Bulletin 1608M MegaDySC User Manual
Contents
1. System Event Notification When the MegaDySC system first detects an alarm condition a popup window will be displayed See Figure 17 The popup window can be closed by tapping the Close button or waiting 15 seconds While the alarm is active the display will show Fault in the status field See Figure 18 Figure 18 System Event In Progress Dynamic Sag Corrector Rockwell Automation Publication 1608M UM002A EN P September 2013 Figure 19 System Event Resetting Maintaining the Touch Screen Panel Display Screen Chapter 6 After the alarm condition is corrected the MegaDySC must reset before sag correction is available During this time the display will show Resetting in the status field and indicate the amount of time left before the reset is complete See Figure 19 When the reset time is complete a new popup window will be displayed Tap View Event to view the complete event detail or Close to close the popup window See Figure 20 Figure 20 System Event Complete o view details Dynamic Sag Corrector If a Call Service severity system event is detected record the system event details including name description location and reading Contact Rockwell Automation Technical Support If the alarm clears the touch screen will automatically go back to normal operation Take care not to damage the touch display e Do not subject the touch display to2. Details of each voltage sag and corresponding MegaDySC protection are captured and saved to the voltage sag log Voltage Sag Log The Voltage Sags screen See Figure 12 displays a list of the last 60 voltage sags You can access this screen by pressing the Voltage Sags button in the menu Figure 12 Voltage Sag Log Allen Bradley f y a wow Dysc Dynamic Sag Corrector Rockwell Automation Publication 1608M UM002A EN P September 2013 Display Screen Chapter 6 The left side of the screen contains the list of voltage sags which are identified by the following fields Description Function Unique ID within the list identifying each voltage sag Time Start date and time of the voltage sag RMS Worst case RMS voltage percent of nominal across all phases Duration Duration of the voltage sag Use the up down arrows to navigate through the list The currently selected voltage sag will appear in the detail pane on the right side of the screen Voltage Sag Detail The right side of the Voltage Sag screen shows detailed information about the selected voltage sag See Figure 13 Figure 13 Voltage Sag Detail Summary Data Dysc Dynamic Sag Corrector Item Description Function Event ID Unique ID within the list 0 29 to identify the voltage sag Event Date Start date and time of the voltage sag RMS Worst case RMS voltage and percent of rated volt
3. Output to load Utility Input Line L1 x1 m 12 N x2 13 _ N if 4 wire system Earth CBI Ground To MegaDySC section s Note The 3 wire MegaDySC models have not been evaluated by Underwriter s Laboratories Inc for connection to a corner grounded or ungrounded delta power source Contact Technical Support for assistance Transient Volta ge Surge Over voltage transient protection is provided on the output of the MegaDySC Su Indicator lights for each phase on the front of the TVSS panel behind Bypass ppression bi f i f cabinet top front panel are illuminated under normal operation In case of a severe over voltage transient event internal fuses in the TVSS module may open If TVSS operation is compromised one or more of the indicator lights will be extinguished A form C contact is provided inside the TVSS module for remote fault indication if desired Refer to the TVSS user manual for details on accessing that contact If a fault is indicated the TVSS disconnect fuse block F25 F26 F27 F34 may be opened to allow servicing of the TVSS module Refer servicing to qualified personnel Servicing Notes Refer servicing to qualified and factory authorized personnel Opening the MegaDySC cabinet door will shut down the MegaDySC system and force an automatic mechanical bypass Refer to manual bypass instructions to perform a seamless transfer of power before ope
4. familiar with the operation ofthe MegaDySC system Contact the factory immediately if the system fails to operate as outlined below Voltage sag protection is not available whenever CBB is closed red BYPASS CLOSED lamp is lighted Automatic System In the event of a fault in the MegaDySC system bypass CBB will close The system will remain in bypass until manually transferred back to the MegaDySC Manual Transfer to Maintenance Bypass Press green CBB ON pushbutton Confirm that red BYPASS CLOSED lamp is lit Press red OFF pushbutton part of CBI Output breaker CBO will open automatically Confirm that both CBI and CBO are open 5 The MegaDySC is now bypassed and isolated for maintenance Manual Transfer to MegaDySC 1 Charge CBI with pump handle Press green CBI ON pushbutton Note CLOSE CBP action is inhibited for one minute after power cycling Confirm that the MegaDySC touch screen is lit and the status displays OK in the upper left corner Charge CBO with pump handle Close CBO by pressing green pushbutton CBO ON Confirm that the MegaDySC touchscreen status displays OK 5 Press red CBB OFF pushbutton The MegaDySC system is now providing power to the load Rockwell Automation Publication 1608M UM002A EN P September 2013 21 Chapter5 Operation Figure 7 Schematic Diagram of Automatic Bypass Switchboard Power Circuit
5. the detected event The maximum relay close time is 25 ms so some single cycle events may not operate this relay contact The maximum relay release time is 25 ms the expected minimum pulse width is approximately 15 25 ms CBB STATUS Contacts Normal position for the CBB Bypass Breaker is defined as the breaker being OFF or Open The Normally Open NO auxiliary contacts are open when the Breaker is open NOTE When the CBB breaker is closed the MegaDySC cannot provide protection against sags Example Normal mode CBB will be Open therefore CBB NO open CBB NC closed If CBB is closed these states will be reversed Rockwell Automation Publication 1608M UM002A EN P September 2013 15 Chapter 3 Communications Conditions that will automatically close the Bypass Circuit Breaker CBB are the last five rows of Table 3 on page 20 Remote Seamless BYPASS Command Operation A normally open PLC contact relay contact or push button contact may be connected between TB1 14 and TB1 15 Close the contact to initiate an automatic seamless bypass operation CBB will close then CBI and CBO will open removing power from the MegaDySC cabinets voltage sag correction will then be disabled This feature may be utilized as an Emergency Power Off EPO function for the MegaDySC cabinets only Power to the output loads or output distribution panel if present will not be interrupted Note that the automatic bypass functionality
6. charged capacitors High voltage remains on capacitors if the red LED indicators above the module capacitor banks are lighted Fast acting fuses are included to protect the MegaDySC system in the event of a load short circuit or other conditions Fuses are located within the Automatic Bypass switchboard cabinet the MegaDySC cabinet and the optional ER storage cabinet To maintain protection of the MegaDySC system fuses must be replaced with the same or exact replacement type Replacement fuses are available through Rockwell Automation Technical Support and should only be replaced by qualified and factory authorized service personnel Rockwell Automation Publication 1608M UM002A EN P September 2013 Maintenance Chapter 7 Automatic Bypass Switchboard Fuses Refer to the fuse listing label located on the switchboard cover for fuse size and type Before replacing a switchboard fuse authorized service personnel will require removal of power to the Automatic Bypass switchboard by opening and locking out the upstream circuit breaker WARNING De energize the Bypass switchboard before removing covers to access fuses Failure to comply with this warning can result in injury or death MegaDySC and ER Cabinet Fuses A large label inside the MegaDySC doors shows fuse locations A similar label is located within the optional ER storage cabinets Fuse types are listed in Table 7 Before replacing a MegaDySC cabinet fuse factory authorized service
