1503-UM051_-EN-P - Rockwell Automation
Contents
1. a CONTROL POWER CAPACITOR OPTIONAL M IV T tls 4 CONTROL gt EC TCO Ta POWER 2 3 ML FUSE M E 4 A MS N 12 5 L1 6 L2N EMCFILTER N G N OVERLOAD rap START 880 O Q Q O 9 10 LON CLOSE Refer to Table 3 A for recommended fuse sizing 15 Hie CONTACTOR STATUS 1503 UM051D EN P June 2013 Figure 3 10 Three Wire Control Installation and Wiring 3 13 15mS CLOSE COMMAND DEBOUNCE TO MICRO 15mS DEBOUNCE 5mS CLAMP DELAY SELECTABLE DROP OUT TIME 0 TO 190mS MICRO OUTPUT TO CLOSE COIL 1 1 1 1 1 CLOSE LEVEL OF CURRENT TO CLOSE 1 COIL ACKNOWLEDGE ra WINDOW CONTACTOR STATUS i RELAY OUTPUT MODULE STATUS RELAY OUTPUT ICONTACTOR PICK UP 90 5 120VAC DROP OUT NATURAL CONTACTOR aA I 30mS CONTACTOR AUXLIARY INPUT TO MICRO 9 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 Forthis 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 wire2. OPEN M IV 7 8 OVERLOAD OPEN CONTROL oL CAPACITOR M IV E Ul mo 51721 416 22 12 3 MON gt gt gt 6 2 CCO 5 w L1 G i P EMCFILTER e P G N CLOSE M IV gt 9 10 CLOSE Refer to Table 3 A for recommended fuse sizing Figure 3 13 Mechanically Latched Contactor with Capacitor Trip Option 1503 UM051D EN P June 2013 Installation and Wiring 3 17 Motor J ogging 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 Refer to Figure 3 14 This method will bypass the standard six second motor re start delay for jogging purposes only CONTROL POWER i M IV 1 4 CONTROL gt TCO gt POWER 2 3 MOV FUSE M I N EXON ax eco EI gt 12 5 iex E L1 6 L2N P EMCFILTER P N OVERLOAD STOP SINT 0 0 Bape a E M IV CLOSE 15H H16 CONTACTOR STAT
3. Flash EEPROM Interface 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 Jeonpsuei 1u8uno 109 s lloO 1oloeluoo xoeqpee4 xny Vacuum Contactor Trip Coil Vacuum Contactor Close Coil Vacuum Contactor Auxiliary Module Status Contactor Status 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 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
4. 200 msec 240 msec 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 ee 1503 UM051D EN P June 2013 Introduction Module Status Copter D Monitoring and Troubleshooting 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 CONTACTOR STATUS MODULE STATUS Figure 5 1 IntelliVAC LEDs 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
5. Allen Bradley InitelliVAC Contactor Control Module Bulletin 1508VC User Manual Rockwell Automation 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 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 softw
6. Please refer to Chapter 4 for information Bulletin 1500 1900 controllers are shipped with IntelliVAC pre configured 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 Table 1 A Electrical Ratings Main Input Voltage L1to 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 a Contactor Ratings Control Voltage Description Amps AC or DC AC Rating DC Rating Inrush Current 400 800 120 240 25 A peak 25 A peak 1 2 cycle 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 120 4 6A 3 6 A 400 Close Current 240 34A 33A 0 2 sec 120 11 3A 48A 800 240 89 45 120 70 37A 400 Trip Current latch 240 3 6A 20A 0 2 sec 120 70A 33A 800 240 43A 1 9A Command Inputs AC 100 to 240 V rms DC 24 to 250 V Maximum on state current for open or close command 9mAac 250 V AC 60Hz 60 9mApc 250 V DC 60 Minimum on state current for open or close command e 2mA c 100 V
7. AC 60Hz 60 600 24 V DC Ta 60 C Maximum off state current for open or close command 400uAac 11 V AC 60Hz 60 400 15 V DC Ta 60 C Status Output 250 V rms 5 R load 2 reactive PF 0 4 Contacts DC 30 V 5 R load 2 A reactive LIR 7 ms Standards and CE cULus CSA IEC pending Approvals 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 1503 UM051D EN P June 2013 1 6 Product Description Specifications cont Table 1 B Mechanical Ratings Temperature Operating 0 to 60 C ambient at the control module Non Operating 40 to 85 Altitude 1000 to 5000 meters Pollution Pollution level Il as defined by UL 840 and IEC 60664 1 Humidity Class Il Shock and Vibration Operational 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 Ambient temperature
