IntelliVAC™ Contactor Control Module USER MANUAL (Series C and later) Bulletin 1503VC
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.
Table of Contents Product Description Chapter 1 Introduction ..........................................................................................1-1 Scope ...................................................................................................... 1-1 Description ........................................................................................... 1-1 IntelliVAC Features ..................................................................... 1-2 IntelliVAC Versions .....................
ii Table of Contents Setup and Commissioning Chapter 4 IntelliVAC Configuration .................................................................. 4-1 DIP Factory Default Settings (Table 4.A) ........................................ 4-2 IntelliVAC DIP Switch Explanation (Table 4.B) ............................ 4-2 Monitoring and Troubleshooting Chapter 5 Introduction ......................................................................................... 5-1 Module Status .............................
Chapter 1 Product Description Introduction This document contains information for the Allen-Bradley Bulletin 1503VC IntelliVAC™ control module. The Bulletin 1503VC is used to control the Allen-Bradley Bulletin 1502 vacuum contactors that are a significant component of the Bulletin 1500/1900 CENTERLINE Medium Voltage Motor Controllers offered by Rockwell Automation.
1-2 Product Description Figure 1.1 – IntelliVAC Contactor Control Module Description (cont.) External Capacitor (Optional) Coil Power Supply Current Regulator Control Power Supply C C IGBT Coil Switching Close Signal Contactor Coil(s) Interface Coil Current Transducer Input Power Conditioning Supply Voltage 110-240 VAC or 110-250 VDC Vacuum Contactor Trip Coil Command Inputs Open Signal Vacuum Contactor Auxiliary Micro Controller CC Aux.
Product Description 1-3 Power loss ride-through (TDUV) allows the vacuum contactor to remain closed during short power loss (may require an optional external capacitor, dependant on ride-through time) 1503-UM052D-EN-P – June 2013
1-4 Product Description IntelliVAC Features (cont.
Product Description Specifications 1-5 Mounting and Connections The IntelliVAC control modules are mounted using two (2) screws (see Figure 1.3). They are typically located in the low voltage control panel of the medium voltage controller (Bulletin 1500/1900 controllers, in the case of Rockwell Automation). IntelliVAC is interfaced to the Bulletin 1502 vacuum contactors using a “quick” connector, located at the module, a wire harness and “quick” connector at the contactor.
1-6 Product Description Table 1.A – Electrical Ratings Main Input Voltage (L1 to L2/N) AC – 110 to 240 V rms, +10/-15%, 47 to 63 Hz DC – 110 to 250 V, +10/-15% Contactor Ratings (Amps) Control Voltage (AC or DC) AC Rating DC Rating Inrush Current 400/800 120/240 25 A peak (1/2 cycle) 25 A peak Idle Current (Maximum without contactor coil energized) 400/800 120/240 125 mA 35 mA Hold Current ⊄ (maximum) 400/800 120/240 300 mA 100 mA 120 4.6 A 3.6 A 240 3.4 A 3.3 A 120 11.3 A 4.
1-7 Product Description Specifications (cont.) Table 1.B – Mechanical Ratings Operating: 0° to 60°C ambient at the control module Temperature Non-Operating: -40° to 85°C Altitude -1000 to 5000 meters Pollution Pollution level II (as defined by UL 840 and IEC 60664-1) Humidity 95% non-condensing Shock – 15 g peak, 11 milliseconds Shock and Vibration (Operational) Vibration – 10 to 57 Hz, 0.015 inch displacement peak to peak – 57 to 150 Hz, 2.
Chapter 2 Receiving and Storage Receiving Upon receiving the controller, remove the packing and check for damage that may have occurred during shipping. Report any damage immediately to the claims office of the carrier. NOTE: If the IntelliVAC module is an integral component of a complete MV controller (Bulletin 1500/1900), special receiving and handling instructions will apply. For details, refer to the service manual provided with the equipment.
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Chapter 3 Installation and Wiring General Precautions In addition to the precautions listed throughout this manual, the following statements, which are general to the system, must be read and understood. ATTENTION The controller contains ESD (electrostatic discharge) sensitive parts and assemblies. Static control precautions are required when installing testing, servicing, or repairing the assembly. Component damage may result if ESD control procedures are not followed.