7. ee ees 13 TBI Schematic Diagram and Contact Ratings 000 eee eee 13 Relay Contact Ratings Terminals 1 9 of TB1 14 CBB Contact Ratings Terminals 10 12 of TB1 14 Remote Bypass Customer Provided Contact Rating Terminals 14450 EB nes ehr 14 TBI Contacts Functionality ran RE Ira 15 ALARM Cont ets u ee innen sense 15 OUTPUT OK Contacts nenne ls 15 SAG EVENT Contacts ea 15 CBBSTATUS Content amas wis hi 15 Remote Seamless BYPASS Command Operation 00000 00s 16 Applying Power near 17 System Description seien Dub le 19 Mega ySC Operation une Ringen 19 Automatic Bypass Switchboard Operation ent 20 Automatic Bypass Switchboard Operating Instructions 64 21 Automatiesystem esa e ee gi nennen 21 Manual Transfer to Maintenance Bypass 2 222 cess ee eee ee eee 21 Manual Transfer to MegaDySC nen ee 21 Transient Voltage Surge Suppression ns kr snnea 22 Servicing Notes ierde ye e EE wage A EE R OEO EE EEA 22 Normal Modes in ass 23 Over Current and Fault Protection vn ee an 23 Circuit Breaker Configuration esse Ban 24 Troubleshooting Notes Aus er a ee res 24 Overview anna einher nennen el nee E 25 Quick Start ee rear ER even 25 PAGMES CHEE 5 hives Raa elle len E 26 SYSCEMMSCALUS nee en ee neh 27 Cabinen Status ae reise 28 Voltage Sa RB ones 28 Volase Sag Los a en E A 28 Woltace Sag Detail an ee ice 29 Voltage Sag RMS Voltage Charts na denate
8. heavy impact e Use your bare finger or a plastic stylus to tap the touch display e Do not tap push or rub the touch display surface with any object that might cut or damage the touch screen membrane no glass metal pens pencils or screwdrivers e The touch display panel is not waterproof Cleaning the Control Panel e Use a soft cloth to clean the touch display e Do not use harsh detergent or an abrasive sponge e DONOT USE alcohol ammonia toluene or acetone Rockwell Automation Publication 1608M UM002A EN P September 2013 33 Chapter6 Display Screen Resta rting the Touch Screen Ifthe touch screen interface becomes unresponsive it can be reset by one of the Interface following methods Soft Reset Press and hold the bottom right corner of the screen for 5 seconds to reinitialize the touch screen interface While you are holding this corner you will see gui restart and a timer counting down in the status bar Hard Reset Press the blue pushbutton to the left of the touch screen to force the touch panel hardware to reboot Upon reboot the touch screen interface will be redisplayed 34 Rockwell Automation Publication 1608M UM002A EN P September 2013 Preventative Maintenance Chapter 7 Maintenance The MegaDySC requires very little preventative maintenance The MegaDySC should be checked periodically for proper air flow and status indicator operation Monthly Checks Ensure the touch screen dis
9. information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations 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 Pe BIE IMPORTANT Identifies information that is critical for successful application and understanding of the product MegaDySC i Sense i Grid 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 info
10. inside the MegaDySC SHOCK HAZARD The MegaDySC has high voltage remaining up to 5 minutes in a temperature and humidity controlled indoor environment free of conductive contaminants Avoid installing the MegaDySC directly near heat emitting equipment such as ovens heaters or furnaces Ambient temperature must not exceed 40 C 104 F Do not operate near water or excessive humidity 95 max When punching or drilling holes for conduit fittings take care to avoid dropping metallic particles inside the enclosure as this can result in electrical damage The system is not intended for outdoor use The operating environment should be maintained within the parameters stated in this manual Only authorized service personnel should perform service on the MegaDySC Ensure all power is disconnected before performing installation or service ATTENTION To reduce the risk of fire or electric shock install this MegaDySC Chapter 1 discharge ESD Do not touch circuit boards or electronic components with hands or metal objects The MegaDySC is not rated to directly power life Support equipment Ensure the area around the MegaDySC is clean and uncluttered Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of the equipment N ATTENTION Internal components can be easily damaged by electrostatic Rockwell Automation Publication 1608M UM002A EN P September 2013 System Com
11. may indicate the type of over current condition ATTENTION Circuit Breaker settings must not be changed without consulting Technical Support Circuit Breaker Configuration See the separate Circuit Breaker User Manuals for instructions on how to adjust the breaker set points Each of CBB CBI and CBO contains an electronic trip unit with several adjustable settings These should be set as follows for Square D Masterpact NW breakers CBB Set Points e Long time Ir 1 100 of rating e Long time tr 24 e Short time Isd 10 e Short time tsd OFF 4 e Instantaneous li OFF CBI and CBO Set Points e Long time Ir 1 100 of rating e Long time tr 4 e Short time Isd 6 e Short time tsd ON 3 e Instantaneous li OFF Note CBI and CBO Long time Ir 0 95 for 2400A Systems only 2500A breaker frame Diagnostic indicators available on the MegaDySC system e Touchscreen display e Red lamp on Automatic Bypass switchboard indicates when mechanical BYPASS CLOSED e Circuit breaker status OPEN or CLOSED e System status relay contacts at TB1 see Chapter 3 e i Sense voltage monitoring results via i Grid see Chapter 3 IMPORTANT Record any Alarm or System Event messages seen on the display before contacting Technical Support Rockwell Automation Publication 1608M UM002A EN P September 2013 Overview Quick Start Chapter 6 Display Screen The MegaDySC touch screen display is a window to voltage sa
12. personnel must transfer the MegaDySC system to maintenance bypass mode No attempt should be made to service the MegaDySC if red LEDs located above the DC bus capacitors are lighted Maintenance Bypass mode before opening the MegaDySC or ER cabinet doors WARNING De energize the MegaDySC electronics by placing the system into to replace any fuse WARNING The MegaDySC has high voltage remaining up to 30 minutes after disconnection from the AC line Touching exposed or disconnected terminals cables or parts of the MegaDySC can lead to serious injuries or even death Wait for a minimum of 5 minutes before performing any service or testing on the MegaDySC after power is removed Keep doors closed until all internal LED indicators are extinguished WARNING Keep the cabinet doors closed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the MegaDySC IMPORTANT Aqualified electrician must replace the fuses Open the front cabinet door s to access the fuse holders and fuses To maintain protection of the MegaDySC be sure to replace the fuse with the same type and rating These fuses are available through Rockwell Automation Technical Support Rockwell Automation Publication 1608M UM002A EN P September 2013 39 Chapter 7 40 Table 7 MegaDySC Fuse Schedule MegaDySC Main Cabinet Fuses Fuse Reference Fuse Location Fuse Rating Man
