Rockwell Automation Allen-Bradley IntelliVAC User Manual
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Rockwell Automation Allen-Bradley IntelliVAC User Manual

Rockwell Automation Allen-Bradley IntelliVAC User Manual

Contactor control module
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IntelliVAC™
Contactor
Control Module
Bulletin 1503VC
User Manual

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Summary of Contents for Rockwell Automation Allen-Bradley IntelliVAC

  • Page 1 IntelliVAC™ Contactor Control Module Bulletin 1503VC User Manual...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of Contents Product Description Chapter 1 Introduction ................1-1 Description ................1-1 IntelliVAC Features ............1-2 IntelliVAC Versions ............1-3 Specifications ................1-4 Mounting and Connections ..........1-4 Configuration ..............1-4 Firmware ................1-4 Electrical Ratings (Table 1.A) .......... 1-5 Mechanical Ratings (Table 1.B) ........1-6 Altitude Derating (Table 1.C) ..........
  • Page 4 Table of Contents Setup and Commissioning Chapter 4 IntelliVAC Configuration ............4-1 Monitoring & Troubleshooting Chapter 5 Introduction ................5-1 Module Status ................. 5-1 Contactor Status ..............5-2 Series B Design ..............5-2 Spare Parts Chapter 6 Spare Parts List ............... 6-1 Optional Equipment ............

  • Page 5: Product Description

    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. An IntelliVAC control module may also be provided as a loose component, for application with a Bulletin 1502 contactor by a third party (OEM).

  • Page 6: Intellivac Features

    Product Description Description (cont.) Vacuum Contactor External Trip Coil Coil Capacitor Current Power (Optional) Regulator Supply Input Power Supply Conditioning Voltage Control 110-240 Power Supply Vacuum Contactor 110-250 Close Coil IGBT Coil Switching Close Signal Command Inputs Open Signal Vacuum Contactor Micro Controller Auxiliary Altitude...

  • Page 7: Intellivac Versions

    Product Description IntelliVAC Features (cont.) Anti-kiss and anti-pumping protection ensure that the vacuum contactor close – open sequence occurs as expected, avoiding rapid re-closure due to faulty control devices Delayed restart protects the vacuum contactor by ensuring that the rated duty cycle is not exceeded Temporary jog function (electrically held contactors only) allows the motor to be positioned for process set-up IntelliVAC Versions...

  • Page 8: Specifications

    (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”...
  • Page 9 Product Description Table 1.A – Electrical Ratings AC – 110 to 240 V rms, +10/-15%, 47 to 63 Hz Main Input Voltage (L1 to L2/N) DC – 110 to 250 V, +10/-15% Contactor Ratings Control Voltage Description AC Rating DC Rating (Amps) (AC or DC) 25 A peak...
  • Page 10 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 -1000 to 5000 meters Altitude Pollution level II (as defined by UL 840 and IEC 60664-1) Pollution Class II Humidity Shock –...

  • Page 11: Receiving And Storage

    Chapter 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.
  • Page 12 Receiving and Storage (This page is intentionally left blank.) 1503-UM051D-EN-P – June 2013...

  • Page 13: Installation And Wiring

    Chapter 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. The controller contains ESD (electrostatic A T T E N T I O N A T T E N T I O N discharge) sensitive parts and assemblies.

  • Page 14: Arrangements

    Installation and Wiring Arrangements The IntelliVAC is offered in two arrangements, Integral (part of a Bulletin 1500/1900 MV controller) or as an OEM component. Integral to an Allen-Bradley MV Controller The IntelliVAC is available as a primary component of an Allen- Bradley Bulletin 1500/1900 MV controller as shown in Figure 3.1.

  • Page 15: Oem

    Installation and Wiring 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.
  • Page 16 Installation and Wiring Arrangements (cont.) CONTROL POWER CONTROL POWER CONTROL CONTROL M-INTELLIVAC M-INTELLIVAC POWER POWER FUSE FUSE OPEN OPEN CLOSE CLOSE START START OVERLOAD OVERLOAD STOP STOP CONTACTOR CONTACTOR STATUS STATUS MODULE MODULE STATUS STATUS CAPACITOR CAPACITOR (OPTIONAL) (OPTIONAL) CONFIGURATION CONFIGURATION DIP SWITCHES DIP SWITCHES...
  • Page 17 Installation and Wiring CONTROL POWER CONTROL POWER M-INTELLIVAC M-INTELLIVAC CONTROL CONTROL POWER POWER OPEN OPEN FUSE FUSE CLOSE CLOSE START START OVERLOAD OVERLOAD STOP STOP CONTACTOR CONTACTOR STATUS STATUS MODULE MODULE STATUS STATUS CAPACITOR CAPACITOR (OPTIONAL) (OPTIONAL) CONFIGURATION CONFIGURATION DIP SWITCHES DIP SWITCHES INPUT POWER INPUT POWER...

  • Page 18: Fuse Protection

    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.

  • Page 19: Connections

    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.

  • Page 20: Interface Connections

    Installation and Wiring Connections (cont.) Interface Connections Ground Connection Ground Connection L2/N L2/N CONTACTOR STATUS OUTPUT (N.O.) CONTACTOR STATUS OUTPUT (N.O.) MODULE STATUS OUTPUT (N.O.) MODULE STATUS OUTPUT (N.O.) POWER INPUT POWER INPUT Figure 3.6 – Bottom side connections (Series B) Interface Connections All other control interface connections are made at a twelve-pole connector located on the top of the module.
  • Page 21 Installation and Wiring Table 3.B – Terminal Assignments for IntelliVAC Interface Connections Terminal No. Terminal Designation Description External capacitor (negative) Power connection for TDUV or capacitor trip options only External capacitor (positive) Latch trip coil (common) Output for mechanical latch contactor trip coil Latch trip coil Close coil (common)

  • Page 22: Wiring Guidelines Electrically Held Contactors

    Installation and Wiring 3-10 Wiring Guidelines The IntelliVAC can be applied with two- or three-wire control circuits. The control system utilized will determine the configuration Electrically Held of the input wiring. Consider the following input and output for the Contactors type of control used: •...

