IntelliVAC Contactor Control Module 1503VC
IntelliVAC Contactor Control Module 1503VC
IntelliVAC Contactor Control Module 1503VC
Contactor
Control Module
Bulletin 1503VC
User Manual
Identifies information that is critical for successful application and understanding of the product.
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) .......................................... 1-6
Chapter 2
Receiving ............................................................................... 2-1
Storage .................................................................................... 2-1
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
ii
Table of Contents
Chapter 4
IntelliVAC Configuration ....................................................... 4-1
Chapter 5
Introduction .............................................................................
Module Status .........................................................................
Contactor Status ......................................................................
Series B Design ................................................................
Spare Parts
5-1
5-1
5-2
5-2
Chapter 6
Spare Parts List ....................................................................... 6-1
Optional Equipment ......................................................... 6-1
Appendix A
Chapter
Product Description
Introduction
Description
1-2
Product Description
Description (cont.)
External
Capacitor
(Optional)
Coil
Power
Supply
Current
Regulator
Control
Power
Supply
C
C
IGBT Coil
Switching
Close
Signal
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.
Feedback
Altitude
Select
Vacuum Contactor
Close Coil
Drop-Out
Select
c
c
c
c
c
c
Status
Outputs
TDUV
Time
Select
Module
Status
Configuration
Inputs
(DIP
switches)
Contactor
Select
Flash EEPROM
Interface
c
c
Power Up
Safety
Contactor
Status
IntelliVAC Features
Product Description
1-3
IntelliVAC Versions
Series A
Series B
1-4
Product Description
Specifications
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 preconfigured for the required application. Please refer to the
documents provided with the order.
Firmware
IntelliVAC has firmware stored in flash EEPROM; therefore, this
may be updated in the field (if necessary). The IntelliVAC board
firmware is updated using the mini-DIN connector, which is
accessible inside the enclosure.
Product Description
1-5
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
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
4.8 A
240
8.9 A
4.5 A
120
7.0 A
3.7 A
240
3.6 A
2.0 A
120
7.0 A
3.3 A
240
4.3 A
1.9 A
Close Current
400
800
400
(0.2 sec)
800
Command Inputs
\
Status Output
Contacts
Standards and
Approvals
DC Rating
Inrush Current
(0.2 sec)
AC Rating
TA = Ambient Temperature
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.
1-6
Product Description
Specifications (cont.)
Altitude
Pollution
Humidity
Class II
Shock and
Vibration
(Operational)
X
X
Y
Altitude
-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
Refer to Chapter 4.
Derate by 2C / 1000 m for high altitude operation
5.1 (0.20)
29.7
(1.17)
165.9 (6.53)
5.8 (0.228)
2 places
174.8
(6.88)
185.3
(7.29)
59.4
(2.34)
Dimensions in mm (inches)
Chapter
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
2-2
Chapter
ATTENTION
ATTENTION
ATTENTION
3-2
Arrangements
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 OEMs 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
(1.50)
Minimum bottom clearance
6.4 (0.25)
Additional Modules
(as required)
3-4
Arrangements (cont.)
CONTROL POWER
M-INTELLIVAC
CONTROL
POWER
FUSE
7 +
9 +
OVERLOAD
STOP
- 8
OPEN
CLOSE
START
16
- 10
CONTACTOR
STATUS
15
14
MODULE
STATUS
CAPACITOR
(OPTIONAL)
13
1 EC
2 +
TCO
4
3
11
AUX
12
CCO
6
5
MOV
M
CONFIGURATION
DIP SWITCHES
L1
INPUT POWER
G
L2/N
3-5
CONTROL POWER
M-INTELLIVAC
CONTROL
POWER
FUSE
7 +
9 +
OVERLOAD
STOP
- 8
OPEN
- 10
CLOSE
START
16
CONTACTOR
STATUS
15
14
MODULE
STATUS
CAPACITOR
(OPTIONAL)
13
1 EC
2 +
TCO
4
3
11
AUX
12
CCO
6
5
MOV
M
CONFIGURATION
DIP SWITCHES
L1
P'
P
INPUT POWER
G
L2/N
EMC FILTER
G
N'
N
3-6
Fuse Protection
110/120 VAC
220/240 VAC
125 VDC
250 VDC
Contactor Type
400A EH
800A EH
400/800A ML
400A EH
800A EH
400/800A ML
400A EH/ML
800A EH/ML
400A EH/ML
800A EH/ML
Recommended Fuse
(minimum)
TRM 2
TRM 2
TRM 2
TRM 2
TRM 2
TRM 2
ATM 3
ATM 5
ATM 3
ATM 5
(maximum)
TRM 3.2
TRM 6.25
TRM 3.2
TRM 6.25
TRM 6.25
TRM 6.25
ATM 3
ATM 6
ATM 5
ATM 6
Grounding
Connections
3-7
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.