13. requires that nominal AC power is present at the switchboard input terminals Rockwell Automation Publication 1608M UM002A EN P September 2013 Chapter 4 Applying Power engineers Do not energize the MegaDySC until instructed to do so by ATTENTION The MegaDySC system must be commissioned by factory trained commissioning engineers e After installation make certain there are no metal filings or any conductive debris in or on any components inside the cabinets e Verify MegaDySC system voltage rating matches ac source voltage e Ensure all input and output terminations including grounding have been completed and are properly tightened e Replace all covers Close and lock all cabinet and switchboard doors e Allow commissioning technicians to complete connections and initial checks e Apply power only when instructed to do so by the commissioning technicians e After commissioning follow instructions on the Automatic Bypass switchboard to put the system into Normal mode The load is now being protected by the MegaDySC The display should show OK in the upper left corner cabinet doors while in the MegaDySC normal mode will cause immediate automatic bypass operation and subsequent loss of voltage sag protection while in maintenance bypass mode Automatic Bypass switchboard cabinet doors are not interlocked and should be kept locked to avoid exposure to dangerous voltages Refer to Servicing Notes o
14. touch screen membrane The touch display panel is not waterproof Do not use alcohol ammonia toluene or acetone cleaners on the display ATTENTION TO AVOID DAMAGING THE TOUCH DISPLAY The HOME screen of the display provides a snapshot view of the status of the entire system See Figure 9 You can return to this screen from any other screen by pressing the Return to Home button at the top of the screen Figure 9 Home Screen Voltage rem Dynamic Sag Corrector Table 4 Home Screen Item Description Function Status Real time system status available runtime output voltage load current and frequency System Operation Graphical view of operational state Last Event Details Information about the last voltage sag event start time event duration and sag depth O0 The menu buttons at the bottom of the screen navigate through Voltage Sags Displays the Voltage Sag Log screen Main Menu System Events Displays the System Event Log screen System Status Displays the System Status screen Configuration Displays the System Configuration screen 26 Rockwell Automation Publication 1608M UM002A EN P September 2013 System Status Display Screen Chapter 6 The System Status screen displays the real time overall system status See Table 5 You can access this screen by pressing the System Status button in the menu Fi
15. 5 1608M 2KOA480V3E 2000A 3W ER E 5 1608M 2K0A480V4S 2000A 4w SR 1 5 1608M 2K0A480V4E 2000A 4w ER 5 1608M 2K4A480V3S 2400A 3W SR 1 6 1608M 2K4A480V3E 2400A 3W ER 6 1608M 2K4A480V45 2400A 4w SR 1 6 1608M 2K4A480V4E 2400A 4w ER 6 Other voltages available 380V 400V 415V 460V or 480V contact Rockwell Automation for more information Rockwell Automation Publication 1608M UM002A EN P September 2013 7 Chapter2 Installation System Orientation and The required layout places the MegaDySC enclosures on the right hand RH Layout and left hand LH sides ofthe Automatic Bypass Switchboard when viewed from the front Each MegaDySC enclosure is labeled with its required position in the lineup System components are labeled as in Table 2 Table 2 System Components Layout Current Rating A LH3 LH2 LH1 Switchboard RH1 RH2 RH3 800 1200 Hu E 1600 a E E a 2000 2400 E E E E u The enclosures must be mounted so that they abut tightly with no gap between the enclosures Typical layout is shown in Figure 1 and Figure 2 The ER components shown in the figures are included only with ER models not with SR models Figure 1 Typical System Layout Top View 800A ER model shown MINIMUM 24 OV AD CLEARANCE ABOVE YSTEM 1 N MN L MER INNECTION VERHE FLUSH AGAINST WA ENTRANCE AT THIS PANEL BE MAINTAINED FOR INSTALLATION 51 08 1297 Rockwell Automa
16. User Manual Allen Bradley Bulletin 1608M MegaDySC Dynamic Voltage Sag Corrector 1608M 800 2400 Amp Models ir meu F Wi ut Allen Bradley Rockuell 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
17. abinet and screw into the weld nuts in the next enclosure in the lineup There are three holes vertically aligned along the front edge and another three holes along the rear edge The three rear bolts are optional and installation will require access from the rear Rockwell Automation Publication 1608M UM002A EN P September 2013 9 Chapter Installation Electrical Interconnections In addition the top mounted wireway sections must be bolted together using the provided 1 4 hardware torque to 66 Ib in 7 5 N m See Figure 3 for typical fastening locations and hardware arrangement Figure 3 Mechanical Interconnections national electric codes Failure to supply proper equipment grounding may result in electrical shock or death Allinterconnection wiring must be installed by a qualified electrician in compliance with the National Electrical Code standards f WARNING Equipment must be earth grounded according to local and The DySC 400A Module MegaDySC cabinets and the Automatic Bypass ABP Switchboard are shipped separately The customer is responsible for system mounting All interconnecting power cables are provided and will be connected by a factory trained technician during commissioning At commissioning the main cables will be routed from the MegaDySC cabinets to the appropriate ABP switchboard busbar terminals via the overhead wireway A control wi
18. age across all phases Summary Duration Duration of the voltage sag Frequency Frequency of the line prior to the start of the voltage sag Temperature Internal temperature of the MegaDySC prior to the start of the voltage sag 2 Magnitude Line Voltage Line RMS voltage and percent of rated L N basis Load Voltage Load RMS voltage and percent of nominal L N basis Rockwell Automation Publication 1608M UM002A EN P September 2013 29 Chapter 6 30 Display Screen Voltage Sag RMS Voltage Charts The line and load RMS voltage are displayed for each phase See Figure 14 You can access this screen by pressing the Charts button as shown in Figure 13 By pressing the A B or C buttons to the right of the charts you can show or hide each of the three phase voltages Figure 14 Voltage Sag Detail RMS Voltage Charts Allen Bradey Dynamic Sag Corrector Voltage Sag Notification When the MegaDySC system first detects a voltage sag a red box displaying Sag In Progress will appear in the upper left hand corner of the screen See Figure 15 When the voltage sag is over the red box will disappear Figure 15 Voltage Sag Detected Sag in Progress Dynamic Sag Corrector Rockwell Automation Publication 1608M UM002A EN P September 2013 System Events Display Screen Chapter 6 The MegaDySC tracks all operational alarms These System Events are classified into
19. anical Bypass Command Manual Reset Unit The DySC was externally commanded to transfer to mechanical bypass Manually reset DySC 53 DYN_BRAKE Dynamic Brake Error Call Service Unit A problem was detected with the DySC dynamic brake controller Call service Verify proper current sharing among slave 54 SLAVE_OL Critical Slave Cabinet Overload User Attention Unit Slave cabinet current exceeded maximum rating Mechanical bypass commanded en proper DySC application 55 MSTR_A_UV Phase A Master Controller Under Voltage Call Service Unit Phase A master controller power supply failure Mechanical bypass commanded Call service 56 MSTR_B_UV Phase B Master Controller Under Voltage Call Service Unit Phase B master controller power supply failure Mechanical bypass commanded Call service 57 MSTR_C_UV Phase C Master Controller Under Voltage Call Service Unit Phase C master controller power supply failure Mechanical bypass commanded Call service 58 PLC_ERR Programmable Logic Controller Error Call Service PLC PLC error detected Call service 37 Rockwell Automation Publication 1608M UM002A EN P September 2013 Chapter7 Maintenance Servicing Fuses 38 A N ATTENTION Service must be performed by qualified personnel only Refer to the Hardware Service Manual for detailed instructions Before attempting any servicing that requires opening the MegaDySC doors first put the system into Maintenance Bypass mode as described in the section Automatic Bypass S
