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.

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.

1503-UM051D-EN-P – June 2013

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)

1503-UM051D-EN-P – June 2013

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.

The OEM is responsible for controller fusing, motor overload

protection, control devices (eg. Start/Stop push buttons), and wiring

between the IntelliVAC and 1502 vacuum contactor (using optional wire harness). Wiring and mounting for optional items, such as TDUV Capacitor are also the OEM’s responsibility. Refer to Figure

3.3 or 3.4 for basic connections.

An optional EMI filter is required to meet CE EMC requirements (refer to Chapter 6 for recommended type).

Minimum top clearance

38.1

(1.50)

Dimensions in mm (inches)

38.1

Minimum bottom clearance

38.1

(1.50)

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).

1503-UM051D-EN-P – June 2013

3-4 Installation and Wiring

Arrangements (cont.)

*

CONTROL

CONTROL POWER

POWER FUSE

FUSE

OVERLOAD

STOP

START

CAPACITOR

CAPACITOR (OPTIONAL)

(OPTIONAL)

M

CONTROL POWER

M-INTELLIVAC

78

+-

OPEN

910

+-

CLOSE

16

15

1

11

11 12

12

CONTACTOR

CONTACTOR STATUS

STATUS

MODULE

STATUS

-

EC

+

AUX CCO

TCO

14

13

4

4 32

32

6

6 5

5

MOV

M

CONFIGURATION

DIP SWITCHES

INPUT POWER

L1 L2/NG

∗ Refer to Table 3.A for recommended fuse sizing.

Figure 3.3 – IntelliVAC Typical Schematic (Electrically Held Vacuum Contactor)

Without Optional EMC Filter

1503-UM051D-EN-P – June 2013

Installation and Wiring 3-5

CONTROL POWER

M-INTELLIVAC

*

CONTROL

CONTROL POWER

POWER FUSE

FUSE

OVERLOAD

STOP

START

CAPACITOR

CAPACITOR (OPTIONAL)

(OPTIONAL)

M

M-INTELLIVAC

78

+-

OPEN

910

+-

CLOSE

16

15

1

11

11 12

12

CONTACTOR

CONTACTOR STATUS

STATUS

MODULE

STATUS

-

+

AUX CCO

EC

TCO

14

13

4

4 32

32

6

6 5

5

MOV

M

CONFIGURATION

DIP SWITCHES

INPUT POWER

L1 L2/NG

N'

N

∗ Refer to Table 3.A for recommended fuse sizing.

P'

P' P

P

EMC FILTER

G

Figure 3.4 – IntelliVAC Typical Schematic (Electrically Held Vacuum Contactor)

With Optional EMC Filter

1503-UM051D-EN-P – June 2013

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. If the supply voltage is DC, the module must be used with an external fuse that is approved for and rated to interrupt the DC voltage supply. The types listed are Ferraz-Shawmut Midget Fuses (1-1/2" X 13/32"). The TRM is a time-delay type, rated 250 VAC. The ATM is a fast-acting type, rated 500 VDC.

Table 3.A – IntelliVAC Fuse Protection

Rated Supply Voltage Contactor Type

400A EH TRM 2 TRM 3.2

110/120 VAC

220/240 VAC

125 VDC

250 VDC

EH = Electrically Held vacuum contactor ML = Mechanically Latched vacuum contactor

800A EH TRM 2 TRM 6.25

400/800A ML TRM 2 TRM 3.2

400A EH TRM 2 TRM 6.25 800A EH TRM 2 TRM 6.25

400/800A ML TRM 2 TRM 6.25

400A EH/ML ATM 3 ATM 3 800A EH/ML ATM 5 ATM 6 400A EH/ML ATM 3 ATM 5 800A EH/ML ATM 5 ATM 6

Recommended Fuse

(minimum) (maximum)

Grounding

The IntelliVAC module must be connected to a common ground

terminal (PE) on the controller panel. The ground terminal is located on top of the module enclosure for Series A design (refer to Figure

3.7), and on the bottom of module enclosure for Series B design, (refer to Figure 3.6)

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

It is important that IntelliVAC is properly grounded using the ground connection provided. Failure to do so may result in damage to equipment or personal injury.

