User Manual

MegaDySC Dynamic Voltage Sag Corrector - 800 Amp, 208 Volt

Bulletin Number 1608M
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.

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.

Labels may also be on or inside the equipment to provide specific precautions.

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).

Allen-Bradley, DySC, i-Sense, MegaDySC, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.
 Summary of Changes

This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.

New and Updated This table contains the changes made to this revision.
Information Topic Page
Fault Protection 33

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 3

Summary of Changes

Notes:

4 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Table of Contents

Preface Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 1
Introduction Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 2
Installation System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SR System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ER System Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pre-Installation Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Preparing the SR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Preparing the ER System for SBS layout . . . . . . . . . . . . . . . . . . . . . . . . 15
Preparing the ER System for BTB layout . . . . . . . . . . . . . . . . . . . . . . . 16
System Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mechanical Interconnection of Cabinets . . . . . . . . . . . . . . . . . . . . . . . 17
MegaDySC Floor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical Supply and Load Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MegaDySC System Installation Connections Checklist. . . . . . . . . . 24

Chapter 3
Communication Remote Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Modbus TCP/IP Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
i-Sense® Voltage Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chapter 4
Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter 5
Operation System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MegaDySC Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Automatic Bypass Switchboard Operation . . . . . . . . . . . . . . . . . . . . . . . . . 30
Automatic Bypass Switchboard Operating Instructions . . . . . . . . . . . . . 31
Automatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Manual Transfer to Maintenance Bypass . . . . . . . . . . . . . . . . . . . . . . . 31
Manual Transfer to MegaDySC System . . . . . . . . . . . . . . . . . . . . . . . . 31
Transient Voltage Surge Suppressor (TVSS). . . . . . . . . . . . . . . . . . . . . . . . 32
Troubleshooting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Normal Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Diagnostic Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Rockwell Automation Publication 1608P-UM003B-EN-P - December 2015 5

Table of Contents

Chapter 6
Display Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Mechanical Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Voltage Sag Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Voltage Sag Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Voltage Sag Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Voltage Sag RMS Voltage Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Voltage Sag Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
System Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
System Event Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
System Event Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Run System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Chapter 7
Maintenance Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Automatic Circuit Breakers, Safety Interlocks and Stored Energy . 52
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Automatic Bypass Switchboard Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
MegaDySC and ER Cabinet Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chapter 8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

6 Rockwell Automation Publication 1608P-UM003B-EN-P - December 2015

 Preface

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
MegaDySC Dynamic Voltage Sag Corrector - 400 Amp Model Provides information on installation, operations,
User Manual 1608M-UM001 maintenance and specifications.
MegaDySC Dynamic Voltage Sag Corrector - 800 Amp Provides information on installation, operations,
Models User Manual -1608M-UM002 maintenance and specifications.
MegaDySC Dynamic Voltage Sag Corrector - 800 Amp Provides information on installation, operations,
Extended Run Models User Manual - 1608M-UM004 maintenance and specifications.
Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell
publication 1770-4.1 Automation industrial system.
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.

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 7

Preface

Notes:

8 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Chapter 1
Introduction
The 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.
Momentary sags in line voltage can reset or damage sensitive production
equipment. The MegaDySC corrector provides instantaneous dynamic sag
correction to help your equipment ride through these common events. The
corrector connects normal utility power directly to the load until a voltage sag
occurs. During sags, the MegaDySC corrector’s 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 corrector is quickly
ready to correct the next sag.

The MegaDySC corrector 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 corrector is designed to operate in industrial applications.

Follow these guidelines to make certain that the safety and installation are
handled with appropriate care.

SHOCK HAZARD: The MegaDySC corrector 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 on the MegaDySC corrector after power is removed. High voltage
remains if red status indicators above capacitor banks are lighted. Keep the
cabinet doors closed and locked to facilitate proper cooling airflow and to help
protect personnel from dangerous voltages inside the MegaDySC corrector.

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 9

Chapter 1 Introduction

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.

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 corrector is not rated to directly power
life support equipment.
• Check that the surrounding area is clean and uncluttered.
• Observe all DANGER, CAUTION, and warning notices affixed to the inside and
outside of the equipment.

10 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Chapter 2

Installation

System Components The Standard Run (SR) MegaDySC® system consists of two enclosures including
one 800A MegaDySC module and one automatic bypass switchboard. The
Extended Run (ER) MegaDySC system consists of three enclosures including
one 800A MegaDySC module, one Extended Run (ER) module and one
automatic bypass switchboard. The enclosures are shipped separately and must be
mechanically and electrically interconnected at the time of installation.

The 800A MegaDySC module houses the static bypass and voltage sag-
correction electronics. The ER module houses the ER energy storage capacitors.
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 only to the following MegaDySC system models.

Catalog Number Current Voltage Rating 3 / 4 Wire SR / ER
Rating
1608M-800A208V3S2S03 800 A 208V 3 SR
1608M-800A208V4S2S03 800 A 208V 4 SR
1608M-800A208V3E2S03 800 A 208V 3 ER
1608M-800A208V4E2S03 800 A 208V 4 ER

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 11

Chapter 2 Installation

SR System Layout Figure 1 - SR System Layout

6+,33,1*63/,7

&$%/((175<3/$7(
72321/<

&86720(5,23/$7(
72321/<







 
 




$8720$7,& $ 

%<3$66 0(*$'\6&  
6:,7&+%25' 02'8/( 
6+,33,1*63/,7

12 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Installation Chapter 2

ER System Layout The ER MegaDySC system can be configured in two ways: with the ER module
mounted to the right of the 800A MegaDySC module (side-by-side), or with the
ER module mounted behind the 800A MegaDySC module (back-to-back). ER
SBS System Layout shows the side-by-side (SBS) system layout. ER BTB System
Layout shows the back-to-back (BTB) system layout.

IMPORTANT The desired system layout, SBS or BTB, must be identified before cabinets are
mounted as described in System Mounting on page 17.

