Rockwell Automation 1503VC User Manual

IntelliVAC™ Contactor Control Module

Bulletin 1503VC

User Manual

Important User Information

IMPORTANT

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.

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, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

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

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) .......................................... 1-6

Receiving and Storage Chapter 2

Receiving ............................................................................... 2-1

Storage .................................................................................... 2-1

Installation and Wiring Chapter 3

General Precautions ................................................................ 3-1

Safety and Codes .................................................................... 3-1

Arrangements .......................................................................... 3-2

Integral to an Allen-Bradley MV Controller .................... 3-2

OEM ................................................................................. 3-3

Fuse Protection ....................................................................... 3-6

Grounding ............................................................................... 3-6

Connections ............................................................................ 3-7

Control Power .................................................................. 3-7

Status Relays .................................................................... 3-7

Interface Connections ....................................................... 3-8

Wiring Guidelines Electrically Held Contactors .................. 3-10

Two-Wire Control .......................................................... 3-11

Three-Wire Control ........................................................ 3-12

Wiring Guidelines Mechanically Latched Contactors .......... 3-14

Mechanically Latched Contactors ........................................ 3-15

Capacitor Trip ................................................................ 3-14

Motor Jogging Control ......................................................... 3-17

Time Delay Undervoltage ..................................................... 3-18

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ii 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 ......................................................... 6-1

Appendix A Typical Contactor Drop-out Times

Table A.1 – Contactor Drop-out Times ................................. A-1

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Chapter 1

Product Description

Introduction

An IntelliVAC control module may also be provided as a loose

Description IntelliVAC is an efficient and flexible solution for controlling

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.

component, for application with a Bulletin 1502 contactor by a third party (OEM).

medium voltage vacuum contactors used in motor starter and feeder applications. IntelliVAC may be used to control both 400 and 800 Amp contactors. Electrically held and mechanically latched contactor types can be controlled with IntelliVAC.

Figure 1.1 – IntelliVAC Contactor Control Module

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1-2 Product Description

Description (cont.)

Contactor Coil(s) In t erface

Coil Current Transducer

C C

Feedback

Aux.

Outputs

Status

Vacuum Contactor

Trip Coil

Vacuum Contactor

Close Coil

Vacuum Contactor

Auxiliary

Module

Status

Contactor

Status

External Capacitor (Optional)

Supply

Voltage

110-240

VAC

110-250

VDC

Signal

Open

Signal

Altitude

Select

Drop-Out

Select

Contactor

Select TDUV

Time

Select

Power Up

Safety

Coil

Power

Input

Power

Conditioning

Command

Inputs

c c

Configuration

Inputs

(DIP

switches)

c c

Supply

Control

Power

Supply

Micro Controller

Flash EEPROM

Interface

Current

Regulator

IGBT Coil Switching

Figure 1.2 – IntelliVAC Block Diagram

IntelliVAC Features

 A wide range of supply voltage (110 – 240 V AC 50/60 Hz,

110 - 250 V DC) allows implementation in multiple applications

 Consistent vacuum contactor pick-up time (at a given supply

voltage) ensures repeatable performance

 Selectable vacuum contactor drop-out time improves

coordination with upstream power fuses

 Electronic altitude compensation (400 A only) eliminates

mechanical compensation required for altitudes above 1,000 meters (800 A contactors include a user-friendly altitude adjustment)

 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)

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Product Description 1-3

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 Series A There are two versions of IntelliVAC control. The

first type is used to control vacuum contactors that are electrically held, with a single electrical coil that is economized electronically. The second is used to control mechanically latched vacuum contactors.

Series B There is a single version of IntelliVAC, to control

both electrically held and mechanically latched vacuum contactors.

Refer to Chapter 6, for catalog numbers for each version of IntelliVAC.

A Series B IntelliVAC module can be used to replace a Series A module.

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1-4 Product Description

Specifications

Mounting & 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. Control power and other control circuit connections are similarly achieved with “quick” connectors.

Configuration

IntelliVAC is easily configured for a wide variety of medium voltage motor and feeder control applications. It is configured using DIP switches, located within the enclosure (front side). Please refer to Chapter 4 for information.

