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Bulletin 1608P ProDySC User Manual - 100/110 Amp

1. TOUCHSCREEN DISPLAY AIR FILTERS SIX PLACES Cd Rockwell Automation Publication 1608P UM002A EN P July 2013 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 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 rockwellautom
2. V3E 937 426 1608P 1004 V4E 922 419 110 1608P 1104 V3E 937 426 1608P 1104 V4E 922 419 36 Rockwell Automation Publication 1608P UM002A EN P July 2013 Specifications and Dimensions Chapter 7 Approxim ate Dimensions Dimensions are shown in inches millimeters Dimensions are not intended to be used for manufacturing purposes Figure 28 Standard Runtime 3 amp 4 Wire AC INPUT OUTPUT CONDUIT ENTRY COMMUNICATIONS PORT K 22 COMMUNICATIONS CONDUIT KNOCK OUT I p 24 7 627 52 2 1327 CLEARANCE FOR DOOR SWING E U 29 0 P 737 al i Eed H SE R Sess s TOUCHSCREEN DISPLAY A AIR FILTERS FOUR PLACES Rockwell Automation Publication 1608P UM002A EN P July 2013 37 Chapter 7 38 Specifications and Dimensions Figure 29 Extended Runtime 3 amp 4 Wire 29 0 737 EE SEE 55E B S 0 S 0 E S S S ZE i Si F E SS s s8 8s3 SE S E S GI S 8 S S S S gt Seres
3. Fuse Rating Charts Replace fuse with the same type or equivalent cross referenced rating You may order these fuses through Rockwell Automation or the manufacturer listed Table 11 DySC Fuse Ratings for 100 A Units Fuse Reference Fuse Rating Manufacturer Part Number F n Power Cabinet Power Module 3004 500y Mersen AS0QS300 4 la Ge 2 Transformer Cabinet 4A 600V Mersen TRS4R 3 wire models only F4 F5 F6 Transformer Cabinet 60A 600V Mersen TRS60R F7 F8 Main Power Cabinet 10A 600V Mersen ATQR10 F1 F2 Extended Run Cabinet ER Module ER models only PCB x12 25A 600V Mersen A60Q25 2 Table 12 DySC Fuse Ratings for 110A Units Fuse Reference Fuse Location Fuse Rating Manufacturer Part Number F1 Main Power Cabinet Power 350A 500V Mersen A50Q 350 4 Module x3 F1 F2 F3 Transformer Cabinet 4A 600V Mersen TRS4R 3 wire models only F4 F5 F6 Transformer Cabinet 60A 600V Mersen TRS60R F7 F8 Main Power Cabinet 10A 600V Mersen ATQR10 F1 F2 Extended Run Cabinet ER 25A 600V Mersen A60Q25 2 ER models only Module PCB x12 circuit breaker before replacing a Bypass Switch fuse Failure to comply with this V WARNING De energize the Bypass Switch by opening the upstream branch warning can result in injury or death Table 13 Bypass Switch Fuse Ratings Bypass Cat No Manufacturer Part Number 1608P BP110A480V3 200A 600V Bussmann DFJ 200 34 Rockwell Au
4. 49 25 Table 4 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 ProDySC 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 UM002A EN P July 2013 Voltage Sag Detail Display Screen Chapter 5 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 6 8U L N 5 for 1 9 cycles Sag Summary ID 36 Time 05 23 2011 15 63 56 RMS 6 8U LH 5 Duration 1 9 cycles Protected Frequency 66 8 Hz Temperature 29 6 C Line L N 68U 5 6 24 6U 20 0 36 8 25 0 Load L N 122 44 162 6 122 44 162 6 122 44 162 6 summary Table 5 Voltage Sag Detail Description Description Fun
5. 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 Ch 1 Introduction Ch 2 Installation Ch 3 Communications Ch 4 Applying Power Ch 5 Display Screen Ch 6 Maintenance Ch 7 Specifications and Dimensions Table of Contents Important User Information ic hearin EN EE EEKE 2 Additional EE 2 SE EE 5 a EE 7 Inspecting and Unpacking cgis Ke OK ee EEN EEN EE EEN H Location Environment 0 6 0 ccc cece nec n cence eee ne tne ene en eens 7 Floot MOUNTING A epatiee sees tbs ue hee E 8 O Elek de 8 Circuit Breaker Recommendations ed Ee Ve E E aes 9 Electrical Terminations es asots ty a A a a E 9 Accessing Terminations Gavan aici Ei Pi an ed aes mats 10 ENEE 11 OP Wire Model nio 11 A Wire Models apra od 12 Electrical Terminations and Ratings dai id 13 E KEE 14 Dry CONTA EE 15 Serial Communications Port 45 4 2i00524 ti das 16 Applying PO AAA 17 OVERVIEW nta A A lada 19 FLOME Sereen eeh 21 SYSTEM
