1503-UM052C-EN-P - Rockwell Automation
Contents
1. RETI NES Minimum bottom clearance 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 Arrangements cont 1503 UM 052D EN P June 2013 Installation and Wiring 3 5 MOV gt CONTROL POWER CoNTROL M INTELLIVAC POWER FUSE a cr 3 crose 9 OVERLOAD START c s Bo s 15 0 o L113 CAPACITOR OPTIONAL E 4 LL EC tco H 2 3 M LLL CONFIGURATION DIP SWITCHES INPUT POWER L1 G L2 N x Refer to Table 3 A for recommended fuse sizing Figure 3 3 IntelliVAC Typical Schematic Electrically Held Vacuum Contactor 1503 UM052D 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 ofinrush currents expected when the contactor is closed or from recommended external capacitors for the TDUV option They will also protect thecontactor coilsin the event of a module malfunction The recommended fuses havebeen tested to ensure reliable protect2. l e M IV OVERLOAD STOP START N olo 9 10 M IV CLOSE 15H CONTACTOR STATUS Joc MeV mt o Tle 8 Refer to Table 3 A for recommended fuse sizing OPEN Figure 3 12 Motor Jogging Control 1503 UM052D EN P June 2013 3 20 Installation and Wiring Undervoltage Protection Time Delay Undervoltage 1503 UM052D EN P June2013 The IntelliVAC controller protects the contactor from control voltage dipsand loss of power It provides undervoltage release and prevents attempts to close the contactor when there is not sufficient power available to guarantee reliable closing of the contacts The undervoltage protection will beinitiated under the following conditions regardless of nominal control voltage 1 Ifthe supply voltage drops below 90 V AC or DC during the first 200 milliseconds after a Close command is received This applies to both electrically held and mechanical latch contactors 2 Ifthe supply voltage drops below72 V AC or DC after the 200 millisecond close sequence electrically held contactors only The IntelliVAC can beconfigured 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 theaddition ofa capacitor see below Refer to Chapter 6 f
3. Li L2N AD POWER INPUT Figure 3 4 Bottom side connections Installation and Wiring 3 9 1503 UM052D EN P June2013 3 10 Installation and Wiring 1503 UM052D EN P June2013 Interface Connections All other controlinterface connections are made at a twelve pole connector located on the top of the module Refer to Figure3 5 and Table 3 B for connections and Table 1 A for electrical ratings Refer to the Wiring Guidelines section in this chapter for guidancein making connections to the control circuit OO OOO 055050505 oc c O 5205050550 O O O OO EX CAP CONTACTOR INTERFACE Figure3 5 Topside connections Table3 B Terminal Assignments for IntelliVAC Interface Connections Terminal No Terminal Designation Description 000 1 External capacitor negative Power connection for TDUV or capacitor trip options only External capacitor positive 3 Latch trip coil common Output for mechanical latch contactor trip coil Latch trip coil gt 5 Close coil common Output to close coil of electrically held amp 6 Close coil mechanical latch contactors N Open Jog command Input to open a mechanical latch contactor or jog 8 Open Jog command common an electrically held contactor mutually exclusive 9 Close command Input to
4. 3 6 Control 3 6 Stat s Relays 3 6 Interface Connections 3 7 Wiring Guidelines Electrically Held Contactors 3 8 Control with Solid State Devices 3 9 ep eR 3 10 Three Wire Control ananassa 3 11 Wiring Guidelines Mechanical Latch Contactors 3 13 Mechanical Latch Contactors inten 3 14 OBEY KEO a E E 3 14 Motor Jogging Control uaa a nn 3 16 Undervoltage Protection n nn 3 17 Time Delay Undervoltage a annua 3 17 1503 UM052D EN P June2013 ii Table of Conte nts Setup and Commissioning Monitoring and Troubleshooting Spare Parts Appendix A 1503 UM052D EN P June 2013 Chapter 4 InteliVAC Configuration 4 1 DIP Factory Default Settings Table 4 A a 4 2 IntelliVAC DIP Switch Explanation Table 4 B 4 2 Chapter 5 tuli uet uin uterque 5 1 Module Status a o dere 5 1 Gontactor 5 2 IntelliVAC Status Indication Series C Table 5 A 5 3 IntelliVAC Status Indication Series D Table S B 5 4 Module Troubleshooting Table 5 C 5 5 Min Intelli VAC Operational Supply Voltages Table 5 D 5 6 Chapter 6 Spare Parts List
5. M IV CLOSE Refer to Table 3 A for recommended fuse sizing 15 H H 16 CONTACTOR STATUS 1503 UM052D EN P June 2013 Figure 3 8 Three Wire Control Installation and Wiring 3 15 Wiring Guidelines Electrically Held Contactors cont 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 15mS DEBOUNCE SELECTABLE DROP OUT TIME 0 TO 190mS 5mS CLAMP DELAY ACKNOWLEDGE WINDOW 1 1 1 PICK UP 1 1 505 NATURAL ins 120VAC CONTACTOR DROP OUT 9 Contact status relay closes on request to close It will open if 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 Figure 3 9 Timing Diagram 4004 Electrically Held Contactor for IntelliVAC Control with three wire Control 1503 UM052D EN P June2013 3 16 Installation and Wiring Wiring Guidelines Mechanical Latch Contactors 1503 UM052D EN P June2013 IntelliVAC control may beused for mechanical latch contactors A momentary control signal is needed to c