3-2 Installation and Wiring ATTENTION Arrangements The Canadian Electrical Code (CEC), National Electrical Code (NEC), or other local codes outline provisions for safely installing electrical equipment. Installation MUST comply with specifications regarding wire type, conductor sizes, branch circuit protection, interlocking and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
Installation and Wiring 3-3 OEM The IntelliVAC may be ordered as an OEM component. This allows the OEM to mount the components in a configuration most suitable to the motor controller equipment layout. Care must be exercised to ensure the IntelliVAC has adequate ventilation provided around it. Refer to Figure 3.2 for mounting the IntelliVAC. It is recommended that a minimum of 1.5 inches (38.1mm) of free air space be provided between the IntelliVAC and any solid barrier above or below.
3-4 Installation and Wiring Minimum top clearance 38.1 (1.50) Dimensions in mm (inches) 38.1 (1.50) Minimum bottom clearance 6.4 (0.25) Additional Modules (as required) Figure 3.2 – Typical Mounting Configurations Note: Adjacent IntelliVAC modules may be mounted with a minimum separation of 6.4 mm (0.25 inches). Arrangements (cont.
Installation and Wiring 3-5 CONTROL POWER * CONTROL POWER FUSE M-INTELLIVAC 7 + OPEN 9 + OVERLOAD STOP CLOSE START 16 - - 10 CONTACTOR STATUS 15 14 MODULE STATUS CAPACITOR (OPTIONAL) M 8 13 1 EC 2 + TCO 11 AUX 12 CCO 4 3 6 5 MOV M CONFIGURATION DIP SWITCHES L1 * INPUT POWER G L2/N Refer to Table 3.A for recommended fuse sizing. Figure 3.
3-6 Installation and Wiring Fuse Protection The IntelliVAC module requires external fuse protection to coordinate with the power supply and contactor. The fuse ratings shown in Table 3.A allow the passage of inrush currents expected when the contactor is closed, or from recommended external capacitors for the TDUV option. They will also protect the contactor coils in the event of a module malfunction. The recommended fuses have been tested to ensure reliable protection of the module.
Installation and Wiring 3-7 1503-UM052D-EN-P – June 2013
3-8 Installation and Wiring Connections There are three green connectors on the IntelliVAC module for connections to the control circuitry. Connector plugs are provided with the module. If additional plugs are required, refer to Chapter 6, Spare parts. Control Power The IntelliVAC can accept either AC or DC control power. Refer to Table 1.A for acceptable input power and control signal ratings.
Installation and Wiring 3-9 1503-UM052D-EN-P – June 2013
3-10 Installation and Wiring Interface Connections All other control interface connections are made at a twelve-pole connector located on the top of the module. Refer to Figure 3.5 and Table 3.B for connections (and Table 1.A for electrical ratings). Refer to the Wiring Guidelines section in this chapter for guidance in making connections to the control circuit. 1 2 3 4 5 6 7 8 9 10 11 12 EX. CAP. CONTACTOR INTERFACE Figure 3.5 – Top side connections Table 3.
Installation and Wiring Wiring Guidelines Electrically Held Contactors 3-11 The IntelliVAC can be applied with two- or three-wire control circuits. The control system utilized will determine the configuration of the input wiring. Consider the following input and output for the type of control used: • Terminals 9 and 10 • Terminals 15 and 16 – – Close Contactor Contactor Status In either case, the CLOSE input must receive a maintained voltage high to keep the contactor closed. Note: 1.
3-12 Installation and Wiring Control with Solid-State Devices If control devices that employ electronic or suppressed output circuits are used in the rung(s) that control the inputs to the IntelliVAC, alternate arrangements may be required. Devices employing transistor or triac output circuits have finite impedance and allow a leakage current to flow in the blocking or off state.
Installation and Wiring Wiring Guidelines Electrically Held Contactors (cont.) 3-13 Two-Wire Control If using two-wire control, the CLOSE contactor input is maintained high using a single contact. Momentarily opening this input will cause the IntelliVAC to open the contactor. Maintaining the contact will provide a CLOSE command to IntelliVAC (given that all permissives are satisfied).