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7. make certain there are no metal filings or any conductive debris in or on any components inside the ProDySC e Ensure that all input output wiring including grounding has been completed and that all access doors are closed e Place the maintenance bypass in Bypass mode e Apply power from the upstream branch protection device Power will flow through the maintenance bypass directly to the load e Place the maintenance bypass in Test mode The ProDySC touchscreen will become active but the load will still be powered through the bypass e 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 e 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 e Place the maintenance bypass in Normal mode e Verify that the output load voltage is present and within its nominal rating e 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 NOTICE Cycling ProDySC input power in the sequence OFF ON OFF ON within a one minute period will case 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
8. 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 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 PEN 21 200 en D E O Date Format 04 21 2009 Time Format Rockwell Automation Publication 1608P UM002A EN P July 2013 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 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 HOME screen is divided into four main areas described
9. 0 seconds assuming cumulative run time available Full Recovery Time Max 5 minutes Mechanical Enclosure Ratings NEMA 1 IP20 Cable Entry Top or Bottom 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 condensing Altitude Rated current available to 1000m 3300ft De rate output current 10 per 1000m from 1000m to 3000m 9900ft Safety Agency Approvals cULus Listed Exceeds SEMI F47 Standard 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 UM002A EN P July 2013 35 Chapter7 Specifications and Dimensions Heat Dissipation Rating Heat Loss J Heat Loss Btu h Efficiency A Standard Run time SR 100 780 2664 98 3 110 816 2787 98 3 Extended Run time ER 100 1071 3657 97 7 110 1107 3780 97 8 Shipping Weights Rating Weight A Ibs kg Standard Run time SR 400 1608P 1004 V35 787 357 1608P 1004 V4S 772 351 140 1608P 1104 V35 787 357 1608P 1104 V4S 772 351 Extended Run time ER 100 1608P 100A
10. 1608P UM002A EN P July 2013 17 Chapter4 Applying Power Notes 18 Rockwell Automation Publication 1608P UM002A EN P July 2013 Chapter 5 Display Screen Overview The ProDySC touch 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 Pas ec ca 2590 Gol 2599 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 S Fi Rockwell Automation Publication 1608P UM002A 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
11. 66 6 60 0Hz 37 5 C B C 207 9U 99 9 25 0A 100 0 Rockwell Automation Publication 1608P UM002A EN P July 2013 21 Chapter5 Display Screen Table 3 System Status Description Description Function System Status Overall system status including current operational status availability to correct sags and internal cabinet temperature Phase Status 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 ProDySC Nominal values are listed on the View Model Information screen 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 Sag Events 22 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 Protected Sag Duration 64 21 2009 15 19 25 64 21 2009 68 22 45 B4 21 7 9 cycles 04 20 2009 11 32 45 04 20 2009 64 36 05 04 19 2009 21 39 25 04 19 2009 14 42 45 04 19 2009 07 46 05 04 19 2009 00
12. Ke EE EE 21 KEE 22 Voltage Sag Events vor Seege IE Sege 22 KREE 22 KREE 24 Voltage Sag RMS Voltage EE 25 Voltage Sag Notification t AE EA AER bands 25 System EVENTS eer eebe eet 26 System Event L g A tee EE EE ie 26 System Eege Dela is IS Ac 27 System Event Notification cerrada EE 28 System Config rtion a cama sade pnia cisi si 29 Model formato ais 29 Run System Tests cuca AEN ENEE ee EN 30 EE 30 Preventative Maintenance 31 EE 31 3 6 Month Checks sainn A RAS 31 F se Replacement EE 33 Fuse Rating Charts seien any ery caved dates E E E ES 34 Technical Specificatio EE 35 Heat Dissipation A dese 36 Shipping Weights srs rops EE EE 36 Approximate Dimensions ooococcocncncncnncncncncnrancn care 37 Rockwell Automation Publication 1608P UM002A EN P July 2013 3 Table of Contents Notes 4 Rockwell Automation Publication 1608P UM002A 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 DySC technology does not use batteries requires only routine maintenance includes three stage transient voltage surge suppression and has unparalleled energy efficiency Most electronic devices found in industry today are susceptible to power disturbances A momentary sag in line voltage can reset or damage sensitive production equipment The ProDySC provides ins