  • Page 23: Two-Wire Control

    Installation and Wiring 3-11 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).

  • Page 24: Three-Wire Control

    Installation and Wiring 3-12 Wiring Guidelines Three-Wire Control Electrically Held If using three-wire control, the CLOSE contactor input is maintained Contactors (cont.) 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).
  • Page 25 Installation and Wiring 3-13 15mS CLOSE COMMAND DEBOUNCE TO MICRO 80mS 15mS SELECTABLE DROP DEBOUNCE OUT TIME (0 TO 190mS) MICRO OUTPUT CLAMP DELAY TO CLOSE COIL 200mS CLOSE LEVEL OF CURRENT TO CLOSE 60mS COIL ACKNOWLEDGE WINDOW CONTACTOR STATUS RELAY OUTPUT MODULE STATUS RELAY OUTPUT...

  • Page 26: Wiring Guidelines Mechanically Latched Contactors

    Installation and Wiring 3-14 IntelliVAC control may be used for mechanically latched contactors. Wiring Guidelines A momentary control signal is needed to close the contactor, and a Mechanically Latched second momentary control signal is needed to open the contactor. Contactors The momentary open/close commands must be at least 50 milliseconds in duration.

  • Page 27: Mechanically Latched Contactors

    Installation and Wiring 3-15 Mechanically Latched Capacitor Trip Contactors The IntelliVAC can be configured to provide capacitor trip functionality with mechanically latched 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.
  • Page 28 Installation and Wiring 3-16 CONTROL POWER CONTROL POWER M-IV M-IV OPEN OPEN OVERLOAD OVERLOAD OPEN OPEN CONTROL CONTROL POWER POWER FUSE FUSE CAPACITOR CAPACITOR M-IV M-IV L2/N L2/N EMC FILTER EMC FILTER M-IV M-IV CLOSE CLOSE CLOSE CLOSE ∗ ∗ Refer to Table 3.A for recommended fuse sizing.

  • Page 29: Motor Jogging Control

    Installation and Wiring 3-17 Motor Jogging Control 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.

  • Page 30: Time Delay Undervoltage

    Installation and Wiring 3-18 Time Delay Undervoltage The IntelliVAC can be configured to provide time delay undervoltage (TDUV) protection. The feature is available to keep electrically held contactors closed during a voltage dip or brief power loss. This option may require the addition of a capacitor (see below). Refer to Chapter 6 for typical capacitor sizing.

  • Page 31: Intellivac Configuration

    Chapter 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.
  • Page 32 Available with IntelliVAC using version 2.001 firmware or newer. 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. 1503-UM051D-EN-P – June 2013...

  • Page 33: Introduction

    Chapter 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.

  • Page 34: Contactor Status

    Monitoring and Troubleshooting Contactor Status The Contactor Status is indicated with a yellow LED that is off until a CLOSE command is received. The LED will stay on if the contactor closes properly, until the contactor is opened. Contactor Status output relay has a normally open contact. The contact is open when the contactor is open (LED off), and closed when the contactor has received a close command (for 200 milliseconds) or if it is closed (LED on).
  • Page 35 Monitoring and Troubleshooting Table 5.B – IntelliVAC Status Indication (Series B design) Module Status Contactor Status Conditions Description LED Color Relay LED Color Relay Normal Healthy Module and Contactor OPEN Green Closed Open Normal Healthy Module and Contactor CLOSED Green Closed Yellow Closed...
  • Page 36 Monitoring and Troubleshooting Table 5.C – Module Troubleshooting Problem or Trip Indicated Indication of the following conditions Possible Solutions Contactor does not energize • Motor Protection activated • Investigate and reset • Both Status LEDs ‘Off’ • Check Control Power •...
  • Page 37 Monitoring and Troubleshooting Table 5.C – Module Troubleshooting (cont.) Problem or Trip Indicated Indication of the following conditions Possible Solutions Contactor opens during operation • Motor Protection activated • Investigate and reset. • Stop command initiated • Verify circuit • Module Status LED ‘Red’ •...
  • Page 38 Monitoring and Troubleshooting (This page is intentionally left blank.) 1503-UM051D-EN-P – June 2013...

  • Page 39: Spare Parts List

    Chapter 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 Internal Fuse: 6.3 A, 250 V (Littlefuse 21506.3) 80174-902-14-R Multi-pole connectors: 2 pole (module power) 80174-014-01-R 4 pole (status outputs) 80174-014-03-R...
  • Page 40 Spare Parts 1503-UM051D-EN-P – June 2013...

  • Page 41: Typical Contactor Drop-Out Times

    The contactor drop-out times shown in the following table are typical 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.
  • Page 42 Typical Contactor Drop-out Times Table A.1 – Contactor Drop-out Times (cont.) Fuse Rating Contactor Drop-out Time (msec) Voltage Current 400A 800A 7200 2X18R 2X24R 8250 100E 125E 150E 175E 200E Fuse not suitable for use with 400A contactor. Note: The drop-out time is chosen to be equal to or greater than the intersection of the rated contactor interrupting current and the fuse melt time curve (except where noted *) 1503-UM051D-EN-P –...
  • Page 44 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-UM051D-EN-P – June 2013 Supersedes Publication 1503-UM051C-EN-P – January 2006 Copyright © 2013 Rockwell Automation, Inc. All rights reserved. Printed in Canada.

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