1503-UM051D-EN-P – June 2013

Installation and Wiring 3-7

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

Control power is applied to the module with a two-pole connector

In order to meet CE electromagnetic interference requirements, an

The IntelliVAC can accept either AC or DC control power. Refer to Table 1.A for acceptable input power and control signal ratings.

located at the bottom rear portion of the module. Refer to Figures

3.5 and 3.6 for connections. The ‘L1’ connection is intended to be the ‘Hot’ or ‘+’ side of the control power, and the ‘L2/N’ connection is intended to be the ‘Neutral’, ‘Return’, or ‘-’ side of the control power.

external EMC filter must be installed. Refer to Chapter 6 for suitable EMC filter part number and install per Figure 3.4.

Status Relays

Status relay connections are accessed with a four-pole connector

located at the bottom front portion of the module. Refer to Figure

3.5 or 3.6 for connections. There are two status relays, each with one normally-open contact:

Module Status: Terminals 13 and 14 Contactor Status: Terminals 15 and 16

Refer to Chapter 5 Monitoring and Troubleshooting for a description

of operation for the relays.

Refer to Table 1.A for electrical ratings of the status relays.

13 161514

CONTACTOR STATUS OUTPUT (N.O.)

Figure 3.5 – Bottom side connections (Series A)

MODULE STATUS OUTPUT (N.O.)

L2/NL1

POWER INPUT

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3-8 Installation and Wiring

Connections (cont.)

Figure 3.6 – Bottom side connections (Series B)

Interface Connections

Ground Connection

13 161514

CONTACTOR STATUS OUTPUT (N.O.)

MODULE STATUS OUTPUT (N.O.)

POWER INPUT

Interface Connections

All other control interface connections are made at a twelve-pole connector located on the top of the module. Refer to Figure 3.7 or

3.8 and Table 3.B for connections. Refer to the Wiring Guidelines

section in this chapter for guidance in making connections to the control circuit.

L2/NL1

11 1289105672341

CONTACTOR INTERFACE

EX. CAP.

CONTACTOR INTERFACE

EX. CAP.

Ground Connection

11 1289105672341

Figure 3.7 – Top side connections (Series A)

CONTACTOR INTERFACE

EX. CAP.

11 1289105672341

Figure 3.8 – Top side connections (Series B)

1503-UM051D-EN-P – June 2013

Installation and Wiring 3-9

Table 3.B – Terminal Assignments for IntelliVAC Interface Connections X

Terminal No. Terminal Designation Description

1 External capacitor (negative) Y

2 External capacitor (positive) Y

3 Latch trip coil (common) Y

4 Latch trip coil Y

5 Close coil (common)

6 Close coil

7 Open / Jog command Y Z

Power connection for TDUV or capacitor trip options only

Output for mechanical latch contactor trip coil

Output to close coil of electrically held & mechanical latch contactors

Input to open a mechanical latch contactor or jog an electrically held contactor

8 Open / Jog command (common) Y Z

9 Close command Z

10 Close command (common) Z

11 Contactor auxiliary contact Z

(mutually exclusive)

Input to initiate the closure of electrically held & mechanical latch contactors

Input to indicate the state of the contactor (typically wired to a normally closed

12 Contactor auxiliary contact Z

X Refer to Table 1.A for electrical ratings. Y No connection required if option is not used. Z 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.

auxiliary contact)

1503-UM051D-EN-P – June 2013

3-10 Installation and Wiring

Wiring Guidelines

The IntelliVAC can be applied with two- or three-wire control

Electrically Held Contactors

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 Close Contactor

• Terminals 15 and 16 Contactor Status

In either case, the CLOSE input must receive a maintained voltage

high to keep the contactor closed.