13. PLC C1 5 Station Addr 200 HOME Table 9 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 UM002A 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 UM002A EN P July 2013 29 Chapter5 Display Screen Notes 30 Rockwell Automation Publication 1608P UM002A 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 e Ensure the touch screen display is working a
14. Ratin gs Output terminal blocks are marked X1 X2 and X3 for the load connections See Figure 7 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 The door must be closed and latched securely when the wiring is completed Figure 7 Figure Terminations and Ratings Pa i i N eY N Input A J g L1 L2 L3 vd d e A 14t0 2 AWG J j q e Output Torque 61 Ib in li 6 AER X1 X2 x3 6 0 N m E ae 14 to 2 AWG l A Torque 61 Ib in 6 0 N m Neutral A Torque 80 Ib in A 9 0 N m Co Ground A J Torque 80 Ib in Z 9 0 N m Z aT f Se Af gt i fA Note AN d y E d l i di di d e Inputs connect to L1 L2 L3 d Outputs connect to X1 X2 X3 N Y i Neutral connects to neutral bus as d Y A Earth Ground connects to ground _Z A bus 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 i WARNING The ProDySC must be safety grounded according to the National Rockwell Automation Publication 1608P UM002A EN P July 2013 13 Chapter2 Installation Bypa ss Terminations The recommended bypass switch input and output terminals are located insid
15. User Manual Allen Bradley Bulletin 1608P ProDySC Dynamic Voltage Sag Corrector Cat No 1608P 100 and 110 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 circuits equi
16. ag RMS Voltage Charts Voltage Sag Notification 24 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 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 Dune a LOAD VOLTAGE 120 AUTO Oscate o 68 126 186 300 Cycles SUMMARY carrs 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 SAG IN PROGRESS Availability Voltage zer al 207 90 207 34 Current 2504 2504 250 C Frea 600 coorc 60062 Last Voltage Sag Statistics 1 9 cycles 90 Voltage Sags O Detected Total Up Time 365d Gh 25m Last Power Up Date 65 68 2613 09 18 Rockwell Automation Publication 1608P UM002A EN P July 2013 System Events Display Screen Chapter 5 The ProDySC tracks all operational events which are classified int
17. ation 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 Feedback 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 1608P UM002A EN P July 2013 Cop
18. ction Sag Summary Sag Magnitude ID Unique ID within the list 0 60 to identify the voltage sag Time Start time of the voltage sag 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 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 85 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 UM002A EN P July 2013 23 Chapter5 Display Screen Voltage S
19. e Power flows directly from the utility to the load No power is present on ProDySC inputs or outputs 8 Rockwell Automation Publication 1608P UM002A EN P July 2013 Circuit Breaker Recommendations Electrical Terminations Installation Chapter 2 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 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 ProDySC Rating Max MCCB Rating 100A 125A 110A 150A The ProDySC must be installed by a qualified electrician The ProDySC input line and output load terminals are located behind the top door as shown in Figure 3 Terminal details are shown in Figure 7 on page 13 Figure 3 Input Output Terminal Location INPUT OUTPUT NEUTRAL _ BUS GROUND BUS Rockwell Automation Publication 1608P UM002A EN P July 2013 9 Chapter2 Installation Accessing Terminations 10 For top entry remove the top gland plate shown in Figur
20. e the bypass enclosure All terminals are labeled and a wiring diagram is provided inside the door as shown in Figure The numbered switch positions correspond to the numbered modes in Figure 2 The N terminals should not be used with 3 wire ProDySC models Bypass Connection TB1 Line Input TB2 Line to DySC TB3 DySC to Load TB4 Output to Load Oo LJ al SH Oo 0 oi x1 DS L1 F1 i External 2 LL el ll IG 0 Dysc o x2 1 h L2 F2 i a aH eo oe FUSES O A el 5 ats os J I Poe il 14 O 2 D Q Alo iw O Z iw O Z oO IK KS Rockwell Automation Publication 1608P UM002A 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 e For access remove the small metal cover from the top of the ProDySC SeeFigure 8 e A removable connector plug is provided to facilitate wiring e All wiring is to be Class 2 limited to 24 Volts AC or DC e Acceptable wire gauges range fr