20. anveSensdeecass 30 Voltage Sag Notification 2 RIEDL 30 SYSTEM EVENES 50 0 esr ee N T E E EE RE 31 Rockwell Automation Publication 1608M UM002A EN P September 2013 3 Table of Contents Ch 7 Maintenance Ch 8 Specifications System PE VERE IOS se Mes waite N enge 31 System Event Detail ann an aa 32 System Event Notiheation 2 eisen 32 Maintaining the Louch Screen Panel u Ze 33 Cleaning the Control Panel A nun 33 Restarting the Touch Screen Interface nes wesves neice el areas 34 Preventative Maintenances eniro deneyi a bai a e ia AES a Ea 35 Monthly Checker 35 3 6 Month Checks ann Bde 35 SELVIEIND ehe ne teen tthe enue ee 38 Automatic Circuit Breakers Safety Interlocks and Stored Energy 38 USE Ha ee T Bere 38 Automatic Bypass Switchboard Fuses 222ceesseeeseennnnen 39 MegaDySC and ER Cabinet Fuses un een 39 Technical Spe itieations yasni 41 Rockwell Automation Publication 1608M UM002A EN P September 2013 Safety Considerations Rockwell Automation Publication 1608M UM002A EN P September 2013 Chapter 1 Introduction The Allen Bradley Bulletin 1608M MegaDySC 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 sus
21. ass mode WARNING Servicing must only be performed by factory authorized and qualified personnel Test Mode The TEST mode for the MegaDySC is for Input Breaker CBI to be closed and Output Breaker CBO to be open The bypass breaker CBB must be closed to provide power to the load while the MegaDySC is being tested off line WARNING Testing must only be performed by factory authorized and qualified personnel Fault protection is provided by a variety of protection devices including electronic circuit breakers and fuses CBI and CBO are set to protect the MegaDySC conductors If an upstream circuit breaker is present CBB is typically coordinated to allow the upstream breaker to be the primary protection for the branch circuit Each MegaDySC section contains semiconductor fuses F1 F2 F3 These fuses provide short circuit protection for the MegaDySC modules In the event of an internal short circuit a fuse will clear and trigger an automatic transfer to mechanical bypass mode Fuse tables appear in Chapter 7 In addition each module has an electronic current limit function that will protect the module from peak over currents during sag protection operation Rockwell Automation Publication 1608M UM002A EN P September 2013 23 Chapter5 Operation Troubleshooting Notes 24 IMPORTANT Inthe event of the operation of any over current protection function check the touchscreen display on the MegaDySC for error codes that
22. automation 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 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 repre
23. ceptible to power disturbances A momentary sag in line voltage can reset or damage sensitive production equipment The MegaDySC provides instantaneous dynamic sag correction to help your equipment ride through these common events The MegaDySC connects normal utility power directly to the load until a voltage sag occurs During a sag the MegaDySC 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 MegaDySC is quickly ready to correct the next sag The MegaDySC 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 MegaDySC is designed to operate in industrial applications Follow these guidelines to ensure that the safety and installation of the MegaDySC are handled with appropriate care after disconnection from the AC line Touching exposed or disconnected terminals cables or parts of the MegaDySC can lead to serious injuries or even death Wait for a minimum of 5 minutes before performing any service or testing on the MegaDySC after power is removed High voltage remains if red LED indicators above capacitor banks are lighted Keep the cabinet doors closed and locked to ensure proper cooling airflow and to protect personnel from dangerous voltages
24. communication problem detected during start up test Call service 40 FlvRM_DIFF eee Controller Firmware Revision Call Service Unit Controller firmware revision mismatch detected during start up test Call service 41 SRL_TO a Test Controller Serial Number Check Call Service Unit Controller communication problem detected during start up test Call service 42 SRL_DIFF Start Up Test Serial Number Mismatch Informational Unit Controller serial number mismatch detected during start up test No action needed 44 T_INV_TO Inverter Test Timeout Call Service Unit Phase control board failed to respond to Comm board s Inverter test Call service 46 DOOR_OPEN DySC Cabinet Door Open ManualReset Unit DySC door was opened Mechanical bypass commanded Close door Manually reset DySC j Verify ambient temperature is within DySC 47 CRIT_OT Critical Over Temperature Manual Reset Unit N temperature exceeded maximum rating Mechanical bypass nn ee Manually reset DySC 48 FUSE_OPEN Fuse Open Call Service Unit One ofthe DySC fuses was detected open Mechanical bypass commanded Call service 49 OPEN_SCR_A Open SCR Phase A Call Service Static Switch The SCR on the phase A module was detected open Call service 50 OPEN_SCR_B Open SCR Phase B Call Service Static Switch The SCR on the phase B module was detected open Call service 51 OPEN_SCR_C Open SCR Phase C Call Service Static Switch The SCR on the phase C module was detected open Call service 52 EXT_MB External Mech
25. d MegaDySC sections Each MegaDySC section contains three power electronics modules one module per phase The modules act in parallel with the like phase modules in the other MegaDySC sections under command of the master controls Each module consists of a static switch and the sag correcting electronics The parallel modules are series connected to the input line and operate by adding the compensating voltage needed to restore the line to its nominal output When the utility line voltage is adequate the static switch will remain closed and no compensating voltage is added When an insufficient line voltage event occurs the static switch opens and the sag correcting electronics inverters quickly add the balance of voltage necessary to regulate the load voltage Thermal switches are included to activate fans ifthe cabinet temperature or other internal temperatures exceed set limits A central touch screen display provides indication of the status of the MegaDySC operation After power is switched on the green OK box will be displayed in the upper left hand corner of the display indicating that the output voltage is within a normal range of 88 5 to 110 of nominal A red FAULT box is displayed in the upper left hand corner of the display when an alarm condition is present on the MegaDySC During this period sag correction is inhibited and the MegaDySC will continue to bypass the utility voltage directly to the load through the s
26. ely Note It is critical to match the phases on each MegaDySC section Plug the 4 duplex fiber optic cables into the appropriate transceiver found on the control PC boards of each MegaDySC Unit s phase inverter module Plug in the control wire harnesses that interconnect the enclosures at the bottom of each unit Check wiring for correct source and destination locations against approved drawings Check all electrical terminations for proper torque Refer start up and commissioning to factory trained and authorized service personnel Rockwell Automation Publication 1608M UM002A EN P September 2013 11 Chapter2 Installation Electrical Terminations for a pone cables e ER ouput to ee Be es Input and Output Power the top or the Automatic ypass WItC oard enclosure at the location labele CUSTOMER CONNECTION ENTRANCE in Figure 1 The top panel should be removed to punch conduit holes Bus bar locations and hole pattern are shown in Figure 4 Utility Input and Load Wiring Connect incoming earth ground conductor to the GROUND bus bar in accordance with the National Electrical Code and local codes UTILITY INPUT cables are terminated at bus bars labeled left to right e Li e I2 e 13 The Neutral input cables are terminated at the bus bar labeled e NEUTRAL For 4 wire systems only Neutral connection is required for proper operation OUTPUT FOR PROTECTED LOADS cables are terminated at bus bars labeled e XI e X2 e X3 The N