8. Series A design Parameter Conditions LED State Relay Contact State Module Status rated supply voltage and valid configuration Green Closed e undervoltage or contactor fault or invalid configuration or internal fault Red Open insufficient supply voltage Off Open Contactor rated supply voltage and close command present and contactor closed Yellow Closed Status insufficient supply voltage or close command absent or contactor open Off Open eeo Applies only to power up condition Fault is reset by cycling control power 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 to remain closed resulting in a yellow state for contactor status For mechanical latch contactors a close command does not need to be maintained for the contactor Monitoring Troubleshooting 5 3 Table 5 B IntelliVAC Status Indication Series B design Conditions Daseriplion Module Status Contactor Status LED Color Relay LED Color Relay 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
9. 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 Module status LED Red and Contactor Status LED Off Series A Module status LED Green and Contactor Status LED Red Flash 1 Series B Armature Plate obstructed from closing to coil face Verify no foreign material behind the armature plate Cycle control power to reset Both status LEDs Off Check internal control fuse Verify IntelliVAC operation in test mode before applying Medium Voltage Refer to Fig 4 1 for location 1503 UM051D EN P June 2013 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 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 Contactor Status feedback between
10. is derated at altitudes above 1 000 meters 3 300 feet Please refer to Table 1 C Table 1 C Altitude Derating Altitude DIP Switch Setting 1 2 3 M amp ximum Operating ae 1000 to 0 000 60 1to 1000 001 60 1001 to 2000 010 58 2001 to 3000 011 56 3001 to 4000 100 54 4001 to 5000 101 52 Referto Chapter 4 Derate by 2 C 1000 m for high altitude operation 6 88 185 3 7 29 1503 UM051D EN P June 2013 H 165 9 6 53 5 8 0 228 2 places Dimensions in mm inches Figure 1 3 Mechanical Dimensions Receiving Receiving and Storage 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 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 1503 UM051D EN P June 2013 2 2 Recei
11. 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 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 OOO OOO OO 0 0 OO 00000000000000 0 0 0 0 0 0 0 0 lt 9 9 0 0 0 0 0 O CONTACTOR STATUS OUTPUT N O MODULE STATUS OUTPUT Q Figure 3 5 Bottom side connections Series A 1503 UM051D EN P June 2013 3 8 Installation and Wiring Connections cont Interface Connections Ground Connection diet ue 00000000000000 OOOO O 0 0 0 0 0 0 0 0 I O O O O O O OO 89 SS 13 14015 16 Q O L1 12 3
12. will have a default configuration per Table 4 A Table 4 A DIP Factory Default Settings DIP switch Description 1 2 3 4 5 6 T 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 4 2 Setup and Commissioning IntelliVA C Configuration IntelliVAC units shipped in a complete MV controller Bulletin 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 1 2 3 4 5 6 7 s 9 19 11 2 EN 12 Power Up Safety eae Ext cap TDUV time 0 2 sec UP 1 DOWN 0 Altitude 1000 to 0 1 0 1 to 1000 0 1001 to 2000 0 0 1 1 1 1 2001 to 3000 3001 to 4000 4001 to 5000 Not defined Not defined 0 5 sec 1 0 sec oO o 2 0 sec TDUV config No TDUV Drop outtime TDUV Enabled 50 msec 75 msec Contactor Config 400A Mech Latch 400A Elec Held 800A Mech Latch 800A Elec Held 100 msec 130 msec 150 msec 175 msec
13. A IntelliVAC Fuse Protection Rated Supply Voltage Contactor Type 400 TRM 2 TRM 3 2 110 120 VAC 800A EH TRM 2 TRM 6 25 400 800A ML TRM 2 TRM 3 2 400A EH TRM 2 TRM 6 25 220 240 VAC 800A EH TRM 2 TRM 6 25 400 800A ML TRM 2 TRM 6 25 125 VDC 400A EH ML ATM3 3 800A EH ML ATM5 ATM6 400A EH ML 3 ATM5 800A EH ML ATM5 ATM6 EH Electrically Held vacuum contactor ML Mechanically Latched vacuum contactor 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 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 Connections Installation and Wiring 3 7 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 Control power is applied to the module with a two pole connector located at
14. AG CONTACTOR STATUS OUTPUT N O MODULE STATUS OUTPUT POWER INPUT Figure 3 6 Bottom side connections Series B Interface Connections 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 000000000 OO OOO O20 OKO O O O O O O 220522020 O O p 12 5 6 10 11 12 EX CAP CONTACTOR INTERFACE Ground Connection Figure 3 7 Top side connections Series A 000000000 0 0 O oo SO 5 234 5 6 7 8 9 10 11 12 EX CAP CONTACTOR INTERFACE Figure 3 8 Top side connections Series B 1503 UM051D EN P June 2013 Installation and Wiring 3 9 Table Terminal Assignments for IntelliVAC Interface Connections Terminal No Terminal Designation Description 1 External capacitor negative Power connection for TDUV or capacitor m trip opti 2 External capacitor positive Loi 3 Latch ED coil common Output for mechanical latch contactor trip il 4 Latch trip gel 9 Close coll common Output to close coil of electrically held amp me