21. e 4 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 Access to the communications port is only from the top as shown in Figure 4 A separate conduit knock out is provided for communications conductors Note When punching or drilling holes for conduit fittings take care to avoid dropping metallic particles inside the enclosure Metallic contamination will void the product warranty Figure 4 Top Conductor Entry AC INPUT OUTPUT CONDUIT ENTRY COMMUNICATIONS PORT 875 22 COMMUNICATIONS CONDUIT KNOCK OUT l 24 7 627 i 52 2 1327 __ o ss CLEARANCE FOR Me Se DOOR SWING Lo WARNING Metallic particles inside the enclosure will void the warranty Rockwell Automation Publication 1608P UM002A EN P July 2013 3 Wire vs 4 Wire Configurations 3 Wire Models Installation Chapter 2 ProDySC 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 Figure 5 shows the 3
22. escription 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 Rockwell Automation Publication 1608P UM002A 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 07 02 2013 06 09 27 Duration 32 sec Type Event ID 14 Description Code DC_OV 15 DC Bus Over Voltage Severity User Attention Component Location Phase C Area Inverter Reading 123 688VDC Table 8 System Event Detail Description Function Time Date and start time of the system event Time Duration 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 Type list of codes and abbreviations Refer to System Event Table on page 32 Severity Seve
23. in Table 2 Figure 14 Home Screen Availability OK Last Voltage St Voltage Sags 1 9 cycles 90 Detected Total Up Time 365d Gh 12m Elapsed Time Since Restart 12m 56 05 EM Table 2 Home Screen Description Description Function Status a time system operation available runtime output Tine to neutra requency 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 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 G e Main Menu VOLTAGE SAGS Displays the Voltage Sag Log screen SE SE geet Gre a creen CONFIG Displays the System Configuration screen E y 9 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 15 System Status Summary Figure 16 System Status Waveforms System Status System Status Availability DySC Cabinet oK 5 0 secs 290 C An SS PE st Phase Status z 66 6H2 37 5 C C A 207 9U 99 9 25 0A 100 0 666H2 37 5 C summary WAVEFORMS d SUMMARY waverorns 64 21 2669 16 29 A Phase Voltage L L Current Freq Switch A B 267 9 99 9 25 54 1
24. nd no active events are displayed e 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 front side 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 e 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 min
25. o five groups based on severity Table 6 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 16 58 42 SLAVE_1 Auto Resetting 65 69 2613 64 62 02 SYNC_ERR Call Service 65 88 2613 21 05 22 GATE_ERR Call Service 65 68 2613 14 08 42 STAT Call Service 65 88 2613 07 12 02 IGBT User Attention 65 68 2613 66 15 22 ULL_OU Call Servic 65 67 2613 17 18 42 OUTPUT_OU Call Service 65 67 2613 10 22 02 DC Lu User Attention 65 67 2613 63 25 22 INV_OC User Attention 65 66 2613 26 28 42 OUTPUT_UV User Attention 05 13 2013 13 41 Table 7 System Event Log D
26. om 24AWG to 12AWG 0 205 2 5mm2 e Torque connections to 5 0 Ib in 0 6 N m e For permanent installations a standard conduit knockout is located within the wiring area SeeFigure 8 Figure 8 Access Cover Location COMMUNICATIONS PORT AND RELAY CONTACT E ACCESS COVER KNOCKOUT FOR CONDUIT FITTING Rockwell Automation Publication 1608P UM002A EN P July 2013 15 Chapter3 Communications Serial Communications Port The ProDySC serial port isa 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 J H H L wavy Se HA 1N3A3 o9vs T MO J indino Pin 5 Return Pin 3 TxD A Pin 2 RxD 1 Rockwell Automation Publication 1608P UM002A EN P July 2013 Chapter 4 Applying Power e Before applying power to the ProDySC
27. pment 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 EPP 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 related products from Rockwell
