Rockwell Automation Allen-Bradley IntelliVAC 1503VC-BMC5 Bedienungsanleitung

IntelliVAC Contactor Control Module

Catalog Number Bulletin 1503VC (Series E)

User Manual

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

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.

Labels may also be on or inside the equipment to provide specific precautions.

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.

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.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 1503-UM053C-EN-P - March 2015 3

Table of Contents

Chapter 1

Product Description

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

IntelliVAC Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

IntelliVAC Versions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 2

Receiving and Storage

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 3

Installation and Wiring

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Arrangements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Integral to an Allen-Bradley MV Controller . . . . . . . . . . . . . . . . . . . . 15

OEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Control Power Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Status Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Electrically Held Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Control with Solid-State Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Two-Wire Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Three-Wire Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Wiring Guidelines Mechanical Latch Contactors . . . . . . . . . . . . . . . . . . . 26

Mechanical Latch Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Capacitor Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Motor Jogging Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Undervoltage Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Time Delay Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chapter 4

Setup and Commissioning

IntelliVAC Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4Rockwell Automation Publication 1503-UM053C-EN-P - March 2015

Table of Contents

Chapter 5

Monitoring and Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Module Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Contactor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chapter 6

Spare Parts

Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Appendix A

Contactor Drop-out Time Settings

Typical Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Rockwell Automation Publication 1503-UM053C-EN-P - March 2015 5

Summary of Changes

This manual contains new and updated information.

New and Updated

Information

This table contains the changes made to this revision.

Topic Page

Attention Table added for TDUV feature limitations 30

Added notations to table for DIP Switch explanation Table 32

6Rockwell Automation Publication 1503-UM053C-EN-P - March 2015

Summary of Changes

Notes:

Rockwell Automation Publication 1503-UM053C-EN-P - March 2015 7

Chapter 1

Product Description

Introduction This document contains information for the Allen-Bradley Bulletin 1503VC

IntelliVAC™ control module. The Bulletin 1503VC is used to control the Allen-

Bradley Bulletin 1502 vacuum contactors that are a significant component of the

Bulletin 1500/1900 CENTERLINE Medium Voltage Motor Controllers

offered by Rockwell Automation. IntelliVAC is an efficient and flexible solution

for controlling medium voltage vacuum contactors used in motor starter and

feeder applications.

An IntelliVAC control module may also be provided as a loose OEM component,

for use with a Bulletin 1502 contactor by a third party (OEM).

Scope This document applies to the Series E version of IntelliVAC. See publication

1503-UM051C-EN-P for information related to the Series A and B designs, and

1503-UM052C-EN-P for information related to Series C and D designs.

Description An IntelliVAC module may be used to control Bulletin 1502 400 and 800 Amp

vacuum contactors. Both electrically held and mechanically latched contactor

types can be controlled with IntelliVAC.

Figure 1 - IntelliVAC Contactor Control Module

8Rockwell Automation Publication 1503-UM053C-EN-P - March 2015

Chapter 1 Product Description

Figure 2 - IntelliVAC Block Diagram

IntelliVAC Features

•A range of supply voltage (110 – 240V AC 50/60 Hz, 110 - 250V DC)

allows implementation in multiple applications.

•Consistent vacuum contactor pick-up time (at a given supply voltage)

ensures repeatable performance.

•Selectable vacuum contactor drop-out time improves coordination with

upstream power fuses.

•Electronic altitude compensation (Bulletin 1502 400 A only) eliminates

mechanical compensation required for altitudes above 1000 meters

(Bulletin 1502 800 A contactors include a user-friendly mechanical

altitude adjustment).

External

Capacitor

(optional)

Supply

voltage

Signal

Open

Signal

Altitude

Select

Dropout Time

Select

Contactor Type

Select

TDUV Select

Power Up

Safety Enable

Unused

Input

Power

Conditioning

Command

Inputs

Call

Power

Supply

Control

Power

Supply

Micro Controller

Flash EEPROM

Interface

Status

Outputs

Aux

Feedback

Current

Regulator

IGBT Coil

Switching

Vacuum

Contactor

Trip Coil

Vacuum

Contactor

Close Coil

Vacuum

Contactor

Auxiliary

Module

Status

Contactor

Status

110 - 240V AC

110 - 250V DC

DIP Sw.1

DIP Sw.2

Rockwell Automation Publication 1503-UM053C-EN-P - March 2015 9

Product Description Chapter 1

•Power loss ride-through (TDUV) allows the vacuum contactor to remain

closed during short power loss (may require an optional external capacitor,

dependent on ride-through time).

•Anti-kiss and anti-pumping protection ensure that the vacuum contactor

close – open sequence occurs as expected, avoiding rapid reclosure 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

See Chapter 6 for part numbers of the various series of modules. The Series Letter

is printed on the large label on the right-hand side of the enclosure, beside the

part number.

Series A There are two versions of IntelliVAC control. The first type is used to

control vacuum contactors that are electrically held, with one electrical coil that is

economized electronically. The second is used to control mechanically latched

vacuum contactors (no longer available).

Series B There is one version of IntelliVAC, to control electrically held and

mechanically latched vacuum contactors (no longer available).

Series C Updated version of the Series B module (no longer available).

Series D Minor functionality (firmware) enhancements, primarily related to

definition and handling of Faults and Warnings (no longer available).

Series E Revised hardware to allow connection to the IntelliVAC Plus or

IntelliVAC MC. The removal of the mini Din connector for updating firmware

(firmware is now updated using the IntelliVAC Plus or IntelliVAC MC boards).

New input circuits to reduce thermal output, and decrease sensitivity to leakage

current.

See Chapter 6 for catalog numbers for each version of IntelliVAC.

IMPORTANT

A Series C, D or E IntelliVAC module can be used to replace a Series A or Series B

module. When replacing an older series of IntelliVAC with a newer one, note

that the Module and Contactor Status outputs may function differently. See

publication 1503-UM051C-EN-P and/or Chapter 5 of this document, and make

any necessary changes to the control circuit.

10 Rockwell Automation Publication 1503-UM053C-EN-P - March 2015

Chapter 1 Product Description

Specifications Mounting and Connections

The IntelliVACcontrol modules are mounted using two screws, see Figure 3 on

page 12. They are typically located in the low voltage control panel of the

medium voltage controller (Bulletin 1500/1900 controllers, in the case of

Rockwell Automation).

IntelliVAC is interfaced to the Bulletin 1502 vacuum contactors using a “quick”

connector, located at the module, a wire harness and “quick” connector at the

contactor. Control power and other control circuit connections are similarly

achieved with “quick” connectors.

Configuration

IntelliVACis 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). See Chapter 3 for information.

Bulletin 1500/1900 controllers are shipped with IntelliVAC preconfigured for

the required application. Please see the documents provided with the order.

Firmware

IntelliVAChas firmware stored in flash EEPROM. This may be updated in the

field (if necessary). The IntelliVACboard firmware is updated using either the

IntelliVAC Plus, or IntelliVAC MC supplementary boards.

The firmware version supplied with the module is displayed on top of the DIP

switches, see Figure 17 on page 31

Series C modules use only version 2.003 application firmware. This firmware is

also compatible with the Series A and B modules. Series D modules use only

version 3.001 or 3.002 application firmware.This firmware is not compatible

with any other Series Letter modules. Series E modules use on 4.004 or newer

firmware. This firmware is not compatible with any other Series Letter modules.

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