Bulletin 1500/1900 controllers are shipped with IntelliVAC configured for the required application. Please refer to the documents provided with the order.

pre-

Firmware

IntelliVAC has firmware stored in flash EEPROM; therefore, this may be updated in the field (if necessary). The IntelliVAC firmware is updated using the mini-DIN connector, which is accessible inside the enclosure.

board

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Product Description 1-5

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%

Main Input Current (L1 to L2/N) 

Command Inputs  \

Description

Contactor Ratings

(Amps)

Inrush Current 400/800 120/240

Control Voltage

(AC or DC)

AC Rating DC Rating

25 A peak (1/2 cycle)

25 A peak

Idle Current (Maximum without contactor

400/800 120/240 125 mA 35 mA

coil energized)

Hold Current  (maximum) 400/800 120/240 300 mA 100 mA

Close Current 

400

(0.2 sec)

800

120 4.6 A 3.6 A

240 3.4 A 3.3 A

120 11.3 A 4.8 A

240 8.9 A 4.5 A

120 7.0 A 3.7 A

400

Trip Current (latch) 

(0.2 sec)

240 3.6 A 2.0 A

120 7.0 A 3.3 A

800

240 4.3 A 1.9 A

AC – 100 to 240 V rms DC – 24 to 250 V

Maximum on state current for open or close command:

9mA

@ 250 V AC, 60Hz, TA=60°C

9mA

@ 250 V DC, TA=60°C

Minimum on state current for open or close command:

2mA

@ 100 V AC, 60Hz, TA=60°C

600µA

@ 24 V DC, TA=60°C

Maximum off state current for open or close command:

400µA

@ 11 V AC, 60Hz, TA=60°C

400µA

@ 15 V DC, TA=60°C

Status Output Contacts

Standards and

AC – 250 V rms, 5 A, R load; 2 A (reactive), PF=0.4 DC – 30 V, 5 A, R load; 2 A (reactive), L/R=7 ms

CE , cULus, CSA, IEC pending

Approvals

 T

Ambient Temperature

A =

 Refer to Chapter 6 for suitable EMC filter needed to meet CE requirements.

Also refer to Chapter 3 for EMC filter installation guidelines.

 Please consult Factory for DC input current ratings.  Includes idle current.

\ Ensure compatibility of IntelliVAC input ratings with those of circuit components activating these inputs.

Consider means of isolating/loading these signals, as required (using interposing relays or load resistors.) Consult factory for assistance, if needed.

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1-6 Product Description

Specifications (cont.)

Table 1.B – Mechanical Ratings

Temperature

Altitude -1000 to 5000 meters Pollution Pollution level II (as defined by UL 840 and IEC 60664-1) Humidity Class II

Shock and Vibration (Operational)

X Ambient temperature is derated at altitudes above 1,000 meters (3,300 feet). Please refer to Table 1.C.

Operating: 0° to 60°C ambient at the control module X

Non-Operating: -40° to 85°C

Shock – 15 g peak, 11 milliseconds

Vibration – 10 to 57 Hz, 0.015 inch displacement peak to peak

- 57 to 150 Hz, 2.5 g acceleration

Table 1.C – Altitude Derating

Altitude DIP Switch Setting 1, 2, 3 X

-1000 to 0 000 60

1 to 1000 001 60

1001 to 2000 010 58

2001 to 3000 011 56

3001 to 4000 100 54

4001 to 5000 101 52

X Refer to Chapter 4. Y Derate by 2°C / 1000 m for high altitude operation

Maximum Operating Ambient

at the control module (°C) Y

5.1 (0.20)

29.7

(1.17)

165.9 (6.53)

5.8 (0.228)

5.8 (0.228) 2 places

2 places

174.8

174.8 (6.88)

(6.88)

185.3

185.3 (7.29)

(7.29)

59.4

(2.34)

Figure 1.3 – Mechanical Dimensions

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Dimensions in mm (inches)

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.

Storage It is important to consider the following storage requirements if you

are not installing your controller immediately after receiving it.

• Store the controller in a clean, dry, dust-free environment.

• Storage temperature should be maintained between -40°C and 85°C (-40°F and 185°F).

• Relative humidity must not exceed 95%, non-condensing.

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2-2 Receiving and Storage

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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.

Chapter 3

A T T E N T I O NA T T E N T I O N

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. If you are not familiar with static control procedures, refer to applicable ESD protection handbooks.

A T T E N T I O NA T T E N T I O N

An incorrectly applied or installed controller can damage components or reduce product life. Wiring or application errors, such as incorrect or inadequate AC supply, or excessive ambient temperatures, may result in malfunction of the system.

A T T E N T I O NA T T E N T I O N

Only personnel familiar with the controller and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage.

Safety and Codes

A T T E N T I O NA T T E N T I O N

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.

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3-2 Installation and Wiring

Arrangements

Integral to an Allen-Bradley MV Controller

The IntelliVAC is available as a primary component of an Allen-

The IntelliVAC is offered in two arrangements, Integral (part of a

Bulletin 1500/1900 MV controller) or as an OEM component.

Bradley Bulletin 1500/1900 MV controller as shown in Figure 3.1.

Figure 3.1 - Typical IntelliVAC Installation within a Bulletin 1500/1900 MV Controller

(Shown with optional external capacitor)

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