer to System Event Table on page 32 Severity Severity of the event Description Name of
34. screen display is a window to voltage sags and ProDySC protection The display provides system status voltage sag notification and history runtime statistics and system history in a simple and intuitive touch based user interface When the system first starts a welcome screen displaying the ProDySC 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 Figure 10 Home Screen at the bottom of the HOME screen See Figure 10 See Figure 10 ec 2520 25 08 2528 90 Voltage Sags Detected Total Up Time 365d h 12m Step 2 Begin calibration by pressing Figure 11 System Configuration CALIBRATE TOUCH SENSOR System Configuration See Figure 11 VIEW MODEL INFORMATION SET SYSTEM CLOCK CALIBRATE TOUCH SENSOR RUN SYSTEM TESTS ENTER DIAGNOSTIC MODE i 19 Rockwell Automation Publication 1608P UM001A EN P July 2013 19 Chapter5 Display Screen 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 sa
35. se units to operate properly Output Terminal blocks are provided marked X2 and N ifused as shown inFigure 7 If there are multiple loads a separate distribution box must be provided so that there is only one set of output wires terminated inside the ProDySC enclosure IMPORTANT The 48013 phase 3W ProDySC has not been evaluated by Underwriter s Laboratories Inc for connection to a corner grounded delta power source 12 Rockwell Automation Publication 1608 July 2013 Table 2 ProDySC 25 Amp Power Cable Terminations Installation Chapter 2 3 Wire with a Ground Terminal x Wire Range Torque Ib in Connection Function Terminal Marking AWG mm Nm AC Input Phase 11 12 13 24 8 0 5 6 7 1 8 9 0 8 1 Ground 14 20 Stud 65 73 AC Output Phase A B C X1 X2 24 8 0 5 6 7 1 8 9 0 8 1 Ground 14 20 Stud 65 73 4 Wire with a Ground AC Input Phase L1 L2 L3 24 8 0 5 6 7 1 8 9 0 8 1 Ground 14 20 Stud 65 73 Neutral N 10 0 1 35 24 9 26 7 2 8 3 AC Output Phase A B X2 24 8 0 5 6 7 1 8 9 0 8 1 Neutral N 10 0 1 35 24 9 26 7 2 8 3 Ground 14 20 Stud 65 73 Table 3 ProDySC 50Amp Power Cable Terminations 3 Wire with a Ground Terminal Wire Range Torque Ib in Connection Function Terminal Marking AWG mm Nm Phase A B C L1
36. the event Refer to System Event Table on page 32 Location The location in the system where the event originated i e Phase A Phase B Phase C Area The specific area within the location where the event originated i e Inverter etc Reading In some cases the system will record a relevant data value during the event i e For an Inverter Over current Fault the component reading is the current value that caused the event If a data value is not appropriate for the event type N A is displayed Component 26 Rockwell Automation Publication 1608 July 2013 Display Screen Chapter 5 System Event Notification When the ProDySC system first detects an event condition the System Fault Detection dialog box will be displayed See Figure 23 Within the System Fault Detection box the name severity and location of the event will be displayed Figure 23 System Fault Detection em Fault Detection System Fault Detected Name OC Severity Auto Resetting Location Phase B Touch OK to view additional details about the fault VOLTAGE SAGS 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 e
37. ts 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 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 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 gt gt gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product ProDySC Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Additional Resources These documents contain additional information concerning relate
38. uo jojponuo sal rep OL 54ND LE M S dn yeys papayap 1IlIqieduuo2 emu uun JIAJ Pire e 43A WO 9E DIAS 159 5 payajap uiajqod uun JIAJ diei TI TION SE DIAS J 159 dn uejs ay 2Ue1 o1 Jo Jno p 2 1 p sem 1nding JIAJ yay abeyon 4591 JD X vt dn M95 I amod Ajjenba pip 90 34 40 sanjey aanebou pue aanisod see 9195 6 auejequn sng yq 359 91 1015 DNVIVENN uoe oN use j mau Sl 1 M AU Asng 1 9 011u0 W3W THLND DIAS seu uoneinfijuoo 13 10170 J 1M9AU DIMAS uonen yuo 9HNO2 DIAS aul 0 paziuoJtpu s JOU 19119AU DIMAS 10113 uoneziuoipufs aur NAS SZ M S Hes jo occ uey 1232316 sem 1ndino 3540 J HAU M S Be oA J A0 1ndin0 AO 14100 0 624985 J 51 9 Ul UA buea mojaq abeyoa snq jq uonuany 1950 sng 30 61 ssedkq Be Ree feat uonoauo bes
39. vent detail or CANCEL to close the dialog box See Figure 24 Figure 24 System Fault Detection Cleared The system fault has cleared Touch OK to view fault details Sags Detected Ifa 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 Rockwell Automation Publication 1608P UM001A EN P July 2013 27 Chapter5 Display Screen System Configuration Model Information 28 Press the CONFIG button at the bottom of the HOME screen to enter the System Configuration screen See Figure 25 The SET SYSTEM CLOCK and CALIBRATE TOUCH SENSOR functions are described at the start of this chapter Figure 25 System Configuration System Configuration VIEW MODEL INFORMATION SET SYSTEM CLOCK CALIBRATE TOUCH SENSOR RUN SYSTEM TESTS ENTER DIAGNOSTIC MODE BACK HOME 12 16 2018 11 36 Touch VIEW MODEL INFORMATION to go to the Model Information screen See Figure 26 Figure 26 Model Information Model Information Model Details Model Number 1688P 825R288U3S Serial Number PM654321 System Rating 208U L L 258 Unit Details Node Firm Type Serial Volts A 18 PH123456 1200 B 16 PM123457 1280 C n 16 123458 1204 COMM 01 12 PM123459 1204 5 Station Rddr 288
40. ving 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 20 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 Figure 12 Touch Screen Calibration Touch Screen Calibration HOME Figure 13 Set System Date and Time Date Time Settings System Clock 2009 1520 3 Date Format 04 21 2009 Time Format Rockwell Automation Publication 1608P UM001A EN P July 2013 Home Screen System Status Figure 15 System Status Summary Sustem Status System Status OK Availability 5 0 secs Phase Status Phase Voltage L L A B 207 9U 99 9 B C 207 9U 99 9 c R 207 90 99 9 Current SUMMARY WAVEFORMS Display Screen Chapter 5 The screen of the display provides a snapshot view of the status of the entire system See Figure 14 You can return to this screen from any other screen 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
41. 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 Ib in 0 6 N m For permanent installations a standard conduit knockout is located within the wiring area SecFigure 8 Figure 8 Access Cover Location 875 22 CONDUIT KNOCKOUT COMMUNICATIONS PORT COVER Rockwell Automation Publication 1608P UM001A EN P July 2013 15 Chapter 3 Serial Communications Port Communications The ProDySC 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 line and load voltages line and load currents status and event and diagnostic logs Consult Rockwell Automation technical support for specifications to the ProDySC SLIP protocol Figure 9 Serial Communications Port Pin 5 Return T _ Pin 3 TxD t _ Pin 2 RxD _ Rockwell Automation Publication 1608P UM001A EN P July 2013 Chapter 4 Applying Power Verify that the ProDySC voltage rating matches the source voltage
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