Note:

1. When used with electrically held contactors, the IntelliVAC

allows close commands every six seconds. This is to ensure the rated contactor duty cycle is not exceeded.

2. If a contactor close command is applied and then removed in less

than 500 milliseconds the IntelliVAC may fault. To clear the fault, module power has to be removed and reapplied.

3. If IntelliVAC powers up configured for an electrically held

contactor, and the vacuum contactor is detected as being closed, the module will not respond to a close command until the vacuum contactor auxiliary contact input is in the correct (open) state and module power is removed and re-applied. (See Chapter 5). This is true if the power-up safety DIP switch is enabled.

4. In general, a Close command should only be applied 4 seconds

after energizing IntelliVAC.

1503-UM051D-EN-P – June 2013

Installation and Wiring 3-11

Two-Wire Control

Some two-wire control schemes may be configured such that a close

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). If a fault occurs, in addition to cycling control power to the IntelliVAC module, the CLOSE command must be removed for a minimum of 4 seconds, before being re-applied. Refer to Figure 3.9.

command is present when IntelliVAC is energized. In this case, the Power-Up Safety feature may be disabled by setting DIP switch 12 accordingly. (Available with an IntelliVAC using firmware 2.001 (or newer) refer to Table 4.B).

Note: Only disable the Power-Up safety feature when absolutely

necessary. Doing so can create unsafe operating conditions.

CONTROL POWER

CAPACITOR

CAPACITOR (OPTIONAL)

(OPTIONAL)

1

*

CONTROL

CONTROL POWER

POWER FUSE

FUSE

OVERLOAD

∗ Refer to Table 3.A for recommended fuse sizing.

M

1

+

11

11 12

12

L1 L2/NG

P'

P

Figure 3.9 – Two-Wire Control

M-IV

-

EC

AUX CCO

EMC FILTER

G

RUN

TCO

4

4 32

32

6

6 5

5

N'

N

MOV

M

M-IV

910

+-

CLOSE

1503-UM051D-EN-P – June 2013

3-12 Installation and Wiring

Three-Wire Control

Wiring Guidelines Electrically Held

If using three-wire control, the CLOSE contactor input is maintained

Contactors (cont.)

In this configuration, the STATUS output acts as a seal-in contact. If a

*

CONTROL

CONTROL POWER

POWER FUSE

FUSE

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).

fault occurs, in addition to cycling control power over to the IntelliVAC module, the CLOSE command must be removed for a minimum of 4 seconds before being re-applied. Refer to Figure 3.10.

CONTROL POWER

CAPACITOR

CAPACITOR (OPTIONAL)

(OPTIONAL)

M

11

11 12

12

1

M-IV

-

EC

+

AUX CCO

TCO

4

4 32

32

6

6 5

5

MOV

M

L1 L2/NG

P'

P

OVERLOAD

∗ Refer to Table 3.A for recommended fuse sizing.

STOP

EMC FILTER

G

N'

N

START

M-IV

15 16

CONTACTOR

STATUS

M-IV

910

+-

CLOSE

Figure 3.10 – Three-Wire Control

1503-UM051D-EN-P – June 2013

Installation and Wiring 3-13

CLOSE COMMAND

TO MICRO

MICRO OUTPUT TO CLOSE COIL

CLOSE LEVEL OF

CURRENT TO CLOSE

COIL

CONTACTOR STATUS

RELAY OUTPUT

MODULE STATUS

RELAY OUTPUT

CONTACTOR

AUXLIARY

INPUT TO MICRO

15mS

DEBOUNCE

200mS

X

CONTACTOR PICK UP

90mS

(@120VAC)

X

Contact status relay closes on request to close. It will open if the contactor auxiliary contact does not close within 200 milliseconds and

15mS

DEBOUNCE

CLAMP DELAY

5mS

ACKNOWLEDGE

WINDOW

NATURAL

CONTACTOR

DROP OUT

80mS

Y

module will fault (opening module status relay).