15. 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 An IntelliV AC control module may also be provided as a loose component for application with a Bulletin 1502 contactor by a third party OEM IntelliV AC is an efficient and flexible solution for controlling 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 1503 UM051D EN P June 2013 1 2 Product Description Description cont 1503 UM051D EN P June 2013 External Capacitor Optional o 3 Supply Voltage 110 240 or 110 250 VDC Close 9 7 Signal o Open 9 7 Signal o j Altitude Select Drop Out Select Contactor Select J TDUV p Time nrP Select i x Power Safety Coil Power Input Supply Power Conditioning Control Power Supply Command Inputs Micro Controller Configuration Inputs DIP Switches Current Regulator IGBT Coil Switching
16. CONTACTOR STATUS CAPACITOR OPTIONAL N M C N28 ux cco 4 MODULE 14 STATUS pd 13 EC TCO de 2 3 CONFIGURATION DIP SWITCHES 00000000000 INPUT POWER L1 G P EMCF TER P Referto Table 3 A for recommended fuse sizing Figure 3 4 IntelliVAC Typical Schematic Electrically Held Vacuum Contactor With Optional EMC Filter 3 5 1503 UM051D EN P June 2013 3 6 Installation and Wiring Fuse Protection Grounding 1503 UM051D EN P June 2013 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
17. Control 1503 UM051D EN P June 2013 3 14 Installation and Wiring Wiring Guidelines IntelliVAC control may be used for mechanically latched contactors Mechanically Latched A momentary control signal is needed to close the contactor and a Contactors 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 Itis permissible to apply an open command to the module as power is re applied CONTROL POWER MO 1 187 4 l CONTROL TCO Ns POWER FUSE pe EN m N ae 2 11 AUX cco 7 we 12 5 L1 G L2 N P EMCFILTER e P G N CLOSE M IV e 40 e CLOSE MV O 7 8 OVERLOAD OPEN Refer to Table 3 A for recommended fuse sizing Figure 3 12 Mechanically Latched Contactor Control 1503 UM051D EN P June 2013 Mechanically Latched Contactors Installation and Wiring 3 15 Capacitor Trip The IntelliVAC can be configured to provide capacitor trip functionality with mechanically latched contactors A
18. Ifthe 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 1503 UM051D EN P June 2013 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
19. L POWER FUSE CAPACITOR M IV fi 4 5 5 l MOV Z lt lt M 6 lt 2 CCO me e EMCFILTER P G N M IV OVERLOAD STOP START N o o Q lt 9 10 CLOSE Refer to Table 3 A for recommended fuse sizing 5 16 CONTACTOR STATUS 1503 UM051D EN P June 2013 Figure 3 15 TDUV Control Circuit 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 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 Ground Stud Series B Status Relay Outputs Supply Power Input Internal Control Fuse Figure 4 1 DIP Switch and Connector Locations An IntelliVAC unit shipped separately from the factory
20. 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 E CAPACITOR OPTIONAL M IV ia 1 4 CONTROL EC TCO POWER 2 3 TT gt gt FUSE M E 11 6 J CCO s e L1 G P EMCFILTER G N OVERLOAD RUN gt H 9 10 CLOSE Referto Table 3 A for recommended fuse sizing Figure 3 9 Two Wire Control 1503 UM051D EN P June 2013 3 12 Installation and Wiring 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 Ifa fault occurs in addition to cycling control power over to the IntelliV AC module the CLOSE command must be removed for a minimum of 4 seconds before being re applied Refer to Figure 3 10
21. Terminals 11 and 12 on the IntelliVAC has closed The IntelliVAC will de energize the coil thinking the contactor has opened for other reasons Both status LEDs Off Check control voltage and internal control fuse Refer to Figure 4 1 for location Contactor does not open mechanical latch only Module Status LED Red and Contactor Status LED Yellow Series A with firmware 2 001 or newer Check control power to ensure that it has not dipped below minimum see Table 5 D Module Status LED Yellow and Contactor Status LED Yellow Series B with firmware 2 001 or newer 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 Contactor Rating Minimum Voltage Voltage Level Amps VAC 47 to 63 Hz Pick Up 400 800 95 Drop Out 400 800 75 400 70 Trip Mechanical Latch 800 80 1503 UM051D EN P June 2013 5 6 Monitoring and Troubleshooting This page is intentionally left blank 1503 UM051D EN P June 2013 Spare Parts List Spare Parts IntelliVAC electrically held Series A IntelliVAC mechanical latch Series A IntelliVAC electrically held and mechanical latch Series B Internal Fuse 6 3 A 250 V Littlefuse 21506 3 Multi pole connectors 2 pole module