27. er 6 Display Screen Figure 17 System Event Detection 32 New System Event A system fault is In pr ogress System Event Detail The right side of the System Event Detail page displays detailed information that was recorded during the selected event See Figure 16 The Animate button displays a time lapse view of the system events as they were recorded Description Function Event Date 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 fault code in parentheses Type A i Severity Severity of the fault Description Name of the event Reference Table 6 on page 36 Location The location in the system where the event originated e g Phase A Phase B Phase C Component Area The specific area within the location where the event originated e g Inverter Reading a data value relevant to the System Event may be recorded in some cases e g detail for an Inverter Over Current alarm would include a reading of the causal high current value The reading N A is displayed if no appropriate data value exists Note Fach time the unit is powered up the system will generate an informational Unit Power On event to record the power up time The duration of this event is the time since the last power down
28. eutral output cables if needed are terminated at the same bus bar labeled e NEUTRAL present only in 4 wire systems Put Automatic Bypass Switchboard circuit breakers in these positions before energizing the system e CBI OFF open e CBB ON closed e CBO OFF open Replace all insulating panels covers close and lock all doors before energizing the system 12 Rockwell Automation Publication 1608M UM002A EN P September 2013 i Sense Voltage Monitor Remote Diagnostics TB1 Relay Contacts Chapter 3 Communications An i Sense voltage monitor is mounted on the Automatic Bypass Switchboard to continuously monitor the 3 phase input and output voltages of the MegaDySC system The i Sense is wired in parallel with the bypass circuit breaker CBB For 3 wire systems the i Sense monitors Line Line voltages For 4 wire systems it monitors Line Neutral voltages The i Sense requires communication via the Internet to access the recorded voltage data Two options for communication are provided Ethernet RJ45 port or PSTN analog only telephone line RJ11 port These communications ports are extended to the top of the Bypass Switchboard for permanent wiring installation The ports are labeled as shown in Figure 5 Refer to the i Sense User Manual publication 1608S UM001A EN P for registration configuration and operation instructions Figure 5 i Sense and MegaDySC low voltage communications ports labeling I Sen
29. five groups based on severity as listed in the following table Severity Description Informational Purely informational No action is required Auto Resetting The DySC will reset within 60 seconds No user action is required User action may be required to correct a problem The DySC will reset 60 User Attention 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 all Service required System Event Log The System Event Log screen displays a list of the last 40 system faults in chronological order See Figure 16 You can access this screen by pressing the System Events button in the menu Figure 16 System Event Log f r P gt System Events Configuration Dysc Dynamic Sag Corrector The left side of the screen contains the list of system events which are identified by these fields Description Function Unique ID within the list identifying each system event Time Start time of the fault Name Name and description of the alarm Use the up down arrows to navigate through the list Detail for the currently selected event is shown to the right of the list Rockwell Automation Publication 1608M UM002A EN P September 2013 31 Chapt
30. gs and DySC 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 At commissioning time perform the following steps to configure your system Note The touch screen is optimized for use with a plastic stylus or bare finger When the system first starts the HOME screen is displayed Step 1 Press the Configuration button at the top of the screen See Figure 8 Figure 8 Quick Start Step 2 Set date and time by pressing Set System Clock on the left side of the screen See Figure 8 Step 3 Use the left right arrows under System Clock to highlight each component Use the plus and minus buttons to set the correct time and or date Rockwell Automation Publication 1608M UM002A EN P September 2013 25 Chapter6 Display Screen Home Screen Step 4 Press the Save button to store the new date time and format settings Note Pressing View Model Information on the Configuration screen provides model information about the MegaDySC system It includes model number serial number voltage and current ratings Unit details are also present including component serial numbers and firmware version numbers Do not subject the touch display to heavy impact Use your bare finger or plastic stylus to tap the touch display Do not use anything that might cut or damage the
31. gure 10 System Status Screen Van Giasesoveesti Dysc Dynamic Sag Corrector Table 5 System Status Item Description Function Overall system status including status availability to correct sags and internal cabinet temperature 11 System 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 MegaDySC unit Nominal values are listed on the View Model Information screen Cabinet Layout The system component cabinets are displayed press a cabinet for more detail Waveforms Real time waveform capture line voltage load voltage or load current can be selected for display Note You can toggle between the two screens in Figure 10 by pressing System Summary and Line amp Load Waveforms on the left side of the screen Rockwell Automation Publication 1608M UM002A EN P September 2013 27 Chapter6 Display Screen Voltage Sags 28 Cabinet Status When a cabinet image is pressed detailed status for the selected cabinet will be displayed in a popup window SeeFigure 11 Press the Close button to close the popup and return to the System Status screen Figure 11 Cabinet Status ic Oynamm Sag Corrector A voltage sag is defined as the period when input rms voltage drops to less than 88 5 of the rated MegaDySC voltage
32. n page 22 WARNING The MegaDySC and optional ER cabinets are interlocked Opening NOTES 1 Cycling input power in the sequence OFF ON OFF ON within a one minute period will cause a Limit Cycle Timeout alarm In such case sag correction will be disabled for one minute after which the alarm will automatically reset 2 Pushbutton CBI ON is disabled for one minute after CBI is opened for any reason Rockwell Automation Publication 1608M UM002A EN P September 2013 17 Chapter4 Applying Power Notes 18 Rockwell Automation Publication 1608M UM002A EN P September 2013 System Description MegaDySC Operation Chapter 5 Operation Raw utility power enters and routes through the Automatic Bypass switchboard to the load In maintenance bypass mode the power bypasses the MegaDySC cabinets and passes directly to the load In this mode the load is unprotected from voltage sags In the Normal operation mode the MegaDySC cabinets are energized and the power is directed through the MegaDySC protecting the load See the following sections for MegaDySC and Automatic Bypass operation details circuit breaker CBB be open OFF otherwise voltage sag correction will be N ATTENTION Operation in Normal Mode requires that the maintenance bypass defeated by the mechanical bypass A master control panel located in the switchboard enclosure constantly monitors the line voltages and issues commands to the parallel connecte