Y

For this example, the 130 millisecond drop-out time has been selected. The base drop-out time is 50 milliseconds. The microcontroller delay is 130-50=80 milliseconds.

Figure 3.11 – Timing Diagram 400A (Electrically Held) Contactor

with IntelliVAC Control for three-wire Control

SELECTABLE DROP

OUT TIME

(0 TO 190mS)

60mS

30mS

1503-UM051D-EN-P – June 2013

3-14 Installation and Wiring

IntelliVAC control may be used for mechanically latched contactors.

Wiring Guidelines Mechanically Latched 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 3.12 for a typical mechanical latch control scheme.

Note:

1. A mechanically latched contactor may already be closed when power is applied to the IntelliVAC control module.

2. It is permissible to apply an open command to the IntelliVAC module as power is re-applied.

CONTROL POWER

M

MOV

TC

MOV

CC

*

CONTROL

CONTROL POWER

POWER FUSE

FUSE

M-IV

1

-

EC

+

M

11

AUX CCO

12

TCO

4

4 32

32

6

6 5

5

L1 L2/NG

P'

P

∗ Refer to Table 3.A for recommended fuse sizing.

EMC FILTER

G

CLOSE

OPEN

OVERLOAD

N'

N

M-IV

910

+-

CLOSE

M-IV

78

+-

OPEN

Figure 3.12 – Mechanically Latched Contactor Control

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Installation and Wiring 3-15

Mechanically Latched Contactors

The IntelliVAC must receive an ‘OPEN’ command within a few

A separate voltage source is needed to provide the ‘OPEN’ command.

Note: Minimum capacitor voltage ratings

• 120V applications – 200V DC (250V DC preferred)

• 240V applications – 400V DC (450V DC preferred)

Capacitor Trip

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. Maximum recommended capacitor size is 1650 µF for 120V control or 330 µF for 240V control. Use of larger capacitors will require a current limiting circuit to prevent opening the control fuse on energization.

seconds of losing AC control power. This time limit depends on voltage and capacitor size as shown in the table below. If the elapsed time exceeds this limit, the contactor cannot be tripped by IntelliVAC.

This may be taken from the external capacitor as shown in Figure

3.13.

Table 3.C – Mechanically Latched Contactor – Capacitor Trip Times

Contactor

Rating

400 Amp

Nominal Voltage

(Vac)

120

240

Actual

V

(Vac)

input

120 3.5

110 2.7

100

240 7.5

200

Ext.

Capacitor

(µF)

1650

330

Max. time

for trip

(sec)

1.7

4.7

1503-UM051D-EN-P – June 2013

3-16 Installation and Wiring

*

CONTROL

CONTROL POWER

POWER FUSE

FUSE

OPEN

OVERLOAD

CONTROL POWER

M-IV

78

+-

OPEN

CAPACITOR

M

1

-

EC

+

11

AUX CCO

12

L1 L2/NG

M-IV

TCO

M

MOV

4

4 32

32

6

6 5

5

TC

MOV

CC

N'

N' N

N

M-IV

910

+-

CLOSE

∗ Refer to Table 3.A for recommended fuse sizing.

P'

P

EMC FILTER

G

Figure 3.13 – Mechanically Latched Contactor with Capacitor Trip Option

1503-UM051D-EN-P – June 2013

Installation and Wiring 3-17

Motor Jogging Control

For motor jogging operations, the second control input, or OPEN

*

CONTROL

CONTROL POWER

POWER FUSE

FUSE

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.

command, will close the contactor for as long as the input is present, and open the contactor when the input is removed. (Refer to Figure

3.14.) This method will bypass the standard six second motor re-

start delay for jogging purposes only.