Figure 2 - ER SBS System Layout

6+,33,1*63/,7
6+,33,1*63/,7

&$%/((175<3/$7(
72321/<

&86720(5
,23/$7(
72321/<

 
   


 


  

  






$8720$7,& $ (502'8/(

%<3$66 0(*$'\6& 
6:,7&+%2$5' 02'8/(  


6+,33,1*63/,7 6+,33,1*63/,7

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 13

Chapter 2 Installation

Figure 3 - ER BTB System Layout

 
 




6+,33,1*63/,7

&$%/((175<3/$7(
72321/< 

&86720(5,23/$7(
72321/<







 
 




$8720$7,& $
0(*$'\6&   (502'8/(
%<3$66   
6:,7&+%25' 02'8/( 


6+,33,1*63/,7 


System Clearance The two automatic bypass switchboard doors are hinged on the left, the 800A
MegaDySC module door is hinged on the left, and the ER Module door is
hinged on the right. Clearance must be given to allow the doors to swing fully
open as shown in the SR System Layout on page 12, the ER SBS System Layout
on page 13, and the ER BTB System Layout on page 14.

Only front access and top access are required for installation and commissioning.
Rear access and left side access should be maintained when possible, to simplify
future maintenance tasks.

14 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Installation Chapter 2

Pre-Installation
Configuration
IMPORTANT Perform system configuration steps before mounting and anchoring.

Follow instructions for: Preparing the SR System, or Preparing the ER System for
SBS layout, or Preparing the ER System for BTB layout on page 16.

Preparing the SR System

1. Remove all tan-colored masking dots, blue-colored tape, and all plastic
sheets.
2. Remove all eight plastic 13 mm hole plugs in the right side of the
switchboard cabinet.
3. Remove and save for later step: four hex-head bolts with lock washer and
flat washer in left side of MegaDySC cabinet. [tool required: 9/16-inch
wrench or socket]

Preparing the ER System for SBS layout

1. Remove all tan-colored masking dots, blue-colored tape, and all plastic
sheets.
2. Remove all eight plastic 13 mm hole plugs in the right side of the
switchboard cabinet.
3. Remove and save for later step: four hex-head bolts with lock washer and
flat washer in left side of MegaDySC cabinet. [tool required: 9/16-inch
wrench or socket]
4. Remove two 75 mm electrical knock-outs (EKO) in the bottom-right side
of MegaDySC cabinet. Refer to Figure 4 on page 16.
5. Remove the two front-most 13 mm plastic hole plugs in the right side of
the MegaDySC cabinet. Leave the two rear-most hole plugs in place. Refer
to Figure 4 on page 16.
6. Remove two 63 mm EKOs in bottom-left side of ER storage cabinet. Refer
to Figure 5 on page 16.
7. Remove and save for later step: two hex-head bolts with lock washer and
flat washer in left side of ER storage cabinet. [tool required: 9/16-inch
wrench or socket]. Refer to Figure 5 on page 16.
8. Remove tie plate from the top of the ER storage cabinet, discard the sheet
of padding material, and replace the tie plate and screws—tie plate is not
needed for the SBS layout.

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 15

Chapter 2 Installation

Figure 4 - MegaDySC Cabinet Preparation for SBS Layout

Do not remove these two plugs

Remove plugs from these two locations

Remove these two 75 mm Ø EKOs

Figure 5 - ER Storage Cabinet Preparation for SBS Layout

Remove and save 3/8 - 16 hardware

from these two locations

Remove these two 63 mm Ø EKOs

Preparing the ER System for BTB layout

1. Remove all tan-colored masking dots, blue-colored tape, and all plastic
sheets.
2. Remove all eight plastic 13 mm hole plugs in the right side of the
switchboard cabinet.

16 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Installation Chapter 2

3. Remove and save for later step: four hex-head bolts with lock washer and
flat washer in left side of MegaDySC cabinet. [tool required: 9/16-inch
wrench or socket]
4. Remove two electrical knock-outs (EKO) in the bottom-rear panel of
MegaDySC cabinet.
5. Remove the cover plate from the bottom-rear of the ER storage cabinet.
Save the cover and screws for possible later use—they are not needed for
the BTB layout.

System Mounting The MegaDySC system is provided with interconnect bus links between
cabinets; proper line-up is critical. The system must be configured as shown in SR
System Layout, ER SBS System Layout, or ER BTB System Layout. The system
must be placed on a flat level surface or shimmed during installation to achieve
the same effect.

The 800A MegaDySC module is shipped separately from the automatic bypass
switchboard and the ER Module. The 800A MegaDySC module, the automatic
bypass switchboard and the ER Module must be mechanically interconnected
with the supplied hardware and each enclosure must be secured to the floor
(Refer to Mechanical Interconnection of Cabinets on page 17 and MegaDySC
Floor Mounting on page 19).

The cabinets should be brought tightly together and all interconnection bolts
should be installed and tightened before tightening the anchor bolt connections.

Mechanical Interconnection of Cabinets

To attach the 800 A MegaDySC module to the automatic bypass switchboard use
two sets of 3/8-16 [inch-thread/inch] hardware (this is the hardware that was
removed and saved during the pre-installation configuration). All hardware
should be installed from the automatic bypass switchboard side and threaded into
the PEM nuts located in the 800A MegaDySC module. Each hardware
connection set consists of one 3/8-16 x 1.0 in. bolt, one 3/8 in. split lock washer,
and one 3/8 in. flat washer assembled as shown in Figure 6 and Figure 7. Tighten
each bolt to 20 N•m [180 in•lb]. The required wrench size is 9/16 in.
(14.3 mm).

To attach the MegaDySC cabinet to the ER storage cabinet in the SBS layout,
install the two 3/8-16 interconnection bolts along the front of the cabinets, as
shown in detail B of Figure 6. Tighten each bolt to 20 N•m[180 in-lb].

To attach the 800A MegaDySC Module to the ER Module in the BTB layout,
remove the tie plate from the top of the ER cabinet, discard the sheet of padding
material, and install the tie plate between the two cabinets using four sets of 1/4-
20 [inch-threads/inch] screws as shown in Figure 6 on page 18. Tighten each
screw to 6.7 N•m [60 in-lb]. The screw heads are Phillips head.

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 17

Chapter 2 Installation

Finally, after all interconnection hardware is installed; tighten the anchor bolt
connections to the torque specified by the anchor manufacturer.