3-14 Installation and Wiring Figure 3.7 – Two-Wire Control Three-Wire Control If using three-wire control, the CLOSE contactor input is maintained high using two contacts. Momentarily opening this input will cause the IntelliVAC to open the contactor. Momentarily closing the START contact will provide a CLOSE command to IntelliVAC (given that all permissives are satisfied). In this configuration, the STATUS output acts as a seal-in contact.
3-15 Installation and Wiring Wiring Guidelines Electrically Held Contactors (cont.
3-16 Installation and Wiring Wiring Guidelines Mechanical Latch Contactors IntelliVAC control may be used for mechanical latch contactors. A momentary control signal is needed to close the contactor, and a second momentary control signal is needed to open the contactor. The momentary open/close commands must be at least 50 milliseconds in duration. Refer to Figure 3.10 for a typical mechanical latch control scheme. Note: 1.
3-17 Installation and Wiring Mechanical Latch Contactors Capacitor Trip The IntelliVAC can be configured to provide capacitor trip functionality with mechanical latch contactors. A capacitor must be connected to the IntelliVAC (terminals #1 and #2) in order to provide this capability. The capacitor provides control power for the IntelliVAC as well as stored energy to trip the contactor. Maximum recommended capacitor size is 1650 µF for 120V control or 330 µF for 240V control.
3-18 Installation and Wiring CONTROL POWER * CONTROL POWER FUSE OPEN M-IV OVERLOAD 7 + - 8 OPEN M MOV M-IV CAPACITOR 1 EC 2 + 4 3 TCO MOV M 11 AUX 12 L1 OVERLOAD CLOSE * Refer to Table 3.A for recommended fuse sizing. TC CCO G 6 5 CC L2/N M-IV 9 + - 10 CLOSE Figure 3.
Installation and Wiring Motor Jogging Control 3-19 Note: Jog functionality can work with electrically held contactor only. When used with electrically held contactors, the IntelliVAC allows close commands every six seconds. This is to ensure the rated contactor duty cycle of 600 operations per hour is not exceeded. For motor jogging operations, the second control input, or OPEN command, will close the contactor for as long as the input is present, and open the contactor when the input is removed.
3-20 Installation and Wiring Undervoltage Protection The IntelliVAC controller protects the contactor from control voltage dips and loss of power. It provides undervoltage release and prevents attempts to close the contactor when there is not sufficient power available to guarantee reliable closing of the contacts. The undervoltage protection will be initiated under the following conditions, regardless of nominal control voltage: 1.
Installation and Wiring 3-21 1503-UM052D-EN-P – June 2013
3-22 Installation and Wiring Time Delay Undervoltage (cont.) CONTROL POWER CAPACITOR M-IV 1 * CONTROL POWER FUSE - 2 + EC TCO 4 3 11 12 L1 OVERLOAD STOP AUX CCO G * Refer to Table 3.A for recommended fuse sizing. M 6 5 L2/N M-IV START M-IV 15 16 CONTACTOR STATUS Figure 3.
Chapter 4 Setup and Commissioning IntelliVAC Configuration The IntelliVAC module is configured for a specific application by setting DIP switches. They are accessed by loosening the two screws on the front of the unit, and removing the cover by sliding it forward. The switches are found on the front edge of the IntelliVAC circuit board (see Figure 4.1). There are 12 switches, with number 1 being at the top next to the mini DIN connector. (Refer to Table 4.B).
4-2 Setup and Commissioning An IntelliVAC unit shipped separately from the factory will have a default configuration per Table 4.A.
4-3 Setup and Commissioning Table 4.A – DIP Switch Factory Default Settings Description 1 2 3 Altitude: 0 – 1000m Drop-out time: 130 msec Contactor config.: 400A EH TDUV config.: No TDUV Ext. cap TDUV time: 0.2 sec Power-Up Safety: Enable 0 0 1 4 5 DIP switch 6 7 0 1 1 8 0 9 10 11 0 0 12 1 0 0 IntelliVAC units shipped in a complete MV controller (Bulletin 1500/1900) will be configured to suit the installed application (i.e. contactor type).
4-4 Setup and Commissioning By-pass contactors in MV SMC applications must be set for 50 millisecond drop-out time. Refer to Appendix A for typical drop-out time settings used when power fuses are provided by Rockwell Automation.