CONTROL POWER

M-IV

4

1

-

EC

+

M

11

AUX CCO

12

TCO

4 32

32

6

6 5

5

MOV

M

L1 L2/NG

EMC FILTER

P'

EMC FILTER

P'

P

OVERLOAD

* Refer to Table 3.A for recommended fuse sizing.

STOP

JOG

G

N'

N

START

M-IV

15 16

CONTACTOR

STATUS

M-IV

910

+-

CLOSE

M-IV

78

+-

OPEN

Figure 3.14 – Motor Jogging Control

1503-UM051D-EN-P – June 2013

3-18 Installation and Wiring

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. The capacitor is connected to terminals 1(-) and 2(+) of the IntelliVAC. (Refer to Figure 3.15.)

Table 4.B of the “Setup and Commissioning” chapter has the dip

switch settings to provide TDUV from 0.2 to 2 seconds. IntelliVAC can provide TDUV protection without the use of an external capacitor, as shown in Table 3.D.

Table 3.D – Maximum TDUV Time (without Capacitor)

Control Voltage Max. TDUV Time (secs)

110/120 V 0.2 220/240 V 1.0

The following conditions will initiate TDUV protection, regardless

of the supply voltage:

1. If the supply voltage drops below 90 VAC/VDC after the first

200 milliseconds after a contact close request.

2. When the supply voltage drops below 72 VAC/FDC after the

200 millisecond close sequence.

If the undervoltage condition persists beyond the set delay time, the

contactor will be opened and an undervoltage fault condition will occur.

CONTROL POWER

M-IV

CAPACITOR

*

CONTROL

CONTROL POWER

POWER FUSE

FUSE

OVERLOAD

∗ Refer to Table 3.A for recommended fuse sizing.

M

11

11 12

12

P'

STOP

Figure 3.15 – TDUV Control Circuit

M-IV

1

-

EC

+

AUX CCO

L1 L2/NG

EMC FILTER

P

TCO

G

15 16

CONTACTOR

N'

N' N

N

START

M-IV

STATUS

4

4 32

32

6

6 5

5

MOV

M

M-IV

910

+-

CLOSE

1503-UM051D-EN-P – June 2013

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).

I M P O R T A N TI M P O R T A N T

Remove power from the module before removing the cover and before changing the DIP switch settings. The new settings are recognized only on power-up.

Ground Stud (Series A)

Interface Connections

EEPROM Programming Port

(Mini DIN Connector)

DIP Switches

Status Relay Outputs

Supply Power Input

Internal Control Fuse

Figure 4.1 – DIP Switch and Connector Locations

Ground Stud (Series B)

An IntelliVAC unit shipped separately from the factory will have a

default configuration per Table 4.A.

Table 4.A – DIP Factory Default Settings

Description 1 2 3 4 5 6 7 8 9 10 11 12

Altitude: 0 – 1000m 0 0 1

Drop-out time: 130 msec 0 1 1

Contactor config.: 400A EH 0 1

TDUV config.: No TDUV 0

Ext. cap TDUV time: 0.2 sec 0 0

*Power-Up Safety: Enable 0

1503-UM051D-EN-P – June 2013

DIP switch

4-2 Setup and Commissioning

IntelliVAC units shipped in a complete MV controller (Bulletin

IntelliVAC Configuration (cont.)

1500/1900) will be configured to suit the installed application (i.e. contactor type). The user should verify the settings before energizing the equipment. Table 4.B defines the settings for each switch.

UP = 1

DOWN = 0

DIP switch SW1

1 2 3 4 5 6 7 8 9 10 11 12

| | | |

Altitude X

-1000 to 0

1 to 1000

1001 to 2000

2001 to 3000

3001 to 4000

4001 to 5000

Not defined

1 2 3 12

0 0 0 0

0 0 1 1

0 1 0

0 1 1 10 11

1 0 0 0 0 1 0 1 0 1 1 1 0 1 0 1 1 1 1 1

9

Drop out time Z

50 msec

75 msec

100 msec

130 msec

150 msec

175 msec

200 msec

240 msec

4 5 6 1

0 0 0

0 0 1 7 8

0 1 0 0 0 0 1 1 0 1 1 0 0 1 0 1 0 1 1 1

1 1 0 1 1 1

Power-Up Safety Y

Enable

Disable

Ext. cap. TDUV time

TDUV config.