Figure 6 - Mechanical Interconnections Between 800A MegaDySC Module, Automatic Bypass

Switchboard, and ER Module for SBS Layout

DETAIL B
SCALE 1 : 8

DETAIL A
SCALE 1 : 8

18 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Installation Chapter 2

Figure 7 - Mechanical Interconnections Between 800A MegaDySC Module, Automatic Bypass

Switchboard, and ER Module for BTB Layout

MegaDySC Floor Mounting

The MegaDySC system is floor-mounted, and should be secured using the

0.63 in. (15.9 mm) diameter mounting holes provided along the bottom
channels. The system should be secured to the floor in the locations indicated in
Figure 8, Figure 9, and Figure 10 on page 20.

The minimum number of anchor bolts is 10 for SR systems and 14 for ER

systems:
• Automatic Bypass Switchboard: 4 places (one in each corner)
• 800 A MegaDySC Module: 6 places (one in each corner and one in each
end of the middle rail)
• ER Module: 4 places (one in each corner)

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 19

Chapter 2 Installation

Figure 8 - Floor Mounting Detail – SR System

 Required Anchor Locations

; 

  

  


  

  

  

  

  

 

  

  

  

  

  

  

  





















Figure 9 - Floor Mounting Detail – ER System SBS Layout

 Required Anchor Locations
; 


  

  


  

  

  
  

  

  

 

  

  

  

  

  

  



























 

 
 

 
Figure 10 - Floor Mounting Detail – ER System BTB Layout












 

 

 

 

 

Required Anchor Locations


; 


  

  


  

  

  

  

  
  

  

  

 

  

  

  

  

  

  




















20 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Installation Chapter 2

Electrical Interconnections
WARNING: Equipment must be earth-grounded according to local and
national electric codes. Failure to supply proper equipment grounding may
result in electrical shock or death.

The 800A MegaDySC Module is shipped separately from the automatic bypass
switchboard and the ER Module. The customer is responsible for system
mounting and electrical supply and load connections. All interconnecting bus
bars and power cables are provided and will be connected by a factory-trained
technician during commissioning. At commissioning the bus links will be
connected between the automatic bypass switchboard and the 800A MegaDySC
Module. A control wiring cable is also provided in the automatic bypass
switchboard and must be connected to the 800A MegaDySC Module. This
control cable is routed through two large holes, one in the automatic bypass
switchboard and one in the 800A MegaDySC Module, located at the bottom
front of the enclosures. The cable is plugged into the associated terminal block
located in the lower, left corner of the 800A MegaDySC Module. In ER systems,
two other cable harnesses are routed between the 800A MegaDySC Module and
the ER Module.

Electrical Supply and Load Electrical termination hardware is supplied with each system. One box contains
all needed hardware for one system installation. The box is labeled:
Connections
MEGA DySC SE
CUSTOMER CONNECT HARDWARE KIT

The incoming 3-phase electrical service and outgoing load cables enter through
the top of the switchboard enclosure and connect to the appropriate bus
locations. To access the main electrical terminals:

1. Remove the CABLE ENTRY PLATE on the top of the switchboard

(Refer to Figure 1, Figure 2, or Figure 3)
2. Open the two right side doors of the switchboard
3. Remove the dead front panel covering the circuit breakers (4 screws)
(Refer to Figure 11). Remove the transparent shield

The cable entry plate may be fitted for conduit or cable ladder as needed. The
other top panels may also be removed if needed. All panels must be replaced after
installation. Locations of the main electrical terminals are shown in Figure 12 and
Figure 13.

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 21

Chapter 2 Installation

Figure 11 - Switchboard Covers

Figure 12 - Main Power Terminals (front view)

22 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Installation Chapter 2

Figure 13 - Automatic Bypass Switchboard Terminations and Conduit Landing Areas

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Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 23

Chapter 2 Installation

MegaDySC System Installation Connections Checklist

• Connect the automatic bypass switchboard ground bus to an earth ground
in accordance with the National Electrical Code and local codes.
• Connect the AC input (line) conductors to the terminals labeled “R in”,
“S in”, and “T in”. The set is labeled “UTILITY INPUT”. See Figure 13
• Connect the AC output (load) conductors to the terminals labeled “R
out”, “S out” and “T out”. The set is labeled “PROTECTED LOAD”. See
Figure 13.
• For 4-wire models only: connect input and output Neutral (N) conductors
to the NEUTRAL bus bar. The input N connection is required for proper
operation of 4-wire models.
• Check all electrical terminations for properly torqued connections.
• For i-Sense and MegaDySC communication: connect an Ethernet cable to
the Ethernet switch located in the upper left compartment of the
automatic bypass switchboard. Refer to Chapter 3 - Communication on
page 25 for details.
• For remote status indication via dry contacts, connect to the “TB1”
terminal block located in the upper left compartment of the automatic
bypass switchboard. Refer to Chapter 3 - Communication on page 25 for
details.

24 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Chapter 3
Communication
Communication connections enter through the top of the switchboard enclosure
marked CUSTOMER I/O PLATE in Figure 1, Figure 2, or Figure 3. This plate
can be fitted as needed for conduit entry. Communication terminals are
described on the following pages. The ports are at the top of the left automatic
bypass switchboard and are shown in Figure 14. Use RJ45 port number 5 for the
communication connection.

Figure 14 - Customer I/O Terminals

Remote Diagnostics Customer-accessible dry contact-closures are available for relaying the state of the
circuit breakers and the state of the MegaDySC system. Connect to terminal
(TB1 Customer Contacts) block TB1 at the top of the left compartment of the automatic bypass
switchboard. See Figure 15 for connection details. The contact ratings are: 10 A
@ 240V AC resistive, 7 A @ 240V AC inductive, 10 A @ 28V DC resistive, and
8 A @ 24V DC inductive.

Figure 15 - Schematic of Customer Dry Contacts

• CBB Closed (CR3A) – Contact is closed when the bypass circuit breaker
(CBB) is closed. Contact is open when CBB is open.
• CBI Closed (CR4A) - Contact is closed when the input circuit breaker
(CBI) is closed. Contact is open when CBI is open.