22. US JOG arias Refer to Table for recommended fuse sizing Figure 3 14 Motor J ogging 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 Intelli VAC 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 Ifthe 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 CONTRO
23. 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 Open Fault Contactor Drop Out During Hold Green Open Red Flash 2 O Open Fault Long Contactor Drop Out Time Green Open Red Flash 3 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 Warning Recoverable Condition Remove and retry offending signal Fault Non recoverable condition Module power must be removed and re applied 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 1503 UM051D EN P June 2013 5 4 Monitoring and Troublesho
24. actors the IntelliVAC allows close commands every six seconds This is to ensure the rated contactor duty cycle is not exceeded 2 Ifacontactor close command is applied and then removed in less than 500 milliseconds the IntelliV AC may fault To clear the fault module power has to be removed and reapplied 3 IfIntelliVAC 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 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 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
25. are 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 P P IMPORTANT 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 ARCFLASH 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 requir
26. 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 uF for 120V control or 330 uF 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 Nominal Voltage Actual C e a Rating Vinput Vac uF sec 120 3 5 120 110 1650 2 7 400 Amp 100 1 7 240 75 240 330 200 4 7 Note Minimum capacitor voltage ratings e 120V applications 200V DC 250V DC preferred 240V applications 400V DC 450V DC preferred 1503 UM051D EN P June 2013 3 16 Installation and Wiring
27. chanical latch contactors 6 Close coil 7 Open Jog command Input to open a mechanical latch contactor or jog an electrically held contactor 8 Open Jog command common mutually exclusive j Close command Input to initiate the closure of electrically held amp mechanical latch contactors 10 Close command common 11 Contactor auxiliary contact Input to indicate the state of the contactor typically wired to a normally closed 12 Contactor auxiliary contact auxiliary contact Referto Table 1 A for electrical ratings No connection required if option is not used 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 1503 UM051D EN P June 2013 3 10 Installation and Wiring Wiring Guidelines Electrically Held Contactors 1503 UM051D EN P June 2013 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 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 cont
28. ction interlocking and disconnect devices Failure to do so may result in personal injury and or equipment damage gt Pl Pl 1503 UM051D EN P June 2013 3 2 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 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 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 1 mm 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 respon
29. ements 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 Table of Contents Product Description Chapter 1 Introduction stet peores ERR PRENNE sts 1 1 Description trece 1 1 IntelliVAC Features esee 1 2 IntelliVAC Versions eene 1 3 Specifications us u nnns 1 4 Mounting and Connections 1 4 Configuration er ice eei rede 1 4 1 4 Electrical Ratings Table 1 5 Mechanical Ratings Table 1 B 1 6 Altitude Derating Table 1 C 1 6 Receiving and Storage Chapter 2 RECEIVING ee He Sun eee er editis 2 1 NIC thiya ak kaypu 2 1 Installation and Wiring Chapter 3 General Precautions ul a nuyu 3 1 Safety and CodeS deeem eee 3 Arrangements 3 2 Integral to an Allen Bradley MV Controller 3 2 paa added 3 3 Fuse Protection cette Pe EO oer eec 3 6 CrtOUnding yaa naspan u D pan OI WT ds 3 6 Connections sci ope RERO Sa aa 3 7 Control P
