Rockwell Automation Allen-Bradley MegaDySC Dynamic Voltage Sag... User manual

MegaDySC Dynamic Voltage Sag Corrector
Bulletin Number 1608M—400 Amp Models sold after 1/1/2016
User Manual
Original Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
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.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 1608M-UM005A-EN-P - March 2016 3
Table of Contents
Preface Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
Installation System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Instructions For Energizing Loads Before Commissioning . . . . 12
MegaDySC System Installation Connections Checklist. . . . . . . 14
MegaDySC System Interconnections Checklist . . . . . . . . . . . . . . 14
Chapter 2
Communication Remote Diagnostics and Remote Bypass. . . . . . . . . . . . . . . . . . . . . . . . . 15
CBB Contacts (Bypass Circuit Breaker) . . . . . . . . . . . . . . . . . . . . . 15
CBI Contacts (Input Circuit Breaker). . . . . . . . . . . . . . . . . . . . . . . 15
Remote Seamless Bypass Command-EPO . . . . . . . . . . . . . . . . . . . 16
Contact Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MegaDySC Status Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
RS-232 Serial communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
i-Sense Voltage Monitor Communication . . . . . . . . . . . . . . . . . . . 17
Chapter 3
Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 4
Operation System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MegaDySC System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Automatic Bypass Switchboard Operation . . . . . . . . . . . . . . . . . . . . . . 22
Automatic Bypass Switchboard Operating Instructions. . . . . . . . . . . 23
Automatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Manual Transfer to Maintenance Bypass (Bypass Mode). . . . . . 23
Manual Transfer to MegaDySC System (Normal Mode). . . . . . 23
Transient Voltage Surge Suppression. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagnostic Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 5
Display Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Mechanical Bypass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4Rockwell Automation Publication 1608M-UM005A-EN-P - March 2016
Table of Contents
Voltage Sag Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Voltage Sag Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Voltage Sag Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Voltage Sag RMS Voltage Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Voltage Sag Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
System Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
System Event Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
System Event Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
System Event Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Model Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Run System Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 6
Maintenance Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Automatic Bypass Switchboard Fuses . . . . . . . . . . . . . . . . . . . . . . . 47
MegaDySC System and ER Cabinet Fuses . . . . . . . . . . . . . . . . . . . 47
Chapter 7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Rockwell Automation Publication 1608M-UM005A-EN-P - March 2016 5
Preface
Introduction The Allen-Bradley® Bulletin 1608M MegaDySC® Dynamic Sag Corrector is
engineered to provide years of 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 voltage sag in line voltage can reset or damage
sensitive production equipment. The MegaDySC system provides instantaneous
dynamic sag correction to help your equipment ride through these common
events. It 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 system is quickly ready to correct the
next sag.
The system 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.
Safety Considerations The MegaDySC is designed to operate in industrial applications. Follow these
guidelines to verify that the safety and installation of the MegaDySC are handled
with appropriate care.
SHOCK HAZARD: The MegaDySC system has high voltage remaining up to 5
minutes after disconnection from the AC line. Touching exposed or
disconnected terminals, cables or parts can lead to serious injuries or even
death. Wait for a minimum of 5 minutes before performing any service or
testing after power is removed. High voltage remains if red LED indicators
above capacitor banks are lighted. Keep the cabinet doors closed and locked to
verify proper cooling airflow and to protect personnel from dangerous voltages
inside.
ATTENTION: - To reduce the risk of fire or electric shock, install in a
temperature and humidity controlled, indoor environment, free of conductive
contaminants.
•Avoid installing 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.
•Verify all power is disconnected before performing installation or service.

6Rockwell Automation Publication 1608M-UM005A-EN-P - March 2016
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
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.
ATTENTION: Internal components can be easily damaged by electrostatic
discharge (ESD). Do not touch circuit boards or electronic components with
hands or metal objects. The MegaDySC system is not rated to directly power life
support equipment.
•Verify the surrounding area is clean and uncluttered.
•Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the
equipment.
ATTENTION: A tip over hazard exists. To guard against death, serious personal
injury, and/or equipment damage do not allow Automatic Bypass Switchboard
to tip beyond 10 degrees in any orientation during unloading and installation.
Resource Description
Bulletin 1608M MegaDySC Dynamic Voltage Sag Corrector,
publication 1608M-IN002
Basic information to install and apply power to corrector, also
includes specifications.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and
other certification details.