6. 1 When used with electrically held contactors the IntelliVAC allows close commands every six seconds Thisis to ensure the rated contactor duty cycleis not exceeded 2 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 closecommand until the vacuum contactor auxiliary contact input isin the correct closed stateand module power is removed and re applied See Chapter 5 3 Ingeneral a Close command should only beapplied 4 seconds after energizing IntelliVAC For Emergency Stop applications requiring removal of power a contact should be placed in A the L1 control power rung to the IntelliVAC Ifthe TDUV feature is used the contactor will not open until the programmed TDUV time has expired 1503 UM052D EN P June 2013 3 12 Installation and Wiring 1503 UM052D EN P June2013 Control with Solid State Devices Ifcontroldevices that employ electronicor suppressed output circuitsare used in the rung s that controltheinputsto the IntelliVAC alternate arrangements may be required Devices employing transistor or triac output circuits have finiteimpedanceand allow a leakage current to flow inthe blocking or offstate Some PLC and I O modules with relay outputsalso have snubber circuits across the contacts to suppress noise generated during contact opening Theimpedance of these circuits
7. Drop Out Select Contactor Select _ TDUV Time Select Power Up Safety Input Power Conditioning Coil Power Supply jmp Current Regulator Control Power Supply IGBT Coil Switching Command Inputs Micro Controller Configuration Inputs DIP switches Flash EEPROM Interface Figure 1 2 IntelliVAC Block Diagram IntelliVAC Features 1503 UM052D EN P June2013 JeonpsueJ WOUND 109 eoepeiu 109 J0 0e U0D xoeqpee4 xny Vacuum Contactor Trip Coil Vacuum Contactor Close Coil Vacuum Contactor Auxiliary Module Status Contactor Status A wide range of supply voltage 110 240 V AC 50 60 Hz 110 250 V DC allowsimplementation in multiple applications Consistent vacuum contactor pick up time ata given supply voltage ensures repeatable performance Selectable vacuum contactor drop out time improves coordination with upstream power fuses Electronicaltitude compensation 400 A only eliminates mechanical compensation required for altitudes above 1 000 meters 800 Acontactors include a user friendly altitude adjustment Product Description 1 3 Power loss ride through TDUV allows the vacuum contactor to remain closed during short power loss may requirean optional external capacitor dependant on ride through time 1503 UM052D EN P June 2013
8. 1 4 Product Description 1503 UM 052D EN P June 2013 IntelliVAC Features cont Anti kisandanti pumping protection ensure that the vacuum contactor close open sequence occurs as expected avoiding rapid re closure due to faulty control devices Delayed restart protects the vacuum contactor by ensuring that the rated duty cycle is not exceeded Temporary jog function electrically held contactors only allows the motor to be positioned for process set up IntelliVAC Versions Series A Series B Series C Series D There are two versions of IntelliVAC control The first typeisused to control vacuum contactors that are electrically held witha single electrical coil that is economized electronically The second is used to control mechanically latched vacuum contactors There is a single version of IntelliVAC to control both electrically held and mechanically latched vacuum contactors Updated version of the Series B module Minor functionality firmware enhancements primarily related to definition and handling of Faults and Warnings Refer to Chapter 6 for catalog numbers for each version of IntelliVAC Note A Series C or Series D IntelliVAC modulecan be used to replacea Series or Series B module When replacing an older series of IntelliVAC witha newer one note that the Module and Contactor Status out puts may function differently Refer to publication 1503 UM051_ EN P and or Chapter
9. 15 H H 16 CONTACTOR STATUS 1503 UM052D EN P June 2013 Figure 3 13 TDUV Control Circuit chapter 4 Setup and Commissioning IntelliVAC Configuration The IntelliVAC moduleis configured fora specific application by setting DIP switches They areaccessed 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 Hazardous voltage is present insidethe module which may cause personal injury or death A Removeall sources of power from the module and discharge any connected capacitors before removing the cover IMPORTANT Remove power from the module before removing the cover and before changing the DIP switch settings The new DIP switch settings are recognized only on power up EEPROM Programming Port Mini DIN Connector DIP Switches LEDs Ground Stud Status Relay Outputs Supply Power Input Internal Control Fuse Figure 4 1 DIP Switch and Connector Locations 1503 UM052D EN P June2013 4 2 Setup and ommissioning An IntelliVAC unit shipped separately from the factory will have a default configuration per Table4 A 1503 UM052D EN P June 2013 Setup and ommissioning 4 3 Table 4 A DIP Switch Factory Default Settings
10. 1900 MV controller or OEM component Integral to an Allen Bradley MV Controller The IntelliVAC is available asa primary component ofan 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 UM052D EN P June 2013 Installation and Wiring 3 3 OEM The IntelliVAC may be ordered as OEM component This allows the OEM to mount thecomponents 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 TD UV Capacitor are also the OEM s responsibility Refer to Figure 3 3 for basic connections 1503 UM052D EN P June 2013 3 4 Installation and Wiring Minimum top clearance 38 1 1 50 S Je Dimensions in mm inches e e e Y LE LOS LCS 31 E lt 4029