0

No TDUV

TDUV Enabled

Contactor Config.

400A Mech. Latch

400A Elec. Held

800A Mech. Latch

800A Elec. Held

X The altitude compensation by DIP switch settings applies to Series E 400 amp vacuum contactors only. All 800 amp contactors are adapted

for altitude by altering the return springs. 800 amp contactors are to be set for 1 to 1000m (001 DIP setting).

Y Available with IntelliVAC using version 2.001 firmware or newer. Z 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.

0.2 sec

0.5 sec

1.0 sec

2.0 sec

1503-UM051D-EN-P – June 2013

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

Module Status The Module Status is indicated with a Green LED if the module is

functioning properly and has a valid configuration. If the module powers up with an invalid configuration the LED will be Red, indicating a Fault condition which will not allow the contactor to close. If the module powers up properly and experiences an undervoltage condition when attempting to close the contactor or while the contactor is closed, the LED will be Red (Fault). If the contactor does not close properly, a Fault is generated, the LED turns Red, and inputs are inhibited until the module power is removed and reapplied. If the processor has an internal fault, the LED will be Red, the outputs will be cleared, and the processor will be reset. 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).

Module Status output relay has a normally open contact. The contact

is open during a Fault condition (LED red), and closed during a healthy condition (LED green).

The module states for Series A are summarized in Table 5.A.

Series B Design

Additional module states are indicated with the LED as per Table 5.B.

1503-UM051D-EN-P – June 2013

5-2 Monitoring and Troubleshooting

Contactor Status

Contactor Status output relay has a normally open contact. The

Series B Design

Additional module states are indicated with the LED as per Table 5.B.

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.

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).

Table 5.A – IntelliVAC Status Indication (Series A design)

Parameter Conditions LED State Relay Contact State

• rated supply voltage and

• valid configuration

Module Status

Y

Contactor

Status

X Applies only to power-up condition. Y Fault is reset by cycling control power. Z If a contactor close command is applied and then removed in less than 500 milliseconds, the

IntelliVAC may fault and the module status LED will turn red. To clear the fault, module power has to be removed and reapplied.

[ For mechanical latch contactors a close command does not need to be maintained for the contactor

to remain closed (resulting in a yellow state for contactor status).

• undervoltage or

• contactor fault or

• invalid configuration X or

• internal fault

• insufficient supply voltage Off Open

• rated supply voltage and

• close command present [ and

• contactor closed

• insufficient supply voltage or

• close command absent [ or

• contactor open

Green Closed

Red Y

Yellow Closed

Off Open

Open

1503-UM051D-EN-P – June 2013

Monitoring and Troubleshooting 5-3

Table 5.B – IntelliVAC Status Indication (Series B design)

Conditions

XY

Description

Normal Healthy Module and Contactor OPEN Green Closed Off Open

Normal Healthy Module and Contactor CLOSED Green Closed Yellow Closed

Warning Invalid Command Present ^ Yellow Closed Off Open

Warning Mechanical Latch Fail to Trip Yellow Open Yellow Closed

Fault Power Up with Contactor CLOSED Red – Flash 2 [ Open Yellow Closed

Fault Contactor Fails to Pick Up Green Open Red – Flash 1 Z Open

Fault Contactor Drop Out During Hold Green Open Red – Flash 2 [ Open

Fault Long Contactor Drop Out Time Green Open Red – Flash 3 Z Open

Fault Microcontroller Malfunction Red Open Red Open

Fault Power Up with Invalid Dip Switch Configuration Red – Flash 1  Open Off Open