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Chapter 3 Communication

• CBO Closed (CR5A) - Contact is closed when the output circuit breaker
(CBO) is closed. Contact is open when CBO is open.
• DySC Alarm (CR7A) – Contact is closed when there is an active alarm on
the MegaDySC system. Contact is open when there is no alarm on the
MegaDySC system.

Modbus TCP/IP The MegaDySC system status and other items are communicated over a Modbus
TCP/IP connection. This can be accessed through RJ45 port number 5 on the
Communication Ethernet switch in the automatic bypass switchboard. Contact
Rockwell Automation technical support for protocol details.

A six-channel i-Sense voltage monitor is mounted on the Bypass Switchboard.

i-Sense® Voltage Monitor The i-Sense continuously monitors both the 3-phase input voltage and the 3-
phase output voltage 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, the i-Sense monitors Line-Neutral
voltage.

The i-Sense requires communication over the Internet. The i-Sense should be
connected through RJ45 port number 5 on the Ethernet switch in the automatic
bypass switchboard.

See Rockwell Automation publication 1608S-UM001 for more information.

26 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Chapter 4
Applying Power

ATTENTION: The MegaDySC® system must be commissioned by factory-trained

engineers. Do not energize the MegaDySC until instructed to do so by
commissioning engineers. If the Automatic Bypass switchboard must be
installed and energized before commissioning, contact Rockwell Automation
technical support.

• After installation, make certain there are no metal filings or any conductive
debris in or on any components inside the cabinets.
• Verify MegaDySC system voltage rating matches AC source voltage.
• Verify all input and output terminations including grounding have been
completed and properly tightened.
• Replace all covers. Close and lock all cabinet and switchboard doors.
• Allow commissioning technicians to complete connections and initial
checks
• Apply power from the upstream branch protection device when instructed
to do so by the commissioning technicians.
• After commissioning, follow instructions on the Automatic Bypass
switchboard to put the system into Normal mode. The load is now being
monitored by the MegaDySC system. The display should show “OK” in
the upper left corner.

WARNING: The MegaDySC and (optional) ER cabinets are interlocked. Opening

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 MegaDySC Operation on page 29.

IMPORTANT • Cycling input power in the sequence OFF--ON--OFF--ON within a one

minute period will cause a “Limit Cycle Timeout” alarm. In this case, the
sag correction will be disabled for one minute, after which the alarm will
automatically reset.
• Push button “Close CBI” is disabled for two minutes after CBI is opened for
any reason.

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Chapter 4 Applying Power

Notes:

28 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Chapter 5
Operation

System Description Raw utility power enters and routes through the Automatic Bypass switchboard
to the load. In maintenance bypass mode the power bypasses the MegaDySC®
cabinet and passes directly to the load. In this mode the load is unprotected from
voltage sags. In the Normal operation mode the MegaDySC cabinet is energized
and the power is directed through the MegaDySC, protecting the load. See the
following sections for MegaDySC and Automatic Bypass operation details.

IMPORTANT Operation in Normal Mode requires that the maintenance bypass circuit
breaker (CBB) be open (OFF)—otherwise CBB will short the sag correction
inverter and prevent sag correction.

MegaDySC Operation The MegaDySC section contains three power electronics modules (one module
per phase) and controls that continuously monitor the line voltage. The 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 within normal range the AC static switch components remain closed
and no compensating voltage is added. When an insufficient line voltage event
occurs, the static switches open and the sag-correcting electronics quickly add the
balance of voltage necessary to regulate the load voltage.

The MegaDySC accepts line input power over 3 wires into terminals Rin, Sin, Tin
and provides sag compensated three-phase output power at terminals Rout, Sout,
and Tout when not in the Maintenance Bypass mode. In 4-wire systems the input
Neutral is connected directly to the output Neutral terminal.

Thermal switches are included to activate fans if the cabinet temperature or other
internal temperatures exceed set limits.

A 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 -13% to +10% of nominal.

A red “FAULT” box is displayed in the upper left-hand corner of the display
when a fault condition is present on the MegaDySC. During this period, sag
correction is disabled and the MegaDySC will continue to bypass the utility
voltage directly to the load through the static bypass path.

An orange “FAULT OVER” box is displayed when the previous fault condition
has cleared. Sag correction will remain inhibited until the reset period expired
(approximately 1 minute). A blue “SYSTEM OFFLINE” box is displayed

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Chapter 5 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 1. Refer to Chapter 6 for

further information on system alarms and status display.

Table 1 - Operational Conditions and Indications

Condition Definition Touch Screen Display STATUS text* Inverter Operation Bypass Mode

Normal: 88.5% < V LINE < 110% Green “OK” Standby Static BP

V LINE < 88.5% for less than available

Sag Event: Green “OK” Running Inverter
Runtime.
Blinks Red, then Orange for 1 min. Repeats
Runtime Exceeded: Cumulative Runtime exceeded Inhibited Static BP
is condition persists
Red during OL condition,
Normal Mode, Overload: Load current > 110% Inhibited Static BP
Orange for 1 min. after OL ends
Inverter Run Mode, Output Blinks Red, then Orange for 1 min. Repeats
Load current > 150% for 3 cycles Inhibited Static BP
Overcurrent: (I2t) is condition persists
Inverter Module Over- Module temperature limit exceeded Blue, MegaDySC offline Disconnected Mech. Bypass
temperature

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 Open Fuse(s) Blue, MegaDySC offline Disconnected Mech. Bypass

Enclosure Door Open Door Open Blue, MegaDySC offline Disconnected Mech. Bypass

* The Touch Screen 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). Under normal
Switchboard Operation operating conditions raw input power is routed through CBI to the input of the
MegaDySC. The output of the MegaDySC is routed to the load through CBO.
CBB is normally open. CBB connects utility power to the load, bypassing the
MegaDySC, when operating in the maintenance bypass mode.

Refer to page 31 for descriptions of the automatic bypass modes

WARNING: Dangerous voltages can still exist within the MegaDySC enclosure
even if the system is in bypass mode. Refer servicing to qualified personnel.