30. oting Table 5 C Module Troubleshooting Problem or Trip Indicated Indication of the following conditions Possible Solutions Contactor does not energize Motor Protection activated Both Status LEDs Off 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 Module Status LED Red upon power up IntelliVAC faulted Cycle control power to Series A reset Replace IntelliVAC if unsuccessful Module Status LED Red upon power up Improper setting of dip switches Check Series A settings and cycle control power Module Status Red Flash 1 upon power up Series B Loose connection in control circuit Verify contactor auxiliary set up Reference 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 Contactor closes momentarily and Module status LED Red and Contactor will not reclose Status LED Off Series A Coil damaged or connections are loose Repair and cycle control power Auxiliary Contact Assembly improperly adjusted Reference Publication 1502 UM052A EN P 400A or 1502 UM051B EN P 800A Auxiliary Contact Set up Procedure Cycle control power to reset Undervoltage
31. ower essere emere 3 7 Status Relays eee tete e oer deer aee rre 3 7 Interface Connections a 3 8 Wiring Guidelines Electrically Held Contactors 3 10 Twos Control a 3 11 Three Wire Control essere 3 12 Wiring Guidelines Mechanically Latched Contactors 3 14 Mechanically Latched Contactors 3 15 Capacitor Trip ene 3 14 Motor Jogging Control a 3 17 Time Delay Undervoltage sse 3 18 1503 UM051D EN P June 2013 ii Table of Contents Setup and Commissioning Monitoring amp Troubleshooting Spare Parts Appendix 1503 UM051D EN P June 2013 Chapter 4 IntelliVAC Configuration sesseeeeeeeeeee 4 1 Chapter 5 5 1 Module Status 5 1 Contactor Status 5 2 Series B Desigh ueniet ee eere etis 5 2 Chapter 6 Spare Parts Pista hasan te titre neg 6 1 Optional Equipment sess 6 1 Typical Contactor Drop out Times Table A 1 Contactor Drop out Times 1 Introduction Description Product Description This document contains information for the Allen Bradley
32. positioned for process set up IntelliVAC Versions Series A There are two versions of Intel VAC control The first type 1s used to control vacuum contactors that are electrically held with a single electrical coil that 15 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 1503 UM051D EN P June 2013 1 4 Product Description Specifications 1503 UM051D EN P June 2013 Mounting amp 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 IntelliV AC 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
33. power 4 pole status outputs 12 pole coil and I O connections Optional Equipment TDUV Capacitor For 110 120V AC control 1650 uF For 220 240V AC control 330 uF Includes mounting bracket and terminal guards EMC Filter Schnaffer FN 670 10 06 Chapter 1503 VC BMC1 1503 VC BMC2 1503 VC BMC3 80174 902 14 R 80174 014 01 R 80174 014 03 R 80174 014 11 R 80158 779 51 80158 779 52 80026 430 01 R 1503 UM051D EN P June 2013 6 2 Spare Parts 1503 UM051D EN P June 2013 Append 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 OR 50 12R 50 18R 19R 24R 100 32R 38R 48X 57X 2x24R 2x32R 2 x 38R 5000 75 200 100 240 240 RO 20 30E 40E 50E 65E 80E 100E 50 125E 150E 50 175E 200E 250E 300E 350E 75 400 100 450 500 600 750 900 lt 5000 75 200 240 ee oos Fuse not suitable fo
34. r use with 400A contactor 1503 UM051D EN P June 2013 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 eR 7200 9R 12R 50 18R 75 24R 150 2X18R 50 2X24R 130 20E 30E 40E 50E 65E 8250 80E 100E 125E 150E 175E 200E 50 50 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 June 2013 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Medium Voltage Products 155 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 S
35. sibility 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 me Dimensions inches 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 POWER CONTROL M INTELLIVAC 5 TIt o 718 CLOSE OVERLOAD STARI N e La a oo 116 CONTACTOR STATUS 15 xd MODULE 14 7 STATUS iod 13 CAPACITOR OPTIONAL S d x M MOV AUX CCO lt A E Nay 12 CONFIGURATION DIP SWITCHES 0000100000000 INPUT L G Referto 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 CONTROL POWER ED M INTELLIVAC m CONTROL POWER 8 OVERLOAD 4 _ 3 t qose 10 N 16
36. upersedes Publication 1503 UM051C EN P January 2006 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in Canada
37. ving and Storage This page is intentionally left blank 1503 UM051D EN P June 2013 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 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 P ATTENTI ON 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 ATTENTION 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 ATTENTION 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 prote
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