Control power is applied to the module with a two-pole connector
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.
In order to meet CE electromagnetic interference requirements, an
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:
Contactor Status:
Terminals 13 and 14
Terminals 15 and 16
13
14
15
16
CONTACTOR STATUS OUTPUT (N.O.)
L1 L2/N
MODULE STATUS OUTPUT (N.O.)
POWER INPUT
3-8
Connections (cont.)
Interface Connections
Ground Connection
13 14 15 16
L1 L2/N
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.
10 11 12
Ground Connection
9 10 11 12
3-9
X
Y
Z
Terminal Designation
Close coil
Close command Z
10
11
12
Description
3-10
Wiring Guidelines
Electrically Held
Contactors
Close Contactor
Contactor Status
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). 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.
Some two-wire control schemes may be configured such that a close
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
(OPTIONAL)
CONTROL
POWER
FUSE
1 EC
2 +
11
AUX
12
L1
P'
P
TCO
4
3
CCO
6
5
G
EMC FILTER
G
MOV
M
L2/N
N'
N
RUN
OVERLOAD
M-IV
M-IV
9 + - 10
CLOSE
3-12
Wiring Guidelines
Electrically Held
Contactors (cont.)
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. If a
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
(OPTIONAL)
*
CONTROL
POWER
FUSE
1 EC
2 +
11
AUX
12
L1
P'
P
OVERLOAD
M-IV
STOP
TCO
4
3
CCO
6
5
MOV
M
L2/N
EMC FILTER
G
N'
N
START
9 + - 10
M-IV
15
CLOSE
16
CONTACTOR
STATUS
M-IV
3-13
15mS
CLOSE COMMAND
TO MICRO
DEBOUNCE
80mS
15mS
DEBOUNCE
Y
5mS
CLAMP DELAY
MICRO OUTPUT
TO CLOSE COIL
200mS
CLOSE LEVEL OF
CURRENT TO CLOSE
COIL
CONTACTOR STATUS
RELAY OUTPUT
SELECTABLE DROP
OUT TIME
(0 TO 190mS)
60mS
ACKNOWLEDGE
WINDOW
MODULE STATUS
RELAY OUTPUT
CONTACTOR PICK UP
90mS
(@120VAC)
NATURAL
CONTACTOR
DROP OUT
30mS
CONTACTOR
AUXLIARY
INPUT TO MICRO
Contact status relay closes on request to close. It will open if the contactor auxiliary contact does not close within 200 milliseconds and
module will fault (opening module status relay).
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.
3-14
Wiring Guidelines
Mechanically Latched
Contactors
1 EC
2 +
CONTROL
POWER
FUSE
M
M-IV
TCO
4
3
MOV
TC
MOV
11
AUX
12
L1
P'
P
CCO
G
EMC FILTER
G
CLOSE
6
5
CC
L2/N
N'
N
M-IV
9 + - 10
CLOSE
OPEN
OVERLOAD
M-IV
7 + OPEN
Mechanically Latched
Contactors
3-15
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 F for 120V control or 330 F
for 240V control. Use of larger capacitors will require a current
limiting circuit to prevent opening the control fuse on energization.
The IntelliVAC must receive an OPEN command within a few
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.
A separate voltage source is needed to provide the OPEN command.
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
Nominal Voltage
(Vac)
Actual
Vinput (Vac)
Ext.