11. from a sharp angle you may see only green or red Please view from directly in front ofthe module to ensure accurate color recognition Monitoring and Troubleshooting 5 3 Table 5 A IntelliVAC Status Indication Series only Conditions Contactor Status Rely LED Color Relay Normal Healthy Module and Contactor OPEN Off Open Normal Healthy Module and Contactor CLOSED Yellow Closed Warning Invalid Command Present Off Open Warning Mechanical Latch Fail to Trip Yellow Yellow Closed Fault Power Up with Contactor CLOSED Red Flash2 Yellow Closed Fault Contactor Fails to Pick Up Gren Ow Red Flash 1 Open Fault Contactor Drop Out During Hold Green Red Flash2 Open Fault Long Contactor Drop Out Time Green Ow Red Flash3 Open Fault Microcontroller Malfunction Fault Power Up with Invalid Dip Switch Configuration Red Flashi Fault Undervoltage with a CLOSE Command Present Waming 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 Only for Electrically Held Contactor Invalid Command Types 1 Close Jog or Trip commands present during power up sequen
12. resolved Faults require control power to be removed until the unit resets Flash 1 1 Flash Red LED followed by a pause Flash 2 2 Consecutive Red LED flashes followed by a pause Yellow R1 Yellow with 1 Red flash followed by a pause Yellow R2 Yellow with 2 consecutive Redflashes followed by a pause Yellow R3 Yellow with 3 consecutive Red flashes followed by a pause Invalid Command Types 1 Close Jog or Trip commands present during power up sequence 2 Close orJog 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 willonly 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 Open during undervoltage Closed ifvoltage restored Will reflect actual status of the contactor Only for Electrically Held Contactor Undervoltage conditions are defined on page 3 17 00000000 1503 UM052D EN P June 2013 Table 5 C Module Troubleshooting Problem or Trip Indicated Contactor does not energize Contactor closes momentarily and will not redose Contactor fails to dose Indication of the following conditions Motor Protection activated Both Status LEDs Off Module Status LED Red upon power up e Module Status Red Flash 1 upon pow
13. 4000 54 4001 to 5000 52 Derate by 2 C 1000 m for high altitude operation 5 1 0 20 20 165 9 6 53 E 5 8 0 228 2 places 6 88 185 3 7 29 m Im z Ban le Dimensions in mm inches Figure 1 3 Mechanical Dimensions 1503 UM052D EN P June2013 Receiving Storage Chapter 2 Receiving and Storage Upon receiving the controller remove the packing and check for damage that may have occurred during shipping Report any damage immediatdy to theclaims office of the carrier NOTE Ifthe IntelliVAC module isan integral component ofa complete MV controller Bulletin 1500 1900 special receiving and handling instructions willapply For details refer to the service manual provided with the equipment It isimportant to consider the following storage requirements if you are not installing your controller immediately after receiving it e Storethecontroller in a clean dry dust free environment e Storage temperature should be maintained between 40 C and 85 C 40 F and 185 F e Relative humidity must not exceed 95 non condensing 1503 UM052D EN P June 2013 2 2 Receiving and Storage This page is intentionally left blank 1503 UM052D EN P June 2013 Chapter 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 und
14. 5 of thisdocument and make any necessary changes to the control circuit Specifications Product Description 1 5 Mounting and Connections The IntelliVAC control modules are mounted using two 2 screws see Figure 1 3 They are typically located in the low voltage control panel of the medium voltage controller Bulletin 1500 1900 controllers in the case of Rockwell Automation IntelliVAC isinterfaced to the Bulletin 1502 vacuum contactors using a quick connector located at the module a wire harness and quick connector at thecontactor 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 controlapplications It isconfigured using DIP switches located within the enclosure front side 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 ifnecessary The IntelliVAC board firmware is updated using the mini DIN connector which is accessible inside the enclosure The firmware version supplied with the module is displayed on top of the DIP switches see Figure 4 1 Series C modules use only version 2 003 applicat
15. 6 1 Optional Equipment petto 6 1 Typical Contactor Drop out Time Settings Typical Contactor Drop out Time Settings Table A 1 1 Introduction Scope Description Chapter Product Description This document containsinformation for the Allen Bradley Bulletin 1503VC IntelliVAC control module The Bulletin 1503VC is used to control the Allen Bradley Bulletin 1502 vacuum contactors that area significant component of the Bulletin 1500 1900 CENTERLINE Medium Voltage Motor Controllers offered by Rockwell Automation An IntelliVAC control module may also be provided asa loose component for application with a Bulletin 1502 contactorby a third party OEM This document applies to Series or later version of IntelliVAC Refer to publication 1503 UM05 1_ EN P for information related to the Series A and B designs IntelliVAC isan 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 1503 UM052D EN P June 2013 1 2 Product Description Figure 1 1 IntelliVAC Contactor Control Module Description cont External Capacitor Optional Supply Voltage 110 240 VAG or 110 250 VDC Close Signal Open Signal Altitude Select