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 Operation Chapter 5

ATTENTION: Follow these instructions to avoid interrupting load power!

Contact the factory immediately if the system fails to operate as outlined below.
Voltage sag protection is not available whenever CBB is closed (red lamp
lighted)

Automatic Bypass Automatic System

Switchboard Operating
Bypass (CBB) will close in the event of a fault in the MegaDySC system. System
Instructions will remain in bypass until manually transferred to back to the MegaDySC. If
CBB trips due to an over current condition, press reset button on CBB. CBB will
automatically close!

Manual Transfer to Maintenance Bypass

1. Press green “CLOSE CBB” push button

2. Confirm that red “BYPASS CLOSED” lamp is lit.
3. Press red “OPEN CBI” push button. Output breaker (CBO) will open
automatically.
4. Confirm that both CBI and CBO are open.
5. The MegaDySC system is now bypassed and isolated for maintenance.

Manual Transfer to MegaDySC System

1. Confirm green “READY TO CLOSE CBI” lamp is on.

IMPORTANT Close CBI is inhibited for 2 minutes after power cycling.

2. Manually close breaker CBI.

3. Confirm that the MegaDySC touch screen is lit, is green and displays
“OK” in the upper left corner.
4. Manually close breaker CBO.
5. Confirm that the screen on the MegaDySC displays “OK”.
6. Press red “OPEN CBB” push button.
7. The MegaDySC system is now providing power to the load.

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Chapter 5 Operation

Figure 16 - Schematic diagram of Automatic Bypass Switchboard Power Circuit

Transient Voltage Surge Over voltage transient protection is provided on the output of the MegaDySC
system. Indicator lights for each phase on the front of the TVSS panel (upper left
Suppressor (TVSS) compartment of the automatic bypass switchboard) 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 (F14-F15-F16-F17) may be opened to allow servicing of
the TVSS module. Refer servicing to qualified personnel.

Troubleshooting 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 opening the enclosure door for servicing.

WARNING: This enclosure contains energy storage devices. Dangerous voltages

may exist within this enclosure after AC power has been removed. Do not touch
any components within the enclosure if the red status indicators located above
capacitor banks are lighted. If the red status indicators do not extinguish within
5 minutes, close the enclosure door and contact Technical Support.

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 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 touch screen 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 1 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 30 or the placard on the bypass
switchboard for instructions on transferring the system into and out of bypass
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
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.

The MegaDySC section contains semiconductor fuses rated at 1600 A. These

fuses provide short circuit protection for the MegaDySC modules. In the event
of a short circuit, this fuse will clear and trigger an automatic transfer to
mechanical bypass mode.

In addition, each module has an electronic current limit function that will

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 33

Chapter 5 Operation

protect the inverter module from peak over currents during sag protection
operation.

IMPORTANT In the event of the operation of any over current protection function, check the
touch screen display on the MegaDySC for error codes that may indicate the
type of over current condition.

ATTENTION: Circuit Breaker settings must not be changed without consulting

Technical Support.

Each of CBB, CBI, CBO contains an electronic trip unit with adjustable trip
settings. Refer to label on the Automatic Bypass Switchboard for circuit breaker
factory settings.

Diagnostic Indicators

Diagnostic indicators available on the MegaDySC system:

• Touch screen display on the door of the MegaDySC enclosure.
• Red lamp on Bypass enclosure indicates mechanical bypass is closed
when lit.
• Circuit breaker status (OPEN or CLOSED)
• Remote contacts and Modbus TCP/IP port

IMPORTANT Record any Alarm or System Event messages seen on the display before
contacting Technical Support.

Open circuit alarm conditions:

• Open static switch (failure in static switch path)
• Open main input fuse (F1-F2-F3-F4-F5-F6)
• Overload of static switch (may cause over-current trip in CBI; see
Specifications)
• Over-temperature of static switch heatsink
• Over temperature of MegaDySC cabinet ambient air
• Open cabinet door

IMPORTANT Alarm types 1, 2, and 3 may result in momentary interruption of power to the
load before transferring to mechanical bypass. Types 4 through 6 will result in a
seamless transfer to mechanical maintenance bypass, without interruption.

34 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Operation Chapter 5

Notes:

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 35

Chapter 5 Operation

36 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Chapter 6
Display Screen
Overview The MegaDySC® touch screen display is a window to voltage sags and
MegaDySC 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 MegaDySC
product logo appears. This screen disappears after 5 seconds, when the “Home”
screen appears.

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 17 - Home Screen

at the bottom of the “HOME” screen
(See Figure 17).

Step 2: Begin calibration by pressing Figure 18 - System Configuration

“CALIBRATE TOUCH SENSOR”
(See Figure 18).

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Chapter 6 Display Screen

IMPORTANT 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.

Step 3: The “Touch Screen Figure 19 - Touch Screen Calibration

Calibration” screen will then appear
(See Figure 19). Press and hold on the
center of the touch target, release when
the touch target begins to flash. Repeat
with the next two touch targets.

Step 4: The screen uses the new

calibration configuration. You can test
the calibration before 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.

Figure 20 - Set System Date and Time

Step 5: Set date and time by pressing
“SET SYSTEM CLOCK” in “System
Configuration.” Press “SAVE” when
completed.

Home Screen The “HOME” screen of the display provides a snapshot view of the status of the
entire system (See Figure 21). 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 inTable 2.

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 Display Screen Chapter 6

Figure 21 - Home Screen

Table 2 - Home Screen Description

Description Function
Real-time system operation: available runtime, output line-to-neutral (L-N) or line-to-line (L-L)
Status voltage (model dependent), load current, and frequency
Last Voltage Rotating information about the last voltage sag: event start time, event duration, and sag depth
Sag
Summary view of MegaDySC performance based on sags detected, plus a rotating display of last
Statistics power-up date, elapsed time (since power up), and total up-time
The menu buttons at the bottom of the screen
navigate through: STATUS: Displays the “System Status”
screen
Main Menu VOLTAGE SAGS: Displays the “Voltage Sag Log”
screen SYSTEM EVENTS: Displays the “System
Event Log” screen
CONFIG: Displays the “System Configuration” screen

Mechanical Bypass

Some systems equipped with a mechanical bypass display the bypass status in the
System Status panel on the Home Screen. When the mechanical bypass is closed,
the DySC unit is bypassed and voltage sags on the line will NOT be corrected.