Chapter 5 Monitoring and Troubleshooting Introduction The IntelliVAC module has two light emitting diodes (LEDs) and relay outputs to indicate the status of the contactor and the module. The LEDs are visible on the front of the module and the relay outputs are accessed on the bottom front of the module. Figure 5.1 – IntelliVAC LEDs Note: Module Status This user manual contains information for both Series C and Series D IntelliVAC versions.
5-2 Monitoring and Troubleshooting Module Status (cont.) If the processor has an internal fault, the LED will be Red, the outputs will be cleared, and the processor must be reset (input power must be cycled). If the reset is successful, the LED will be Green and the module will respond to the control inputs. The input command must be toggled before the module will respond to a new command (rising edge triggered).
Monitoring and Troubleshooting 5-3 Table 5.
5-4 Monitoring and Troubleshooting Contactor Status (cont.) Table 5.
Monitoring and Troubleshooting 5-5 Table 5.C – Module Troubleshooting Problem or Trip Indicated Contactor does not energize Indication of the following conditions • • Motor Protection activated Both Status LEDs ‘Off’ Possible Solutions • • • • • • Module Status LED ‘Red’ upon power up • • Module Status ‘Red Flash 1’ upon power up • • Loose connection in control circuit. • • Contactor closes momentarily and will not reclose. • • Contactor fails to close.
5-6 Monitoring and Troubleshooting Contactor Status (cont.) Table 5.C – Module Troubleshooting (cont.) Problem or Trip Indicated Contactor opens during operation Indication of the following conditions Possible Solutions • • Motor Protection activated Stop command initiated • • Investigate and reset. Verify circuit • Module Status LED ‘Red’ (Series C) or ‘Yellow – Flashing’ (Series D) • Undervoltage fault (no TDUV), control voltage dipped below trip point.
Chapter 6 Spare Parts Spare Parts List IntelliVAC (electrically held) Series A 1503VC-BMC1 IntelliVAC (mechanical latch) Series A 1503VC-BMC2 IntelliVAC (electrically held and mechanical latch) Series B 1503VC-BMC3 IntelliVAC (electrically held and mechanical latch) Series C and D 1503VC-BMC4 Internal Fuse: 6.3 A, 250 V (Littlefuse 21506.
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Appendix A Typical Contactor Drop-out Time Settings The contactor drop-out time settings shown in the following table are typical minimum values used when the power fuses are provided as part of a complete MV controller from Rockwell Automation. The recommendations are based on Ferraz-Shawmut power fuses. Other fuse types may require alternate drop-out time settings. The IntelliVAC module DIP switches are set up to provide the minimum drop-out times shown (refer to Chapter 4). Table A.
A-2 Typical Contactor Drop-out Times Table A.1 – Typical Contactor Drop-out Time Settings (cont.) Fuse Rating ⊇ Contactor Drop-out Time Setting (msec) Voltage Designation < 5000 20E 30E 40E 50E 65E 80E 100E 125E 150E 175E 200E 250E 300E 350E 400E 450E 500E 600E 750E 900E 2 x 250E 2 x 300E 2 x 350E 2 x 400E 2 x 450E 2 x 500E 2 x 600E 2 x 750E 2 x 900E 400A 800A 50 50 75 100 130 240 240 * ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ 75 200 240 * 50 75 75 100 130 240 240 * ⊇ ⊇ Fuse not suitable for use with contactor.
Typical Contactor Drop-out Times A-3 Table A.1 – Typical Contactor Drop-out Time Settings (cont.) Fuse Rating Voltage 7200 8250 ⊇ Contactor Drop-out Time Setting (msec) Designation 2R 3R 4R 6R 9R 12R 18R 24R 32R 38R 48X 57X 2 x 18R 2 x 24R 2 x 32R 2 x 38R 2 x 48X 2 x 57X 10E 15E 20E 25E 30E 40E 50E 65E 80E 100E 125E 150E 175E 200E 400A 800A 50 50 75 150 240 * ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ ⊇ 75 150 200 50 130 240 * ⊇ ⊇ ⊇ 50 50 Fuse not suitable for use with contactor.
A-4 Typical Contactor Drop-out Times 1503-UM052D-EN-P – June 2013
Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb Publication 1503-UM052D-EN-P – June 2013 Supersedes Publication 1503-UM052C-EN-P – June 2007 Copyright © 2013 Rockwell Automation, Inc. All rights reserved. Printed in Canada.