16. IntelliVAC Contactor Control Module Nu m USER MANUAL Series C and later Bulletin 1503VC ALLEN BRADLEY ROCKWELL SOFTWARE 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 infor
17. Procedure Cycle control power to reset Series C Armature Plate obstructed from closing to coil face Verify no foreign material behind the armature plate Cyde control power to reset Check internal control fuse Verify IntelliVAC operation in test mode before applying Medium Voltage Refer to Fig 4 1 for location Refer to Table 5 A Series or Table 5 B Series D for definition of Module LED states 1503 UM052D EN P June 2013 5 6 Monitoring and Troubleshooting Contactor Status cont Table 5 Module Troubleshooting cont Indication of the following conditions Problem or Trip Indicated Contactor opens during operation Module Status LED Red Series C or Yellow Flashing Series D Module Status LED Green and Contactor Status LED Red Flash 2 Series C or Module Status LED Yellow R2 and Contactor Status LED Off Module Status LED Yellow and Contactor Status LED Yellow Contactor does not open mechanical latch Series Module Status LED Green and Contactor Status Red Flash 3 Series D Module Status LED Yellow R3 and Contactor Status LED Yellow Contactor does not open electrically held Motor Protection activated Stop command initiated Both status LEDs Off Possible Solutions Investigate and reset Verify circuit Undervoltage fault no TDUV control voltage dip
18. TROL POWER OPEN M IV L o 7 84 OVERLOAD OPEN CONTROL 22 CAPACITOR C 1 4p TCO N 2 3 MOV fce 27 X D AUX cco EP CEA T L1 G L2 N OVERLOAD CLOSE M IV 9 ve 9 10 CLOSE Installation and Wiring 3 19 Motor Jogging Control Note Jog functionality can work with electrically held contactor only When used with electrically held contactors the Intelli VAC allows close commandsevery 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 aslong asthe input is present and open thecontactor when the input is removed Refer to Figure 3 12 This method will bypass the standard six second motor re start delay for jogging purposes only Operations willbe limited to two starts every twelve seconds Ifthe TDUV featureis used the contactor will not open until the programmed TDUV time has expired Therefore applications requiring an immediate removal of power during emergency stop conditions are not compatible withthe TDUV feature CONTROL POWER M IV 1l CONTROL EC TCO POWER 2 3 MOV gt FUSE M 7 CN ax lt lt P 12 5 25 o L1 L2 N STOP when required
19. Wiring 3 7 1503 UM052D EN P June2013 3 8 Installation and Wiring Connections 1503 UM052D EN P June2013 There are three green connectors on the IntelliVAC module for connections to thecontrol circuitry Connector plugs are provided with the module Ifadditional 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 the bottom rear portion of the module Refer to Figure3 4 for connections The L connection is intended to be the Hor or side of the control power and the L2 N connection is intended to bethe Neutral Return or sideof the control power Status Relays Status relay connections areaccessed witha four pole connector located at thebottom front portion of the module Refer to Figure 3 4 for connections There aretwo 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 Ground Connection 00000000000000 0 O COCO O OS OOOO OO res gt Co e E uer N O MODULE STATUS OUTPUT N O
20. also allows leakage current to flow when thecontactsare open The high impedance input circuits of the IntelliVAC may be triggered by this leakage current or residual terminal voltage causing unintended operation of the contactor or maintenance of the closed state when the control signal is removed This situation can be prevented by consideration of the control devices when designing the controlsystem If PLC or similar control devices are to be interfaced to the IntelliVAC consider using relay outputs with no suppression devices across the contacts the IntelliVAC inputs area high impedance resistive load Ifthis cannot be done consider the leakage current of the device to see if it is compatible with IntelliVAC inputs see Table 1 A Ifnot compatible consider using an interposing relay connected as shows in Figure 3 6 lt CONTROL POWER gt M IV CONTROL M POWER ZH ee rco FUSE ll 3 ot gt gt MOV Ll lt N AUX cco lt NM gt 5 INPUT POWER G SOLID STATE OVERLOAD OUTPUT CR s N a p 9 f close 10 R efer to Table 3 A for recommended fuse sizing CR Figure 3 6 Control with Solid State Devices Wiring Guidelines Electrically Held Contactors cont Installation and Wiring 3 13 Two Wire Co