33. ning the enclosure door for servicing may exist within this enclosure after AC power has been removed Do not touch any components within the enclosure if the red LEDs located above capacitor banks are lighted If the red LEDs do not extinguish within 5 minutes close the enclosure door and contact Technical Support WARNING This enclosure contains energy storage devices Dangerous voltages 22 Rockwell Automation Publication 1608M UM002A EN P September 2013 Over Current and Fault Protection Operation Chapter 5 Normal Mode The NORMAL mode for the MegaDySC is Input Breaker CBI and Output Breaker CBO closed The bypass breaker CBB must be open or the MegaDySC will not be able to correct voltage sags There is a red indicator light on the bypass enclosure that is lighted when the bypass is closed The green OK status box should be shown on the touchscreen display The green OK box indicates that the voltage at the output of the MegaDySC is within the 10 13 normal window Refer to Table 3 for operational conditions and indications Bypass Mode The BYPASS mode for the MegaDySC is for Input Breaker CBI and Output Breaker CBO to be open The bypass breaker CBB must be closed to provide power to the load while the MegaDySC is being serviced Refer to Automatic Bypass Switchboard Operation on page 20 or the placard on the bypass switchboard for instructions on transferring the system into and out of byp
34. on Publication 1608M UM002A EN P September 2013 Chapter 7 Maintenance en Code Name Full Name Severity Area Event Description Event Resolution 31 CONFIG Configuration Alert Call Service Inverter Controller configuration has changed Call service 32 CNTRL_MEM Controller Memory Busy Auto Resetting Inverter Controller is loading new data into Flash memory No action needed 33 UNBALANCE Start Up Test DC Bus Unbalance Call Service Inverter Positive and negative halves of the DC bus did not charge equally during power up Call service 34 AC_V_CHK Start Up Test AC Voltage Check Call Service Inverter Output voltage was detected out of tolerance during the start up test Call service 35 ROLL_CALL Start Up Test Controller Roll Call Timeout Call Service Unit Controller communication problem detected during start up test Call service 36 COM_VER aes Communication Compatibility Call Service Unit Firmware communication compatibility problem detected during start up test Call service 37 CNFG_TO Start Up Test Controller Configuration Timeout Call Service Unit Controller communication problem detected during start up test Call service 38 CNFG_ERR ee Controller Configuration Call Service Unit Controller firmware configuration problem detected during start up test Call service 39 FIRM_TO en Test Controller Firmware Check Call Service Unit Controller
35. pen Fuse s Blue MegaDySC offline Disconnected Mech Bypass Enclosure Door Open Door Open Blue MegaDySC offline Disconnected Mech Bypass The touchscreen will power down if both input and output voltages fall below approx 75 of nominal An error message will be displayed while the red or orange text box is displayed Refer to Chapter 6 for further information on accessing fault codes and status history Automatic Bypass The Automatic Bypass Switchboard consists of a bypass circuit breaker CBB an input circuit breaker CBI and an output circuit breaker CBO Refer to Figure 7 Under normal operating conditions raw input power is routed through CBI to the input of the MegaDySC sections The output of the MegaDySC sections is routed to the load through CBO CBB is normally open CBB connects utility power to the load bypassing the MegaDySC sections when operating in the maintenance bypass mode Switchboard Operation Refer to page 23 for descriptions of the automatic bypass modes A WARNING Dangerous voltages can still exist within the MegaDySC enclosures even if the system is in Bypass mode Refer servicing to qualified personnel 20 Rockwell Automation Publication 1608M UM002A EN P September 2013 Automatic Bypass Switchboard Operating Instructions Operation Chapter 5 attempt to change the position of any circuit breakers without becoming N ATTENTION Follow these instructions to avoid interrupting load power Do not
36. play is working and no active events are displayed Check that the Automatic Bypass switchboard is in the MegaDySC Normal mode Update system time if needed see Figure 8 on page 25 Clean the display screen if needed See page33 Ensure air intake and exhaust filters are not covered or obstructed 3 6 Month Checks Check air filters and clean when necessary Air filters for the MegaDySC will require periodic cleaning with the frequency depending on the environment Filters are located on the doors of each MegaDySC and ER cabinet and can be accessed with the doors closed The MegaDySC 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 Replace or 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 re install the knurled nuts until finger tight Replace filters 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 Refer to the Hardware Service Manual for fan test instructions Rockwell Automation Publication 1608M UM002A EN P September 2013 35 Chapter 7 Maintenance Table 6 System Even
37. ponents Installation Chapter 2 MegaDySC systems comprise several sections including multiple DySC 400A Module MegaDySC electronics cabinets and one Automatic Bypass Switchboard The separate shipping split components must be mechanically and electrically interconnected at the time of installation The MegaDySC cabinets house the static bypass semiconductor switches and voltage sag correction electronics The Automatic Bypass Switchboard houses the maintenance bypass circuit breakers master control circuits and voltage and current monitoring circuits Table 1 shows the s ystem components shipping splits of 480V rated Table 1 MegaDySC System Models MegaDySC systems Models with other voltage ratings are similarly configured This document applies to 1608M MegaDySC systems rated 800A to 2400A at 380V 400V 415V 460V or 480V i i DySC 400A Gtaloghumbers rent ia seer Se adno Modules 1608M 800A480V3S 800A 3W SR 1 2 s 1608M 800A480V3E 800A 3W ER 1 2 1608M 800A480V4S 800A 4w SR 1 2 5 1608M 800A480V4E 800A 4w ER 1 2 1608M 1K2A480V3S 1200A 3W SR 1 3 1608M 1K2A480V3E 1200A 3W ER i 3 1608M 1K2A480V4S 1200A 4w SR 1 3 1608M 1K2A480V4E 1200A 4w ER 3 1608M 1K6A480V35 1600A 3W SR 1 4 1608M 1K6A480V3E 1600A 3W ER 4 1608M 1K6A480V4S 1600A 4w SR 1 4 1608M 1K6A480V4E 1600A 4w ER 4 1608M 2KOA480V35 2000A 3W SR 1
38. ring harness is also provided in the ABP and must be connected to the MegaDySC cabinets Finally the incoming electrical service and outgoing load cables are brought in through the top or bottom of the ABP switchboard and connected to the appropriate bus locations as shown in Figure 4 AC input is Rockwell Automation Publication 1608M UM002A EN P September 2013 Installation Chapter 2 connected to the bus bar terminals labeled L1 L2 L3 and the protected load is connected to the bus bar terminals labeled X1 X2 X3 Figure 4 Bus Bar Details for Utility Input and Load Output Terminations e Top Entry Area NEUTRAL UTILITY INPUT Detail Typical bus bar hole pattern Right side cut away view of Switchboard MegaDySC System Interconnections Checklist The following list of checks is provided for reference only Interconnections must be completed by factory trained and authorized installation personnel Connect each MegaDySC Unit s ground cable to the ground bus in ABP Switchboard Connect line side cables from each MegaDySC Unit to the respective line input bus in the ABP Switchboard labeled L1 L2 and L3 respectively Connect load side cables from each MegaDySC Unit to the respective load output bus in the ABP Switchboard labeled X1 X2 and X3 respectiv