28. po we 9 81 Juang Wayshs OL 2192 SIULUDIUIE 9 saydey Maintenance Chapter 6 Fuse Replacement Fast acting fuses are included to protect the ProDySC in the event of a load short circuit If the screen is dark when power is applied it may indicate a blown fuse Check the fuse s for continuity WARNING Turn the power to the ProDySC off by placing the Bypass Switch into Lo BYPASS 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 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 UM002A EN P July 2013 33 Chapter6 Maintenance
29. rity of the event Description Name of 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 etc 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 1608P UM002A EN P 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 HU DC 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 Pres
30. s OK to view the complete event 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 Uckwoe 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 UM002A 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 2616 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 1668P 825A288U3S Serial Number PM654321 System Rating 208V L L 25A Unit Details Node Firm Type Serial Volts A n 16 PM123456 1204 B 1 16 PM123457 126 e 1 16 PM1234538 1204 comm Qi 12 PM123459 1204
31. t emitting equipment such as ovens heaters or furnaces Ambient temperature must not exceed 40 C 104 F Do not operate near water or excessive humidity 95 max When punching or drilling holes for conduit fittings take care to avoid dropping metallic particles inside the enclosure as this can result in electrical damage The system is not intended for outdoor use The operating environment should be maintained within the parameters stated in this manual Only authorized service personnel should perform service on the ProDySC Ensure all power is disconnected before performing installation or service i ATTENTION To reduce the risk of fire or electric shock install this ProDySC in Rockwell Automation Publication 1608P UM002A EN P July 2013 Chapter 1 discharge ESD Do not touch circuit boards or electronic components with hands or metal objects Use an insulated screw driver when connecting the lines The ProDySC is not rated to directly power life support equipment Ensure the area around the ProDySC is clean and uncluttered e Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of the equipment i ATTENTION Internal components can be easily damaged by electrostatic Rockwell Automation Publication 1608P UM002A EN P July 2013 Installation Check List Inspecting and Unpacking Location Environment Chapter 2 Installation Before proceeding please take a fe
32. tantaneous 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 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 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 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 hea
33. tomation Publication 1608P UM002A EN P July 2013 Connection Configuration Chapter 7 Specifications and Dimensions Table 14 Technical Specifications 100 and 110 A ProDySC Electrical Input Output Normal Mode Static Switch Series connected with load Under normal line condition the static switch passes utility voltage directly to the load Standard Input Voltages 3p 208 380 400 415 480V Voltage Range 10 Current Overload Static Switch 200 30Sec 400 5 Sec 600 0 5 Sec Frequency 50 60 Hz Auto Sensing Frequency Range 45 65 Hz TVSS Built in 3 Layers consisting of MOVs amp Capacitors Efficiency gt 99 480V Electrical Output Sag Correction Mode Inverter Output Voltage Pre sag rms voltage Voltage Regulation 5 13 of nominal ProDySC Output Current 100 a 100Ars Not rated for DC loads max allowable 2 DC loading ProDySC Output Current 110 a 110Arvs Not rated for DC loads max allowable 2 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 2 3 or 8 12 cycles standard or extended run time DySCs Based on nameplate ratings with a power factor of 0 7 and frequency of 60Hz Multiple Event Max Sag Correction Time 5 seconds cumulative usage Sequential Sag Recovery