21. ce 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 Undenmoltage conditions are defined on page 3 17 Open Off Open Off Open o9o9o0cocec 1503 UM052D EN P June2013 5 4 Monitoring and Troubleshooting Contactor Status cont Table 5 B IntelliVAC Status Indication Series Donly Conditions Module Status Contactor Status Normal Healthy Module and Contactor OPEN Green Off Open Normal Healthy Module and Contactor CLOSED Green Yellow Closed Warning Invalid Command Present Yellow Off Open f Description Relay Warning Yellow Yellow Closed Fault Red Flash2 Yellow Closed Warning Yellow R1 Off Yellow Open Closed Warning Yellow R2 Off Yellow Open Closed Warning Yellow R3 Off Yellow Open Closed Fault Microcontroller Malfunction On R Open Fault Power Up with Invalid Dip Switch Configuration Red Flash 1 lt Of Open Warning Undervoltage with a CLOSE Command Present Yellow Flashing Open Closed Off Yellow Open Closed Wamings will be cleared when a change of input state occurs and the condition has been
22. ctor Status 1503 UM052D EN P June 2013 Ifthe processor hasan internal fault the LED will be Red the outputs will be cleared and the processor must be reset input power must be cycled Ifthe reset is successful the LED will be Green and the module willrespond to thecontrol inputs Theinput command must be toggled before the module will respond to new command rising edge triggered For Series D the Module Status LED is also used to indicate various Warning conditions related to the contactor performance see Table 5 8 Module Status output relay hasa normally open contact The contact is open during Fault condition LED red and closed during a healthy condition LED green The relay is open for some warning conditions but closed for less severe issues The module states are summarized in Tables 5 A and 5 B The Contactor Statusisindicated with a yellow LED that isoffuntila CLOSE command isreceived The yellow LED will stay on if the contactor closes properly until the contactor isopened Ifthe processor has an internal fault the LED will be red Contactor Status output relay hasa normally open contact Thecontact is open when thecontactor isopen LED off and closed when the contactor has received a close command for 200 milliseconds or ifit is closed LED on The contactor states are summarized in Tables 5 A and 5 B The LEDsare red green types with both sections ON to produceyellow Ifviewed
23. d M IV OVERLOAD RUN N 7 8 CLOSE Refer to Table 3 A for recommended fuse sizing 1503 UM052D EN P June2013 3 14 Installation and Wiring Figure 3 7 Two Wire Control Three Wire Control Ifusing three wirecontrol the CLOSE contactor input is maintained high using two contacts Momentarily openingthisinput will cause the IntelliVAC to open the contactor Momentarily closing the START contact will providea CLOSE command to Intelli VAC given that all permissives are satisfied In this configuration theS TATUS output actsasa seal in contact Ifa fault occurs in addition tocycling control power over tothe IntelliVAC module the CLOSE command must be removed fora minimum of 4 seconds before being re applied Refer to Figure 3 8 For Emergency Stop applications requiring removal of power a contact should be placed in the L1 control power rung to the IntelliVAC Ifthe TDUV featureis used the contactor will not open until the programmed TDUV time has expired CONTROL POWER CAPACITOR OPTIONAL M IV ill 4 CONTROL 3 EC TCO 3 gt ll POWER FUSE 11 6 M GNO AUX CCO lt NZ 12 5 olo L1 G L2 N EMERGENCY STOP IS when required M IV OVERLOAD STOP START N o o 0 0 9 10
24. er up Loose connection in control circuit Module status LED Red Series C and Contactor Status LED Off or Module status LED Yellow Flashing and Contactor Status LED Off Series D Module status LED Green and Contactor Status LED Red Flash 1 Series C or Module status LED Yellow R1 Series D and Contactor Status LED Off Both status LEDs Off Monitoring and Troubles hooting 5 5 Possible Solutions 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 control power Verify contactor auxiliary set up Reference Publication 1502 UM052_ EN P 400A or 1502 UM051_ EN P 800A Auxiliary Contact Set up Procedure Verify circuit continuity is contactor plug connected properly Undervoltage fault no TDUV control voltage dipped below trip point Verify voltage levels are 110 to 240 VAC 110 to 250VDC Coil damaged or connections are loose Repair and control power Series C Auxiliary Contact Assembly improperly adjusted Reference Publication 1502 UM052_ EN P 400A or 1502 UM051_ EN P 800A Auxiliary Contact Set up
25. erstood ATTENTION gt ATTENTION A ATTENTION A Safety and Codes The controller contains ESD electrostatic discharge sensitive partsand assemblies Static control precautions 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 staticcontrol procedures refer to applicable ESD protection handbooks An incorrectly applied or installed controller can damage componentsor reduce product life Wiringor application errors such asincorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction ofthe system Only personnel familiar with the controller and associated machinery should plan or implement the installation start up and subsequent maintenance ofthe system Failureto do this may result in personal injury and or equipment damage 1503 UM052D EN P June2013 3 2 Installation and Wiring The Canadian Electrical Code CEC National Electrical Code NEC or other local AN 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 Arrangements The IntelliVAC is offered in two arrangements Integral part ofa Bulletin 1500