39. rmation concerning related 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 Ch 1 Introduction Ch 2 Installation Ch 3 Communications Ch 4 Applying Power Ch 5 Operation Ch 6 Display Screen Table of Contents Important User Information ne ar 2 Additional Reseires anne a 2 Sdf ty Considerati h Sen ete eon eine aa r wehtoulae en 5 System Components une eo E E E E OE ES 7 System Orientation and Layout anne Rene 8 System Clearance nee EE EE EEEE A 9 System Mountings u S gre PAAR EE EN EAEN Ta ERE EA ENGA 9 Mechanical Interconnections sa a rer 9 Electrical Interconnections ae an 10 MegaDySC System Interconnections Checklist 0 0000 0008 11 Electrical Terminations for Input and Output Power 000 e008 12 Utility Input and Load Winnie 12 iSense Voltage Monltet ss anona Keowee AE E 13 Remote Diagnostics TB1 Relay Contacts 0 60 00 cece ee eee ee
40. se I Sense DySC DySC J es RS232 TB1 Schematic Diagram and Contact Ratings The Automatic Bypass Switchboard contains relay dry contacts available at terminal block TB1 for remote monitoring of the state of the Bypass Circuit Breaker and certain status conditions in the MegaDySC Refer to Figure 6 TB1 is located in a compartment at the top of the right switchboard section The terminal block is labeled TB1 CUSTOMER CONTACTS any alarm notification device Access to the terminal contacts risks exposure to 120 VAC potential Accidental operation of the automatic bypass circuit is possible N ATTENTION Remove power from the MegaDySC system prior to connecting Rockwell Automation Publication 1608M UM002A EN P September 2013 13 Chapter 3 Communications Figure 6 Schematic Diagram Customer Contacts TB1 CUSTOMER SIDE 1 1 K1 NC 2 K1 NO 3 ALARM 4 OUTPUT OK K2 NO 6 7 K3 NC 8 SAG EVENT K3 NO 9 CBB NC CBB STATUS A status as shown when CBB NO CBB is open OFF Customer provided contact Close to activate Bypass BP Neut TB1 Relay Contact Ratings Terminals 1 9 of TB1 Relays ratings are e 110 277VAC 10A continuous 16A short time e 110 120VAC 1 3 hp max e 220 250VAC 1 2 hp max e 28VDC 10A continuous 16A short time e Min recommended load 100mA 5VDC or 0 5 W CBB Contact Ratings Terminals 10 12 of TB1 e 110 600VAC 6A e 24 48 VDC 2 5A e 125 250 VDC 0 5A Remote Bypass Customer Provided Con
41. sentative 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 1608M UM002A EN P September 2013 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in the U S A
42. t Table Event Code Code Name Full Name Severity Area Event Description Event Resolution 1 POWER_ON DySC Power On Informational Unit Power re applied to the DySC No action needed 4 T_FAN_ST Fan Test Start Informational Unit Start acknowledgment of DySC fan test No action needed 5 T_IN_ST_1 Inverter Test 5 cycles Start Informational Unit Start acknowledgment of DySC 0 5 cycle inverter test No action needed 6 T_IN_ST_2 Inverter Test 3 cycles Start Informational Unit Start acknowledgment of DySC 3 cycle inverter test No action needed 7 T_IN_ST_3 Inverter Test 5 5 seconds Start Informational Unit Start acknowledgment of DySC 5 5 second inverter test No action needed 9 EXTERNAL External Inhibit Auto Resetting Inverter Controller is inhibited by another phase controller a details from other phase 10 EXT_SLAVE External Slave Cabinet Inhibit Auto Resetting Inverter Master controller is inhibited by another phase master controller Review event details from slave controllers 11 RUN_TO Inverter Run Timeout Auto Resetting Inverter DySC inverter had a total cumulative runtime of more than rated No action needed 12 LIM_CYCLE Inverter Limit Cycle Timeout Auto Resetting Inverter Power was re applied more than once within a 58 second period No action needed Verify ambient temperature is within DySC 13 STAT_OT Static Switch Over Temperat
43. t for servicing Rear access required for bottom entry installation Environmental Ambient Temperature 0 to 40 C 32 F to 104 F Storage Temperature 40 C to 75 C 40 F to 167 F 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 Audible Noise lt 70dBA at 1 meter Safety and Compliance Agency Approvals cULus Listed UL 1012 Standards Compliance Exceeds SEMI F47 Standard IEEE Std C62 41 1 and UL 1449 3rd Ed Compliant 1 MegaDySC has not been evaluated for use in Corner Grounded or Ungrounded Delta Power Systems in systems rated over 240V 2 When using MegaDySC with motor drive loads either insert 3 to 5 line reactance at MegaDySC output or limit motor drive loads to 60 of MegaDySC rating Rockwell Automation Publication 1608M UM002A EN P September 2013 41 Chapter8 Specifications Notes 42 Rockwell Automation Publication 1608M UM002A EN P September 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 rockwell
44. tact Rating Terminals 14 15 of TB1 The customer provided contact must be rated for at least 120VAC Coil power is 2 VA at 120 VAC 17 mA Rockwell Automation Publication 1608M UM002A EN P September 2013 Communications Chapter 3 TB1 Contacts Functionality ALARM Contacts The NC contact will be closed during normal operating conditions The NC contact will open if an alarm condition occurs that inhibits sag correction It will also close when the DySC system is powered down when the touchscreen display is off If and when an alarm condition clears for example a Static Switch Overload no longer exists the relay will revert to its pre fault position Alarms that will energize the Alarm Relay K1 coil are all those listed in Table 6 on page 36 with a severity of Auto Resetting or Call Service OUTPUT OK Contacts The NC contact will be open during normal output load voltage conditions The NC contact will close if the output rms voltage falls below 87 of rated for more than 3 cycles It will also close when the DySC system is powered down SAG EVENT Contacts The NC contact will be closed during normal input line voltage conditions The NC contact will open during a detected voltage sag event It will also close when the DySC system is powered down During a voltage sag the relay coil will be energized for a minimum of 1 cycle 16ms in 60 Hz application 20ms in 50 Hz application and for the duration of
45. tatic bypass path An orange Resetting box is displayed when the previous alarm condition has cleared Sag correction will remain inhibited until the reset period has expired approximately 1 minute A blue SYSTEM OFFLINE box is displayed Rockwell Automation Publication 1608M UM002A EN P September 2013 19 Operation whenever the MegaDySC system is in the Maintenance Bypass mode CBB closed and CBI open A list of conditions and indications is given in Table 3 Refer to Chapter 6 for further information on system alarms and status display Table 3 Operational Conditions and Indications temperature CONDITION DEFINITION Touchscreen Display STATUS text INVERTER OPERATION BYPASS MODE Normal 88 5 lt V jie lt 110 Green OK Standby Static BP Sag Event an ee fores thamavailable Green OK Running Inverter Runtime Exceeded Cumulative runtime exceeded ect a au Inhibited Static BP Normal Mode Overload Load current gt 110 a un ends Inhibited Static BP ler Output Load current gt 150 for 3 cycles e A min Inhibited Static BP LIVER EC Modul Overs Module temperature limit exceeded Blue MegaDySC offline Disconnected Mech Bypass MegaDySC Over temperature Internal temperature limit exceeded Blue MegaDySC offline Disconnected Mech Bypass Static Switch Failure Open SCR s Blue MegaDySC offline Disconnected Mech Bypass Main Fuse Open O