Capacitor
(F)
120
120
400 Amp
3.5
1650
100
240
Note:
110
240
200
Max. time
for trip
(sec)
2.7
1.7
330
7.5
4.7
3-16
CONTROL POWER
M-IV
OPEN
CONTROL
POWER
FUSE
OVERLOAD
7 + -
OPEN
M
CAPACITOR
1 EC
2 +
TCO
4
3
MOV
TC
MOV
11
AUX
12
L1
P'
P
CLOSE
M-IV
CCO
G
EMC FILTER
G
6
5
CC
L2/N
N'
N
M-IV
9 + - 10
CLOSE
3-17
CONTROL
POWER
FUSE
1 EC
2 +
11
AUX
12
L1
P'
P
OVERLOAD
M-IV
STOP
TCO
4
3
CCO
6
5
MOV
M
L2/N
EMC FILTER
G
N'
N
START
9 + - 10
M-IV
15
CLOSE
16
CONTACTOR
STATUS
JOG
M-IV
M-IV
7 + -
OPEN
3-18
110/120 V
220/240 V
0.2
1.0
*
CONTROL
POWER
FUSE
1 EC
2 +
11
AUX
12
L1
P'
P
OVERLOAD
M-IV
TCO
4
3
CCO
6
5
MOV
M
L2/N
EMC FILTER
G
N'
N
START
STOP
9 + - 10
M-IV
15
M-IV
CLOSE
16
CONTACTOR
STATUS
Chapter
IMPORTANT
1
0
2
0
3
1
DIP switch
6
7
10
11
12
1
0
4-2
IntelliVAC Configuration
(cont.)
UP = 1
DOWN = 0
10
11
12
12
Power-Up Safety Y
-1000 to 0
Enable
1 to 1000
Disable
1001 to 2000
2001 to 3000
10
11
3001 to 4000
1
1
1
1
0
0
1
1
0
1
0
1
0
0
1
1
0
1
0
1
0.2 sec
Not defined
Not defined
TDUV config.
No TDUV
TDUV Enabled
50 msec
75 msec
Contactor Config.
100 msec
0
0
1
1
1
1
0
0
0
1
0
1
0
0
1
1
0
1
0
1
1
1
1
1
0
1
130 msec
150 msec
175 msec
200 msec
240 msec
Y
Z
Altitude X
4001 to 5000
0.5 sec
1.0 sec
2.0 sec
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).
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.
Chapter
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.
Module Status
Series B Design
Additional module states are indicated with the LED as per Table 5.B.
5-2
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).
Series B Design
Additional module states are indicated with the LED as per Table 5.B.
Table 5.A IntelliVAC Status Indication (Series A design)
Parameter
Conditions
Module Status
Y
Contactor
Status
X
Y
Z
[
LED State
Green
Closed
Red Y
Open
Off
Open
Yellow
Closed
Off
Open
5-3
Description
Module Status
LED Color
Contactor Status
Relay
LED Color
Relay
Normal
Green
Closed
Off
Open
Normal
Green
Closed
Yellow
Closed
Warning
Yellow
Closed
Off
Open
Warning
Yellow
Open
Yellow
Closed
Fault
Red Flash 2 [
Open
Yellow
Closed
Fault
Green
Open
Red Flash 1 Z
Open
Fault
Green
Open
Red Flash 2 [
Open
Fault
Green
Open
Red Flash 3 Z
Open
Fault
Microcontroller Malfunction
Red
Open
Red
Open
Fault
Red Flash 1
Open
Off
Open
Fault
Red
Open
Off
Open
X
Y
Z
[
\
]
^
5-4
Possible Solutions
5-5
Possible Solutions
Contactor Rating
(Amps)
Minimum Voltage
(VAC, 47 to 63 Hz)
Pick-Up
400/800
95
Drop-Out
400/800
75
400
70
800
80
5-6
Chapter
Spare Parts
Spare Parts List
1503VC-BMC1
1503VC-BMC2
80174-902-14-R
Multi-pole connectors:
2 pole (module power)
4 pole (status outputs)
12 pole (coil and I/O connections)
80174-014-01-R
80174-014-03-R
80174-014-11-R
1503VC-BMC3
Optional Equipment
TDUV Capacitor*
For 110/120V AC control (1650 F)
For 220/240V AC control (330 F)
80158-779-51-R
80158-779-52-R
EMC Filter
Schnaffer (FN 670-10/06)
80026-430-01-R
6-2
Spare Parts
Appendix
< 5000
< 5000
400A
800A
50
50
100
240
75
200
100
240
240 *
50
50
75
100
130
75
200
240 *
A-2
7200
8250
400A
800A
50
50
75
150
130
50
50
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 *)
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
Copyright 2013 Rockwell Automation, Inc. All rights reserved. Printed in Canada.