Figure 22 - Home Screen Mechanical Bypass

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Chapter 6 Display Screen

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 23 - System Status Summary Figure 24 - - System Status Waveforms

Table 3 - System Status Description

Description Function
Overall system status including current operational status, availability to correct sags, and
System Status internal cabinet temperature
Voltage, current, frequency, and static switch temperature are displayed for all phases. The
Phase Status percentage displayed following the voltage and current is the percent of nominal value for the
MegaDySC. Nominal values are listed on the “View Model Information” screen.
A sample of a 4 cycle waveform that includes real-time line voltage, load voltage, or load current
Waveforms can be selected for display

Mechanical Bypass

Some systems equipped with a mechanical bypass will display the bypass status in
the System Status panel on the Status Screen. When the mechanical bypass is
closed, the DySC unit is bypassed and voltage sags on the line will NOT be
corrected.

Figure 25 - Status Screen Bypass Status

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 Display Screen Chapter 6

Voltage Sag Events 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
MegaDySC protection are captured and saved to the voltage sag log.

Voltage Sag Log

The “Voltage Sag Log” screen (See Figure 26) displays a list of the last 61 voltage
sags. Reach this screen by pressing “VOLTAGE SAGS” button on the “HOME”
screen.

Figure 26 - Voltage Sag Log

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 MegaDySC 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

Voltage Sag Detail

Voltage Sag Detail” screen (See Figure 27) 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.

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Chapter 6 Display Screen

Table 5 describes the remaining screen content.

Figure 27 - Voltage Sag Detail

Table 5 - Voltage Sag Detail Description

Description Function

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
Sag 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

Line Voltage: Line RMS voltage and percent of rated (L-N). Voltages ≤ 80% of nominal are
Sag Magnitude displayed in red.
Load Voltage: Load RMS voltage and percent of nominal (L-N).

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 MegaDySC performed correcting
the voltage sag. The possible values are:

Protected: The output RMS voltage on all phases is ≥ 85 percent of nominal and the
Correction Result MegaDySC 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 MegaDySC 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.

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 Display Screen Chapter 6

Voltage Sag RMS Voltage Charts

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 28). Reach this screen by pressing “CHARTS” on the “Voltage Sag
Detail” screen as shown in Figure 27 on page 42.

Figure 28 - RMS Voltage Charts

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.

Voltage Sag Notification

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 29.

Figure 29 - Voltage Sag Detected

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Chapter 6 Display Screen

System Events The MegaDySC tracks all operational events which are classified into five groups
based on severity.

Table 6 - System Event Description

Description Function

Informational Purely informational. No action is required.

Auto-Resetting The MegaDySC will reset within 60 seconds. No user action is required.

User action may be required to correct a problem. The MegaDySC will reset 60
User Attention seconds after the error condition is corrected.
For system events that cause circuit breaker CBI to open a manual reset of the
Manual-Reset DySC system will be required.
For events classified as Call Service, factory trained service support will be
Call Service required. Contact Rockwell Automation technical support.

System Event Log

The “System Event Log” screen displays a list of the last 40 system events in
chronological order (See Figure 30). Reach this screen by pressing “SYSTEM
EVENTS” on the “HOME” screen.

Figure 30 - System Event Log

Table 7 - System Event Log Description

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.

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 Display Screen Chapter 6

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 30 on page 44). It provides detailed information that was
recorded during the event (See Figure 31).

Figure 31 - System Event Detail

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 see Table 10 on page 50
Severity: Severity of the event
Description: Name of the event see Table 10 on page 50

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.).
Component
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.

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 45

Chapter 6 Display Screen

System Event Notification

When the MegaDySC system first detects an event condition, the “System Fault
Detection” dialog box will be displayed (See Figure 32). Within the “System
Fault Detection” box, the name, severity, and location of the event will be
displayed.

Figure 32 - System Fault Detection

Pressing the “OK” button will open the “System Event Detail” screen. The event
will appear in the event list after the event is over. The window can be closed by
pressing the “CANCEL” button or waiting 15 seconds.
When the event condition clears, a new dialog box will be displayed. Press “OK”
to view the complete event detail, or “CANCEL” to close the dialog box (See
Figure 33).

Figure 33 - System Fault Detection - Cleared

If a “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.

46 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Display Screen Chapter 6

System Configuration
Press the “CONFIG” button at the bottom of the “HOME” screen to enter the
“System Configuration” screen (See Figure 34). The “SET SYSTEM CLOCK”
and “CALIBRATE TOUCH SENSOR” functions are described at the start of
this chapter.

Figure 34 - System Configuration

Model Information
Touch “VIEW MODEL INFORMATION” to go to the “Model Information”
screen. (See Figure 35).

Figure 35 - Model Information

Table 9 - Model Information

Description Function
Model 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.
Unit Details
Serial: The serial number for the location indexed
Volts: The rated voltage for the locations
Amps: The rated current for the location indexed

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 47

Chapter 6 Display Screen

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 36).

Figure 36 - System Tests

Diagnostics Mode
This is not a user function. It is numerical code protected for authorized service
personnel.

48 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Chapter 7
Maintenance

Preventative Maintenance The MegaDySC system requires very little preventative maintenance. Check the
system periodically for proper air flow and status indicator operation.

Monthly Checks
• Check that the touch screen display is working and no active events are
displayed.
• Verify that the bypass switch is in the NORMAL mode.
• Update system time, if needed, Figure 20 on page 38.
• 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.
• Verify 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
front side of the MegaDySC, and can be accessed with the door closed.
The MegaDySC need not have power removed for this operation.
Remove grill covers by unscrewing the thumb screw on the left side and
sliding the filter retainer up; the washable foam filter pads are behind
the grill cover. Gently wash the foam filter pads as needed with a light
non-abrasive soap and water mixture. Towel-dry; do not wring-out.
Place the filter and grill cover back into their location and replace the
screw caps by rotating clockwise until finger tight. Replace filter if
damaged. Consult Rockwell Automation technical support for
replacement filters. Replacement filters must be no more restrictive to
air flow than the original equipment filters.