46. tion Publication 1608M UM002A EN P September 2013 55 06 _ E Installation Chapter 2 Figure 2 Typical System Layout Front View 800A ER model shown 102 93 2614 EB a 1 AUTOMATIC 400A ER BYPASS SWITCH DySC UNIT RHI SHIPPING SHIPPING BREAK System Clearance System Mounting Mechanical Interconnections BREAK The MegaDySC and ER cabinet doors are hinged on the left and clearance must be given to allow the door to swing open 90 degrees to the front of the enclosure as shown in Figure 1 Clearance for the Automatic Bypass switchboard should allow the door to swing left side hinged open 90 degrees to the front of its enclosure The MegaDySC is floor mounted and should be secured using the 0 63 diameter mounting holes provided at the bottom of each section Since each MegaDySC cabinet is provided with interconnecting cables to the Automatic Bypass switchboard proper arrangement is critical Follow the MegaDySC cabinet arrangement label located on the front of the Automatic Bypass switchboard for proper unit arrangement MegaDySC cabinets are identified with a label located just above the main door handle The MegaDySC and Switchboard cabinets should be bolted together for maximum stability 3 8 x 1 bolts with 1 flat washer and lock washer are provided for this purpose tighten to 25 lb ft 42 4 N m The bolts pass through the right side of each c
47. uency Range tracking 45 to 65 Hz TVSS Output SPD 80kA mode Protects L L amp L G on all models L N amp N G 4 wire models Efficiency gt 99 System Short Circuit Current Rating SCCR 65kA 800A 1200A models 85kA 1600A 2000A models 100kA 2400A models Phase wiring 3 phases Ground 3 wire models or 3 phases Neutral Ground 4 wire models Electrical Output Sag Correction Mode Inverter Sag Detection Voltage 88 5 of rated voltage Response Time typical 0 7 ms detection 1 2 ms inverter reaction lt 2ms Output Voltage Pre sag rms voltage Voltage Regulation 5 typical 5 13 of nominal max Output Current rated current rms amperes Crest Factor at rated load 1 45 Load Power factor 0 5 to 0 9 Not rated for DC loads max allowable 2 DC loading 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 SR or 200ms ER Based on nameplate ratings with a power factor of 0 7 Multiple Events 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 or Bottom of Switchboard section Cooling Filtered Forced air controlled Access Fron
48. ufacturer Part Number F1 F2 F3 Main Cabinet Main Power Input 800A 500V Mersen A5005800 4lL F4 F5 F6 Main Cabinet Cross Coupling Transformer 200A 600V Mersen AJT200 F10 F11 Main Cabinet Output Control Transformer 4A 600V Mersen TRS4R F12 Main Cabinet Input Control Transformer 2A 600V Mersen TRS2R A Main Cabinet Dynamic Brake 20A 600Vdc Mersen ATM20 SR Models A Main Cabinet Dynamic Brake 25A 600Vdc Mersen ATM25 ER Models MegaDySC Power Module Fuses Fuse Reference Fuse Location Fuse Rating Manufacturer Part Number F1 F2 Power Module x3 Voltage Feedback 2A 600V Mersen ATQR2 F3 Power Module x3 Inverter Output 400A 500V Mersen A500S400 41L MegaDySC ER Cabinet Module Fuses ER models only Fuse Reference Fuse Location Fuse Rating Manufacturer Part Number F1 F2 F3 F4 ER Module x6 70A 500Vdc Mersen A500S70 4 Rockwell Automation Publication 1608M UM002A EN P September 2013 Connection Configuration Chapter 8 Specifications Table 8 Typical Technical Specifications 800 2400 A MegaDySC 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 Rated Input Voltage 3 Phase 380 400 415 460 480V Voltage Range 10 Static Bypass Current 100 rated rms current continuous 150 400 5 sec 400 600 0 5 sec 600 0 1s Frequency 50 60 Hz Auto Sensing Freq
49. ure User Attention Static Switch Static switch heatsink temperature was greater than maximum rating specification Check for damaged fans Check for dirty or obstructed air filters Reduce load In parallel DySC systems verity 14 OVERLOAD Overload User Attention Unit Inverter inhibited because load current exceeded maximum rating proper current sharing among slave cabinets 15 DC_OV DC Bus Over Voltage User Attention Inverter Positive or negative half of DC bus voltage exceeded maximum rating Verify line voltage is within ratings Verify proper DySC application Call service 16 CNTRL_UV Controller Power Under Voltage User Attention Inverter DySC control power supply is out of tolerance Verify DySCis online and line voltage is within ratings Call service 7 OUTPUT_UV Output Under Voltage User Attention Inverter DyST output voltage was Tess than 80 of nominal during sag correction Sag Verify Tine voltage is within ratings Verify condition likely outside of DySC specification proper DySC application Verify Toad current is within ratings Verify 18 INV_OC Inverter Over Current User Attention Inverter Inverter current exceeded maximum rating during sag correction mechanical bypass circuit breaker CBB is open Verify proper DySC application 19 DC_UV DC Bus Under Voltage User Attention Inverter DC bus voltage below operational range u voltage is within ratings Cal 20 OUTPUT_OV Output Over Voltage Call Service Inverter DySC outp
50. ut voltage was greater than 115 of nominal during sag correction Call service 22 IGBT IGBT Pack User Attention Inverter IGBT pack reported error Possible sag condition outside of DySC specification Verify ine voltage within ratings Verity proper DySC application Call Service 24 GATE_ERR Gate Command Error Call Service Static Switch Master slave gate command error Call service 25 SYNC_ERR Line Synchronization Error Call Service Inverter Inverter not synchronized to line when sag detected Call service 26 SLAVE_1 Slave Cabinet 1 Inhibit Auto Resetting Inverter Master controller inhibited by slave controller Review event details from slave controllers 27 SLAVE_2 Slave Cabinet 2 Inhibit Auto Resetting Inverter Master controller inhibited by slave controller Review event details from slave controllers 28 CR_SLV_1 Critical Slave Cabinet 1 Inhibit Manual Reset Static Switch Master controller inhibited by slave controller Mechanical bypass commanded En details from slave controllers 29 CR_SLV_2 Critical Slave Cabinet 2 Inhibit Manual Reset Static Switch Master controller inhibited by slave controller Mechanical bypass commanded een details from slave controllers Verify proper current sharing among slave 30 CRIT_OL Critical Static Switch Overload User Attention Static Switch Slave cabinet current exceeded maximum rating Mechanical bypass commanded cabinets Verify proper DySC application Call service 36 Rockwell Automati
51. witchboard Operation on page 20 cabinet doors while in the MegaDySC normal mode will cause immediate automatic bypass operation and subsequent loss of voltage sag protection while in maintenance bypass mode Automatic Bypass switchboard cabinet doors are not interlocked and should be kept locked to avoid exposure to dangerous voltages N WARNING The MegaDySC and optional ER cabinets are interlocked Opening Automatic Circuit Breakers Safety Interlocks and Stored Energy Figure 7 on page 22 shows the arrangement of circuit breakers CBI CBO and CBB ofthe Automatic Bypass switchboard Ifthe MegaDySC cabinet doors are opened while the system is operating in normal mode the circuit breaker CBB will automatically close and CBI and CBO will be automatically opened putting the system into maintenance bypass mode until it is manually reset Voltage sag protection is not possible in the maintenance bypass mode All doors should be kept locked to avoid this situation The MegaDySC includes a fast discharge circuit to quickly dissipate stored energy when the circuit breaker CBI is opened CBI may be operated automatically by the door interlock switches or other protection devices CBI can also be operated manually If the upstream power is interrupted before CBI is opened the fast discharge circuit will not be triggered In that case wait at least 30 minutes before opening the MegaDySC cabinet or ER cabinet doors to avoid exposure to
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