Fault Undervoltage with a CLOSE Command Present Red Open Off Open

X Warning = Recoverable Condition – Remove and retry offending signal Y Fault = Non-recoverable condition – Module power must be removed and re-applied. Z Flash 1 = 1 Flash Red LED followed by a pause. [ Flash 2 = 2 Consecutive Red LED flashes followed by a pause. \ Flash 3 = 3 Consecutive Red LED flashes followed by a pause. ] EH = Only for Electrically Held Contactor ^ Invalid Command Types:

1. Close, Jog or Trip commands present during power up sequence.

2. Close or Jog command re-applied too quickly (before contactor opening sequence is verified). Allow at least 60 msec, plus drop out delay time, before re-applying these signals. NOTE: Contactor will only respond to a close command re-applications after the re-start delay timer has expired.

3. Close and Trip commands present simultaneously (valid with Mechanical Latch contactors only).

Module Status Contactor Status

LED Color Relay LED Color Relay

1503-UM051D-EN-P – June 2013

5-4 Monitoring and Troubleshooting

Table 5.C – M

Problem or Trip Indicated Indication of the following conditions Possible Solutions

Contactor does not energize

Contactor closes momentarily and will not reclose.

odule Troubleshooting

• Motor Protection activated

• Both Status LEDs ‘Off’

• Module Status LED ‘Red’ upon power up

• Module Status ‘Red Flash 1’ upon power up

• Loose connection in control circuit. • Verify contactor auxiliary set up. Reference

• Module status LED ‘Red’ and Contactor

• Module status LED ‘Green’ and Contactor

• Both status LEDs ‘Off’ • Check internal control fuse. Verify IntelliVAC

(Series A)

(Series B)

Status LED ‘Off’ (Series A)

Status LED ‘Red Flash 1’ (Series B)

• Investigate and reset

• Check Control Power

• Loose connections in control circuit

• Verify IntelliVAC power input plug is in place and properly seated

• Verify internal control fuse has not opened (Refer to Figure 4.1 for location)

• IntelliVAC faulted. Cycle control power to reset. Replace IntelliVAC if unsuccessful.

• Improper setting of dip switches. Check settings and cycle control power.

Publication 1502-UM052A-EN-P (400A) or 1502-UM051B-EN-P (800A) – Auxiliary Contact Set-up Procedure.

• Verify circuit continuity (is contactor plug connected properly?)

• Coil damaged or connections are loose. Repair and cycle control power.

• Auxiliary Contact Assembly improperly adjusted. Reference Publication 1502UM052A-EN-P (400A) or 1502-UM051B-EN-P (800A) – Auxiliary Contact Set-up Procedure. Cycle control power to reset.

• Undervoltage fault (no TDUV), control voltage dipped below trip point. Cycle control power to reset. Verify voltage levels are 110 to 240 VAC, 110 to 250VDC

• Armature Plate obstructed from closing to coil face. Verify no foreign material behind the armature plate. Cycle control power to reset.

operation in test mode before applying Medium Voltage. (Refer to Fig. 4.1 for location.)

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Monitoring and Troubleshooting 5-5

Table 5.C – Module Troubleshooting (cont.)

Problem or Trip Indicated Indication of the following conditions Possible Solutions

Contactor opens during operation

Contactor does not open (mechanical latch only)

• Motor Protection activated • Investigate and reset.

• Stop command initiated • Verify circuit

• Module Status LED ‘Red’ • Undervoltage fault (no TDUV), control voltage dipped below trip point. Cycle control power to reset. Verify voltage levels are 110 to 240 VAC, 110 to 250 VDC.

• With external capacitor and TDUV feature activated, undervoltage condition for longer than programmed TDUV time. Undervoltage fault activated. Cycle control power to reset.