Rockwell Automation Publication 1608M-UM005A-EN-P - March 2016 7
Chapter 1
Installation
System Components The MegaDySC™ system consists of two enclosures including one “DySC™ 400 A Module”
MegaDySC section and one Automatic Bypass Switchboard, which is shipped separately and
must be mechanically and electrically interconnected at the time of installation. The MegaDySC
section houses the static bypass and voltage sag-correction electronics as well as the optional
extended-run (ER) module. The Automatic Bypass Switchboard houses the maintenance bypass
circuit breaker (CBB), the MegaDySC input (CBI) and output (CBO) circuit breakers,
automatic controls, and the i-Sense® voltage-monitoring sensor. This document applies to the
following MegaDySC System Models.
Table 1 - 400 A MegaDySC System Models
Catalog Number Voltage Rating 3 / 4-wire SR / ER
1608M-400A380V3S
380V
3SR
1608M-400A380V3E ER
1608M-400A380V4S 4SR
1608M-400A380V4E ER
1608M-400A400V3S
400V
3SR
1608M-400A400V3E ER
1608M-400A400V4S 4SR
1608M-400A400V4E ER
1608M-400A415V3S
415V
3SR
1608M-400A415V3E ER
1608M-400A415V4S 4SR
1608M-400A415V4E ER
1608M-400A460V3S
460V
3SR
1608M-400A460V3E ER
1608M-400A460V4S 4SR
1608M-400A460V4E ER
1608M-400A480V3S
480V
3SR
1608M-400A480V3E ER
1608M-400A480V4S 4SR
1608M-400A480V4E ER

8Rockwell Automation Publication 1608M-UM005A-EN-P - March 2016
Chapter 1 Installation
System Layout Figure 1 - Standard Run (SR) System Layout
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Rockwell Automation Publication 1608M-UM005A-EN-P - March 2016 9
Installation Chapter 1
Figure 2 - Extended Run (ER) System Layout
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10 Rockwell Automation Publication 1608M-UM005A-EN-P - March 2016
Chapter 1 Installation
System Clearance The MegaDySC 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.
Clearance for the Automatic Bypass switchboard must allow the front panels
to swing (left side hinged) open 90 degrees to the front of its enclosure.
Only front side access to the Automatic Bypass switchboard will be required
during installation wiring and cabinet interconnect wiring.
System Mounting The MegaDySC system is floor-mounted, and should be secured using the
0.63” diameter mounting holes provided along the bottom channels. The
MegaDySC section is provided with all necessary interconnect wiring to the
Automatic Bypass switchboard section. Proper line-up is critical: The
MegaDySC section must be to the right of the Automatic Bypass section when
viewed from the front of the system.
The DySC 400A Module MegaDySC section is shipped separately from the
Automatic Bypass switchboard. It must be secured to the Automatic Bypass
enclosure with the 3/8” hardware supplied. See Figure 3 for fastening locations
and hardware arrangement. The optional ER enclosure is permanently
connected to the MegaDySC section prior to shipment.
Figure 3 - System Mounting
Attach the MegaDySC section to the Automatic Bypass
switchboard using the six sets of 3/8” hardware supplied.
• Install three sets along the front door frame and three sets
along the rear frame. Hardware along the rear frame can be
omitted if rear access to the switchboard is not available: it
is necessary to remove the rear panel of the switchboard to
install the rear sets of hardware.
• Install bolts from the switchboard side and thread into the
weld nuts in the MegaDySC section enclosure.
• Each set consists of one 3/8-16 x 1.0” bolt, one 3/8 split lock
washer and one 3/8” flat washer, assembled as shown.