26. initiate the closure of electrically held and mechanical latch contactors Close command common 1 Contactor auxiliary contact Input to indicate the state of the contactor typically wired to a normally closed auxiliary 12 Contactor auxiliary contact contact Refer to Table 1 A for electrical ratings No connection required if optionis 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 The Series C and D IntelliVACs are compatible with most PLC outputs and have been verified with Rockwell Automation OA type 120V triac outputs See Wiring Guidelines For electrically held contactor this command will energize the close coil output CCO For mechanically held contactor this command will energize the trip coil output Wiring Guidelines Electrically Held Contactors Installation and Wiring 3 11 The IntelliVAC can be applied with two or three wirecontrolcircuits The control system utilized will determine the configuration of the input wiring Consider the following input and output for the typeof control used e Terminals9and10 Close Contactor e Terminals 15and 16 Contactor Status In either case the CLOSE input must receivea maintained voltage high to keep thecontactor closed Note
27. ion firmware This firmware isalso compatible with the Series A and B modules Series D modules use only version 3 001 or 3 002 application firmware This firmwareisnot compatible with any other Series Letter modules Refer to Chapter 6 for part numbers of the various series of modules The Series Letter of the module is printed on the label on the cover of the module beside the part number 1503 UM052D EN P June 2013 1 6 Product Description Table 1 A Electrical Ratings Main Input Voltage L1 to L2 N Main Input Current L1 to L2 N Command Inputs 5C Status Output Contacts Standards and Approvals Includes idle curent n AW Ta Ambient Temperature AC 110 to240 V ms 10 15 47 to 63 Hz DC 110 to 250 V 10 15 ts Contactor Ratings Control Voltage 3 400 800 120 240 ae LE 25 A peak Idle Current Maximum without contactor coil 400 800 120 240 125 mA 35mA energized Hold Current zz maximum 400 800 120 240 300 mA 100 mA 46 EEDM 364 400 0 2 sec BE E 113A 48 A 800 120 7 0 A 37 400 Trip Current latch Z 240 3 6 A 20A 0 2 sec 120 70A 33A 800 240 19 100 to 240 V rms DC 50 to 250 V Maximum on state current for open or close command 9mA 250 V AC 60Hz Ta 60 C 9mAy 250 V DC Ta 60 C Minimum on state current for open or close command 2mAac 100 V AC 60Hz T 60 C 1 2 mA 50V DC Ta 60 C Maximum off state current for open
28. ion of the module If the supply voltageis DC the module must be used with an external fuse that isapproved 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 isa time delay type rated 250 VAC The ATM isa fast acting type rated 500 VDC Table 3 A IntelliVAC Fuse Protection Recommended Fuse vain 400A EH 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 400A EH ML ATM 3 ATM 3 125 VDC 800A EH ML 5 6 400A EH ML ATM 3 ATM5 250 VDC 800A EH ML ATM 5 ATM 6 EH Electrically Held vacuum contactor ML Mechanical Latch vacuum contactor Rated Supply Voltage Contactor Type Note Ifexternal capacitors are connected or more than one IntelliVAC module is protected by common control fuse the maximum recommended fuse should be used to prevent fuse opening due to increased inrush current when control power is applied Grounding The IntelliVAC module must be connected toa common ground terminal PE onthecontroller panel The ground terminal is located on the bottom of module enclosure refer to Figure 3 4 It isimportant that IntelliVAC is properly grounded using the ground connection A provided Failure to do so may result in damage to equipment or personal injury 1503 UM052D EN P June 2013 Installation and
29. lose the contactor anda second momentary control signalis needed to open the contactor The momentary open close commands must be at least 50 milliseconds in duration Refer to Figure 3 10 fora typical mechanical latch control scheme Note 1 A mechanical latch contactor may already be closed when power is applied to the IntelliVAC control module 2 Itispermissible to apply an open command to the IntelliVAC moduleas power is re applied CONTROL POWER oli WW MOV a CONTROL Wee 512 s OL gt POWER 2 3 FUSE aux e A gt gt G L2IN OVERLOAD CLOSE M IV N 9n 9 101 CLOSE OPEN M IV ILL 1 8 OVERLOAD OPEN Refer to Table 3 A for recommended fuse sizing Figure 3 10 Mechanical Latch Contactor Control Mechanical Latch Contactors Installation and Wiring 3 17 Capacitor Trip The IntelliVAC can be configured to provide capacitor trip functionality with mechanical latch 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 thecontactor Maximum recommended capacitor size is 1650 uF for 120V control or 330
30. m si Sa ER RAR Ee eee Altitude 0 to00m_ Contactor config 400A EH TDUV config No TDUV Ext cap TDUV time 0 2 sec Power Up Safety Enable IntelliVAC units shipped in a complete MV controller Bulletin 1500 1900 willbe configured to suit the installed application i e contactor type The user should verify the settings before energizingthe equipment Table 4 B defines the settings for each switch Table 4 B IntelliVAC DIP Switch Explanation ia Porn Cw m owe foo 0 Low DT mew wem T mem Dr o fo wem wes beep vine I 9 TDUV config O mee 5 gt ww o sewee ww fo 99e r aca 200 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 retum springs 800 amp contactors are to be set for 1 to 1000m 001 DIP setting 1503 UM051C EN P June 2005 4 4 Setup and ommissioning By pass contactors in MV SMC applications must be set for 50 millisecond drop out time Refer to Appendix A for typical drop out time settings used when power fuses are provided by Rockwell Automation 1503 UM052D EN P June 2013 Introduction Module S