• Check fan for proper operation.

– Tap on “CONFIG” on the touch screen display. Tap on “Run System

Test”. This will bring up a “System Test” screen to test the fans. After
tapping the “Fan Test” button, you should hear the fans run for two
minutes.

Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 49

 Chapter 7 Maintenance
Table 10 - System Event 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.
Start acknowledgment of DySC 0.5 cycle inverter
5 T_IN_ST_1 Inverter Test (.5 cycles) Start Informational Unit No action needed.
test.
Start acknowledgment of DySC 3 cycle inverter
6 T_IN_ST_2 Inverter Test (3 cycles) Start Informational Unit No action needed.
test.
7 T_IN_ST_3 Inverter Test (5.5 seconds) Start Informational Unit Start acknowledgment of DySC 5.5 second No action needed.
inverter test.
9 EXTERNAL External Inhibit Auto-Resetting Inverter Controller is inhibited by another phase controller. Review event details from other phase controllers.

11 RUN_TO Inverter Run Timeout Auto-Resetting Inverter DySC inverter had a total cumulative runtime of No action needed.
more than rated.
12 LIM_CYCLE Inverter Limit Cycle Timeout Auto-Resetting Inverter
Power was re-applied more than once within a 58 No action needed.
second period.
Verify ambient temperature is within DySC
Static Static switch heatsink temperature was greater
13 STAT_OT Static Switch Over-Temperature User Attention specification. Check for damaged fans. Check for dirty
Switch than maximum rating.
or obstructed air filters.
Inverter inhibited because load current exceeded Reduce load. In parallel DySC systems, verify proper
14 OVERLOAD Overload User Attention Unit
maximum rating. current sharing among slave cabinets.
Positive or negative half of DC bus voltage Verify line voltage is within ratings. Verify proper DySC
15 DC_OV DC Bus Over-Voltage User Attention Inverter
exceeded maximum rating. application. Call service.
Verify DySC is online and line voltage is within ratings.
16 CNTRL_UV Controller Power Under-Voltage User Attention Inverter DySC control power supply is out of tolerance.
Call service.
DySC output voltage was less than 80% of Verify line voltage is within ratings. Verify proper DySC
17 OUTPUT_UV Output Under-Voltage User Attention Inverter nominal during sag correction. Sag condition
application.
likely outside of DySC specification.
Inverter current exceeded maximum rating during Verify load current is within ratings. Verify mechanical
18 INV_OC Inverter Over-Current User Attention Inverter sag correction. bypass switch is open. Verify proper DySC application.
19 DC_UV DC Bus Under-Voltage User Attention Inverter DC bus voltage below operational range. Verify line voltage is within ratings. Call service.
DySC output voltage was greater than 115% of
20 OUTPUT_OV Output Over-Voltage Call Service Inverter Call service.
nominal during sag correction.
IGBT pack reported error. Possible sag condition Verify line voltage is within ratings. Verify proper DySC
22 IGBT IGBT Pack User Attention Inverter
outside of DySC specification. application. Call Service.
Inverter not synchronized to line when sag
25 SYNC_ERR Line Synchronization Error Call Service Inverter Call service.
detected.
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.

50 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

Chapter 7 Maintenance

Event Code Code Name Full Name Severity Area Event Description Event Resolution
Positive and negative halves of the DC bus did not
33 UNBALANCE Start-Up Test: DC Bus Unbalance Call Service Inverter Call service.
charge equally during power up.
Output voltage was detected out of tolerance
34 AC_V_CHK Start-Up Test: AC Voltage Check Call Service Inverter Call service.
during the start-up test.
Controller communication problem detected
35 ROLL_CALL Start-Up Test: Controller Roll Call Timeout Call Service Unit during start-up test. Call service.

36 COM_VER Start-Up Test: Communication Call Service Unit Firmware communication compatibility problem Call service.
Compatibility Mismatch detected during start-up test.
37 CNFG_TO Start-Up Test: Controller Configuration Call Service Unit Controller communication problem detected Call service.
Timeout during start-up test.
Start-Up Test: Controller Configuration Controller firmware configuration problem
38 CNFG_ERR Mismatch Call Service Unit detected during start-up test. Call service.
Start-Up Test: Controller Firmware Check Controller communication problem detected
39 FIRM_TO Timeout Call Service Unit during start-up test. Call service.
Start-Up Test: Controller Firmware Controller firmware revision mismatch detected
40 FIRM_DIFF Call Service Unit Call service.
Revision Mismatch during start-up test.
41 SRL_TO Start-Up Test: Controller Serial Number Call Service Unit Controller communication problem detected Call service.
Check Timeout during start-up test.
42 SRL_DIFF Start-Up Test: Serial Number Mismatch Informational Unit Controller serial number mismatch detected No action needed.
during start-up test.
Phase control board failed to respond to Comm
44 T_INV_TO Inverter Test Timeout Call Service Unit board's Inverter test. Call service.
DySC door was opened. Mechanical bypass
46 DOOR_OPEN DySC Cabinet Door Open Manual Reset Unit Close door. Manually reset DySC.
commanded.
Verify ambient temperature is within DySC
Internal DySC temperature exceeded maximum
47 CRIT_OT Critical Over-Temperature Manual Reset Unit rating. Mechanical bypass commanded. specification. Check for damaged fans. Check for dirty
or obstructed air filters. Manually reset DySC.
One of the DySC fuses was detected open.
48 FUSE_OPEN Fuse Open Call Service Unit Call service.
Mechanical bypass commanded.
Static The SCR on the phase A module was detected
49 OPEN_SCR_A Open SCR Phase A Call Service Call service.
Switch open.
Static The SCR on the phase B module was detected
50 OPEN_SCR_B Open SCR Phase B Call Service Call service.
Switch open.
Static The SCR on the phase C module was detected
51 OPEN_SCR_C Open SCR Phase C Call Service Call service.
Switch open.
52 EXT_MB External Mechanical Bypass Command Manual Reset Unit The DySC was externally commanded to transfer Manually reset DySC.
to mechanical bypass.
A problem was detected with the DySC dynamic
53 DYN_BRAKE Dynamic Brake Error Call Service Unit Call service.
brake controller.
58 PLC_ERR Programmable Logic Controller Error Call Service PLC PLC error detected. Call service.