34. utes e Ensure that the optional bypass switch is in Normal mode so that the ProDySC is protecting the load Rockwell Automation Publication 1608P UM002A EN P July 2013 31 ELOZ Aine d N3 VZOOWN d809L OPO uopewozny amoy TE DIAS L sat J9J 49AU S pae oq WLU 0 puodsaJ 0 Dag p1eoq 0140 SL Yd uun age 18 NOaWI 159 JA JBAU DU WI vv papaau uoe ON 1591 dn J1e35 Duunp pap Yesu Jaquuinu P S J9 01JU0 uun euopeuoyu UDIEWSIWY 19qUIN RAS 359 dp 11815 HYS tv DIAS 8 sai dn J1e15 Bunp pap Wajqosd uolJe gt UNWWWOD 43 01 U0 uun DIMAS UE INOW 994 qWNy P S 19101340 153 df J1e1S OL Tus Tv DIAS P sai dn 11e s Buunp payda ap YDJELWSILW UOS ARMULY 43 01 U0 uun age 18 UDIEWSI UOISIADY ALMULLY 13 101 U0 359 dN HLIS A0 Wu Ov DIAS P eat dn ye s Buynp pap waqosd Uolyed1UN WWOD 49 01 U0 uun DIAS NOAWI 994 ALMULLY 19101340 eat d 3 15 OL WY 6 DIMAS II 159 dn ue s buunp payajap Wajqosd uoneanyuo aeMULY 19 101 U0 yun 91498 UE pews uone yuo Lotto 153 dy 14815 wud DIN SE DIAS UE 159 dp ups Buunp pap wajqosd UO JE1UN LLO J9 01JUO uun 31499 18 moau UoeINbyUO gt J3 01JU0 eat dy 3 815 Ol DND LE DIAS V eat dn ueys Duunp payajap wajqoid yqgedwo uopeunwwo zemu uun 21495 12 YDIEWSIW yqnedwo uoneunwwo 153 di 11815 YA WO 9 DIAS IN sai dn Age Bu
35. ve contaminants Do not operate the ProDySC in an environment where the ambient temperature or humidity is beyond the specified limits given in this manual Rockwell Automation Publication 1608P UM002A EN P July 2013 Chapter2 Installation Floor Mounting The ProDySC is to be secured to the floor using 3 8 hardware 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 SeeFigure 1 and Figure 4 on page 10 Figure 1 Bottom View Floor Mount Dimensions MOUNTING HOLE D 63 4 PLACES 16 e s z SE C 21 0 533 ALTERNATE o POWER O ACCESS oO O no A 28 26 4 1 3 T 671 Ka 33 Bypass Switch Installation of the ProDySC with an external maintenance bypass switch is required for service and or maintenance Mount the bypass switch adjacent to the ProDySC if possible The recommended Bulletin 1608P bypass switch has three modes of operation and is configured as shown in Figure 2 Figure 2 Bypass switch and mode operation NORMAL Mode Power flows from the utility source through the ProDySC to the load TEST Mode Power flows directly from the utility to the load ProDySC outputs are not connected to the load ProDySC inputs have power provided for testing by a qualified technician BYPASS Mod
36. w minutes to review the necessary steps to install your ProDySC All packing materials and restraints have been removed The ProDySC is placed in its installed location All conduits and cables are properly routed to the ProDySC All power cables are properly terminated A ground conductor is properly installed and terminated If neutral connection is required that it is properly terminated on the ProDySC The area around the installed ProDySC is clean and dust free Adequate work space exists around the ProDySC Adequate lighting is provided around the ProDySC Operational checks have been reviewed and completed 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 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 conducti
37. wire ProDySC system wiring schematically including the recommended Bypass Switch Figure 5 ProDySC 3 Wire Configuration Customer supplied circuit breaker 3 WIRE SOURCE A MAKE BEFORE BREAK BYPASS SWITCH Output to Loads Li 1004 110A ProDySC ND GN Note The 3 wire ProDySC models rated greater than 240V have not been evaluated by Underwriter s Laboratories Inc R for connection to a corner grounded or ungrounded delta power source Contact Rockwell Automation Technical Support for assistance Rockwell Automation Publication 1608P UM002A EN P July 2013 11 Chapter2 Installation 4 Wire Models Bulletin 1608P part numbers containing V4 are configured for 4 wire source Ll 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 7 Figure 6 shows the 4 wire ProDySC system wiring schematically including the recommended Bypass Switch Figure 6 ProDySC 4 Wire Configuration Customer supplied circuit breaker O per ww ww ew een ewe wwe wwe ween eee E E EE E e Ps Se A MAKE BEFORE BREAK BYPASS SWITCH 009104 CH ProDySC GND D 12 Rockwell Automation Publication 1608P UM002A EN P July 2013 Installation Chapter 2 Electrical Terminations and Input terminal blocks are marked L1 L2 and L3 for the source connections
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39. yright 2013 Rockwell Automation Inc All rights reserved Printed in the U S A

Bulletin 1608P ProDySC User Manual - 100/110 Amp

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