31. mation 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 gt 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 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 Equi
32. ntrol Ifusing two wirecontrol the CLOSE contactor input is maintained high using a single contact Momentarily opening thisinput will cause the IntelliVAC to open the contactor Maintaining the contact will provide a CLOSE command to IntelliVAC given that all permissives are satisfied Ifa 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 7 Sometwo 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 Refer to Table 4 B ATTENTION Only disable the Power Up safety feature when absolutely necessary Doing so can create A unsafe operating conditions ATTENTION For Emergency Stop applications requiring removal of power a contact should be placed in A the L1 control power rung to the IntelliVAC Ifthe TD UV featureis used the contactor will not open until the programmed TDUV time has expired lt CONTROL POWER gt CAPACITOR OPTIONAL M IV acn CONTROL EC TCO POWER 2 3 9 gt MOV FUSE TS 11 SN 1 AUX cco lt P gt Se LI G L2 N EMERGENCY STOP when require
33. or close command 700 uA 20 V AC 60 Hz Ta 60 C 900 pA 30 V DC Ta 60 AC 250 V rms 5 A R load 2 A reactive PF 0 4 DC 30 V 5 A R load 2 reactive L R 7 ms CE cULus CSA IEC pending Ensure compatibility of IntelliVAC input ratings with those of circuit components activating these inputs Consider means of isolating loading these signa as required using interposing relays or load resistors Consult factory for assistance if needed The Series D IntelliVACs are compatible with most PLC outputs and have been verified with Rockwell Automation OA type 120Vtriacoutputs See Chapter 3 Wiring Guidelines 1503 UM 052D EN P June 2013 Specifications cont Product Description 1 7 Table 1 B Mechanical Ratings Operating 0 to 60 C ambient at the control module Temperature Non Operating 40 to 85 C Altitude 1000 to 5000 meters Pollution Pollution level Il as defined by UL 840 and IEC 60664 1 Humidity 95 non condensing Shock 15 g peak 11 milliseconds Shock and Vibration Operational Vibration 10 to 57 Hz 0 015 inch displacement peak to peak 57 to 150 Hz 2 5 g acceleration Ambient temperature is derated at altitudes above 1 000 meters 3 300 feet Please refer to Table 1 C Table 1 C Altitude Derating Maximum Operating Ambient ee at the control module C 1000 to 0 60 1 to 1000 60 1001 to 2000 58 2001 to 3000 56 3001 to
34. or typical capacitor sizing The capacitor is connected to terminals 1 and 2 ofthe IntelliVAC Refer to Figure 3 13 Ifthe TDUV featureis used the contactor will not open until the programmed TDUV time A has expired Therefore applicationsrequiring animmediateremovalof power during emergency stop conditionsare not compatible with the TDUV feature 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 ofan external capacitor as shown in Table 3 D Table 3 D Maximum TDUV Time without Capacitor Max TDUV Time secs Control Voltage 110 120 V 220 240 V Ifthe undervoltage condition persists beyond the set delay time the contactor will be opened andan undervoltage fault or warningconditionwill occur see Chapter 5 Installation and Wiring 3 21 1503 UM052D EN P June2013 3 22 Installation and Wiring Time Delay Undervoltage cont CONTROLPOWER _ CAPACITOR M IV x C m 4 CONTROL ihe TCO 3 m gt POWER FUSE T 11 6 M aux CCO gt gt 12 5 L1 G L2 N M IV OVERLOAD STOP START N al 9 10 M IV CLOSE Refer to Table 3 A for recommended fuse sizing
35. ped below trip point 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 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 Check control voltage and internal control fuse Refer to Figure 4 1 for location Trip mechanism is damaged Inspect and replace if needed Check for loose connections in the control circuit Contactor welded or mechanisms binding Inspect and repair if needed Refer to Table 5 A Series or Table 5 B Series D for definition of Module LED states Table 5 0 Minimum IntelliVAC Operational Supply Voltages Voltage Level Contactor Rating Amps Minimum Voltage VAC 47 to 63 Hz Pick Up 400 800 95 Drop Out Trip Mechanical Latch 1503 UM052D EN P June 2013 400 800 75 s 80 Spare Parts List Spare Parts IntelliVAC electrically held Series A IntelliVAC mechanical latch Series A IntelliVAC electrically held and mechanical latch Series B IntelliVAC electrically held and mechanical latch Series C and D Internal Fuse 6 3 A 250 V Littlefuse 21506 3 Multi pole connectors 2 pole modulepower pole statusoutputs 12 pole coiland I O connections Optional Equipmen