• Module Status LED ‘Green’ and Contactor Status LED ‘Red Flash 2’ (Series B only)

• Both status LEDs ‘Off’ • Check control voltage and internal control

• Module Status LED ‘Red’ and Contactor Status LED ‘Yellow’ (Series A, with firmware

2.001 or newer)

• Module Status LED ‘Yellow’ and Contactor Status LED ‘Yellow’ (Series B, with firmware

2.001 or newer)

• Contactor Status feedback between Terminals 11 and 12 on the IntelliVAC has closed. The IntelliVAC will de-energize the coil, thinking the contactor has opened for other reasons.

fuse. (Refer to Figure 4.1 for location.)

• Check control power to ensure that it has not dipped below minimum (see Table 5.D).

• Trip mechanism is damaged. Inspect and replace if needed.

• Check for loose connections in the control circuit.

Refer to Tables 5.A or 5.B for definition of Module LED states.

Table 5.D – Minimum IntelliVAC Operational Supply Voltages

Voltage Level

Pick-Up 400/800 95

Drop-Out 400/800 75

Trip (Mechanical Latch)

Contactor Rating

(Amps)

400 70

800 80

Minimum Voltage

(VAC, 47 to 63 Hz)

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5-6 Monitoring and Troubleshooting

(This page is intentionally left blank.)

1503-UM051D-EN-P – June 2013

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

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 12 pole (coil and I/O connections) 80174-014-11-R

Optional Equipment

TDUV Capacitor* For 110/120V AC control (1650 µF) 80158-779-51-R For 220/240V AC control (330 µF) 80158-779-52-R

EMC Filter

Schnaffer (FN 670-10/06) 80026-430-01-R

*Includes mounting bracket and terminal guards

1503-UM051D-EN-P – June 2013

6-2 Spare Parts

1503-UM051D-EN-P – June 2013

Appendix A

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.

Table A.1 – Contactor Drop-out Times

Fuse Rating Contactor Drop-out Time (msec)

Voltage Current 400A 800A

2R 3R 4R 6R

9R 12R 18R

< 5000

 Fuse not suitable for use with 400A contactor.

19R 24R 100 32R 240 38R

48X

57X 2 x 24R 2 x 32R 2 x 38R

20E

30E

40E

50E

65E

80E

100E 125E 150E 175E 200E 250E 300E 350E 75 400E 100 450E 130 500E 600E 750E 900E

50

     

50

   

50

75 200 100 240

240 *

50

75 200

240 *

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A-2 Typical Contactor Drop-out Times

Table A.1 – Contactor Drop-out Times (cont.)

Fuse Rating Contactor Drop-out Time (msec)

Voltage Current 400A 800A

2R 3R 4R 6R

7200

8250

 Fuse not suitable for use with 400A contactor.

9R 12R 18R 75 24R 150

2X18R 2X24R

20E 30E 40E 50E 65E 80E

100E 125E 150E 175E 200E

50

 

50 50

130

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 – 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-UM051D-EN-P – June 2013

Rockwell Automation 1503VC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Table of Contents

Product Description

Introduction

IntelliVAC Features

Specifications

Configuration

Firmware

Receiving Upon receiving the controller, remove the packing and check for

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

General Precautions

Safety and Codes

Arrangements

Integral to an Allen-Bradley MV Controller

Fuse Protection The IntelliVAC module requires external fuse protection to

Grounding

Connections There are three green connectors on the IntelliVAC module for

Control Power

Status Relays

Interface Connections

Two-Wire Control

Three-Wire Control

Wiring Guidelines Mechanically Latched Contactors

Mechanically Latched Contactors

Capacitor Trip

Motor Jogging Control

Time Delay Undervoltage The IntelliVAC can be configured to provide time delay undervoltage

IntelliVAC Configuration The IntelliVAC module is configured for a specific application by

Introduction The IntelliVAC module has two light emitting diodes (LEDs) and

Module Status The Module Status is indicated with a Green LED if the module is

Spare Parts List IntelliVAC (electrically held) Series A 1503VC-BMC1