51 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

Chapter 7 Maintenance

Servicing

ATTENTION: Service must be performed by qualified personnel only.

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 Switchboard Operation on page 30

WARNING: The MegaDySC system and optional ER cabinets are interlocked.

Opening cabinet doors while in the “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.

Automatic Circuit Breakers, Safety Interlocks and Stored Energy

Figure 16 on page 32 shows the arrangement of circuit breakers CBI, CBO, and
CBB of the Automatic Bypass switchboard. If the 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 system 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 charged
capacitors. High voltage remains on capacitors if the red LED indicators above
the module capacitor banks are lighted.

Fuses 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.

52 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 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 door shows fuse locations. A similar label is located within
the optional ER storage cabinet. Fuse types are listed in Table 11. Before
replacing a cabinet fuse, factory authorized service personnel must transfer the
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.

WARNING: De-energize the electronics by placing the system into

Maintenance Bypass mode before opening the MegaDySC or ER cabinet doors
to replace any fuse.
WARNING: The system has high voltage remaining up to 30 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.
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.

IMPORTANT A qualified electrician must replace the fuses. Open the front cabinet door(s) to
access the fuse holders and fuses.
To maintain the protection of the MegaDySC system, 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-UM003B-EN-P - December 2015 53

Chapter 7 Maintenance

Table 11 - MegaDySC Fuse Schedule

Rockwell Automation
Fuse Reference Fuse Location Fuse Rating Manufacturer Part Number Cat. No.
F1, F2, F3, F4, F5, F6 Main Power Input 800A/500V Mersen A50QS800-4IL 43-00042
F7, F8, F9 Inverter Input 800A/500V Mersen A50QS800-4IL 43-00042
F10, F11, F12 Cross-Coupling Transformer 500A/600V Mersen AJT500 43-00204R
F13, F14, F15 Main Cabinet Series Injection Transformer 110A/600V Mersen AJT110 43-00114R
F16, F17 Input Control Transformer 2A/600V Mersen ATQR2 43-00030
F18 - F29 Dynamic Brake 25A/600V DC Mersen ATM25 43-00094
F30, F31 Output Control Transformer 8A/600V Mersen TR8R 43-00115R
F1, F2 Voltage Feedback 2A/600V Mersen ATQR2 43-00030
Power Module (x3)
F3 Inverter Output 400A/500V Mersen A50QS400-4IL 43-00062
F1, F2, F3, F4 ER Module (x9) 30A/500V DC Mersen A60Q30-2 43-00144R

54 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

 Chapter 8
Specifications
Table 12 - Technical Specifications 800A MegaDySC System
Electrical Input/Output (Normal Mode—Static Switch)
Connection Configuration Series-connected with load. Under normal line condition, the static switch passes utility
voltage directly to the load
Standard Input Voltage DySC 3-phase: 208V
Voltage Range ±10%
Static Bypass Current 800A-rms continuous, 110%-150% @ 60 s, 150%-300% @ 5 s, 300%-400% @ 0.5 s, 400%-
600% @ 0.05 s”
Frequency 50/60 Hz Auto Sensing
Frequency Range (tracking) 45 to 65 Hz
TVSS Output SPD, 80 kA/mode. Protects L-L & L-G on all models; L-N & N-G (4-wire models)
Efficiency > 98.5%
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 (<2 ms)
Output Voltage Pre-sag rms voltage
Voltage Regulation ±5% typical, +5% / -13% of nominal max
Output Current 800A-rms1
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 50 ms (SR) or 400 ms (ER). Based on nameplate ratings with a power factor of 0.7
remaining
Multiple Events
Max Sag Correction Time 5 seconds cumulative usage
Sequential Sag Recovery 0 seconds (assuming cumulative run-time available)
Full Recovery Time 5 minutes, max
Mechanical
Enclosure Ratings NEMA 1 (IP20)
Cable Entry Top of Switchboard section
Cooling Filtered Forced air
Access Front for servicing. Left or Rear access for 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
Rated current available to 1000 m (3300 ft). De-rate output current 10% per 1000 m, from
Altitude 1000 m to 3000 m (9900 ft).
Audible Noise < 70 dBA at 1 meter
1. When using MegaDySC with motor drive loads, either insert 3% to 5% line reactance at MegaDySC system output
or limit motor drive loads to 60% of MegaDySC system rating
Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015 55
Chapter 8 Specifications

Table 13 - Standards Compliance and Certifications

Standards and Certifications
Agency Approvals cULus Listed (UL 1012)
Standards Exceeds SEMI F47 Standard; IEEE Std C62.41.1 and UL 1449 3rd Ed. Compliant
Compliance

Table 14 - MegaDySC Heat Loading and Typical Efficiency

Rated Voltage SR/ER Heat Loss (W) Heat Loss (BTU/h) Efficiency

208V SR 3500 11900 > 98.5%

208V ER 3900 13300 > 98.5%

Table 15 - MegaDySC System Weight

MegaDySC Automatic Bypass Total System
3W/4W SR/ER ER weight
Weight Switchboard Weight Weight
3W SR 2400 lb [1089 kg] -- 1700 lb [771 kg] 4100 lb [1860 kg]

3W ER 2400 lb [1089 kg] 1580 lb [717 kg] 1700 lb [771 kg] 5680 lb [2577 kg]

4W SR 2400 lb [1089 kg] -- 1660 lb [753 kg] 4060 lb [1842 kg]

4W ER 2400 lb [1089 kg] 1580 lb [717 kg] 1660 lb [753 kg] 5640 lb [2559 kg]

56 Rockwell Automation Publication 1608M-UM003B-EN-P - December 2015

Rockwell Automation Support
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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.
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Publication 1608M-UM003B-EN-P - December 2015

Supersedes Publication 1608M-UM003A-EN-P - December 2013 Copyright © 2015 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.