36. pment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt P 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 ae 1 1 SCO PO 1 1 Description cest eO REIR er 1 1 Incell V AC Features 1 2 meeli VAC 1 3 S PEIN CATIONS 222 tran AAEREN E E 1 4 Mountingand Connections e e eoa t RN 1 4 1 4 1 4 Electrical Ratings Table 1 A cease aaa 1 5 Mechanical Ratings Table LB 1 6 Altitude Derating Table 1 6 1 6 Receivingand Storage Chapter 2 hcec awahita kasanqa akapa daha sa ah daqa nkuna 2 1 orn S 2 1 Installation and Wiring Chapter 3 General Precautions tn a ica er e ra ae o pra 3 1 Safety and Codes a en cec etel eet etel e um e s e Pont 3 1 Arrangements Loud Ede ode Fen Par t de Farid icio deu be de drea ubi 3 2 Integral to an Allen Bradley MV Controller 32 OEM 3 3 Buse PrOg cti a assaqahunalauuatuia haqhanuiqalaqhasusn shamuy 3 5 Iu T a a 3 5
37. t TDUV Capacitor For 110 120V AC control 1650 uF For 220 240V AC control 330 uF Includes mounting bracket and terminal guards Chapter 1503VC BMCI 1503VC BMC2 1503VC BMC3 1503VC BMC4 80174 902 14 R 80174 014 01 R 80174 014 03 R 80174 014 11 R 80158 779 51 R 80158 779 52 R The Series Letter is printed on thelarge label on the right hand side of the enclosure beside the part number 1503 UM052D EN P June2013 6 2 Spare Parts This page is intentionally left blank 1503 UM052D EN P June 2013 Appendix Typical Contactor Drop out Time Settings The contactor drop out time settings shown in the followingtableare typical minimum values used when the power fuses are provided as part of a complete MV controller from Rockwell Automation The recommendationsare based on Ferraz Shawmut power fuses Other fuse types may require alternate drop out time settings The IntelliVAC module DIP switches are set up to provide the minimum drop out times shown refer to Chapter 4 Table A 1 Typical Contactor Drop Out Time Settings Fuse Rating Contactor Drop out Time Setting msec so i 5 w IU 1 gt w n3 3 Jw x 3 8 _ 3X 2 Fuse not suitable for use with contactor IU JU JU U IU JU JIU Note The drop out timeis chosen to be equal to or greater than the intersection of the rated contactor interrupting c
38. tatus Chapter 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 thebottom front of the module CONTACTOR STATUS MODULE STATUS Figure 5 1 IntelliVAC LEDs Note This user manual containsinformation for both Series C and Series D Intelli VAC versions Refer to thecorrect information below for the IntelliVAC series in use The Module Status is indicated with a Green LED if the moduleis functioning properly and hasa valid configuration Ifthe module powers up with an invalid configuration the LED will be Red flashing once indicating 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 e Series the LED willbe Red Fault 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 Series D the LED will be yellow flashing once If the undervoltage condition is corrected during the selected interval asset via DIP switch then normal operation resumes 1503 UM052D EN P June 2013 5 2 Monitoring and Troubleshooting Module Status cont Conta
39. the intersection of the rated contactor interrupting current and the fuse melt time curve except where noted 1503 UM052D EN P June 2013 A 4 Typical Contactor Drop out Times 1503 UM052D 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 42 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 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 www ab com mvb Publication 1503 UM052D EN P June 2013 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in Canada Supersedes Publication 1503 UM052C EN P June 2007
40. uF for 240V control Use of larger capacitors will requirea 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 voltageand capacitor sizeas shown in the table below Ifthe elapsed time exceeds this limit the contactor cannot be tripped by IntelliVAC In this case the contactor can be tripped by pressing the release button on the door in front of the contactor A separate voltage source is needed to provide the OPEN command This may be taken from the external capacitor as shown in Figure 3 11 Table 3 C Mechanical Latch Contactor Capacitor Trip Times Contactor Nominal Voltage Actual Ext Capacitor ipa Rating Vac Vinput Vac uF 3 5 2 7 1 7 75 47 400 Amp Note Minimum capacitor voltage ratings e 120V applications 200V DC 250V DC preferred e 240V applications 400V DC 450V DC preferred 1503 UM052D EN P June 2013 3 18 Installation and Wiring R efer to Table for recommended fuse sizing Figure 3 11 Mechanical Latch Contactor with Capacitor Trip Option 1503 UM052D EN P June 2013 _ CON
41. urrent and the fuse melt time curve except where noted 1503 UM052D EN P June 2013 A 2 Typical Contactor Drop out Times Table A 1 Typical Contactor Drop out Time Settings cont Contactor Drop out Time Setting msec Voltage Designation 400A 800A 100E 125E 150E 175E 200E 250E 300E 350E lt 5000 400E 100 450E 30 500E 600E 750E 900E 2x 250E 2 x 300E 2x 350E 2x 400E 2x 450E 2x 500E 2x 600E 2x 750 2 900E 50 gt gt gt gt rn rn rn rn rn rn 92 75 200 240 m 2 D g gt Fuse not suitable for use with contactor Note Thedrop outtimeischosen 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 UM 052D EN P June 2013 Typical Contactor Drop out Times A 3 Table A 1 Typical Contactor Drop out Time Settings cont Contactor Drop out Time Setting msec Voltage Designation 400A 800A gt 50 m z wn D gt gt un e 2R 18R 24R 32R 38R 7200 amp gt lt 57X 2x 18R 2x 24R 2x ZR 2x 38R 2x 48X 2x 57X OE 15E 20E 25E 30E 40E 50E 65E 80E 100E 125E 150E 175E 200E 8250 50 U 5 Fuse not suitable for use with contactor Note The drop out timeischosen to be equal to or greater than
Download Pdf Manuals
Related Search