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1503-UM053_-EN-P - Rockwell Automation

1. Control Power gt Capacitor IV 4 C Control Power Fuse 11 EC ae 2 gt gt li LH MOV Ne 5 AUX cco lt M gt L1 G L2IN 4 Overload Stop Start M IV N odlo o 0 9 10 M IV d Close 15 16 lahat See Table 5 on page 19 for recommended fuse sizing Status Rockwell Automation Publication 1503 UM053C EN P March 2015 Chapter 4 Setup and Commissioning IntelliVAC Configuration The IntelliVAC module is configured for a specific application by setting DIP switches They are accessed by loosening the two screws on the front of the unit and removing the cover by sliding it forward The switches are found on the front edge of the IntelliVAC circuit board see Figure 17 There are 16 switches with number 1 being at the top closest to the circuit board part number label see Table on page 32 cause personal injury or death Remove all sources of power from the module SHOCK HAZARD Hazardous voltage is present inside the module which may 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 Figure 17 DIP Switch and Connector Locations Interface Connections Supply Power Input fround Stud Status Indicat
2. Fuse Rating Contactor Drop out Time Setting ms Voltage Designation 400A 800A 2R 3R 48 6R 50 9R 50 12R 18R 75 248 150 32R 240 7200 38R 75 48X 150 57X 4 200 2x 18R 50 2x 24R 130 2x 32R 4 240 2x 38R D D 2x48X e D 2x57X D 10 15 20E 25E 30E 40E 50E 8250 65E 50 50 80E 100E 125 150 175 200E 1 Fuse not suitable for use with contactor IMPORTANT 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 Rockwell Automation Publication 1503 UM053C EN P March 2015 43 AppendixA Contactor Drop out Time Settings Notes 44 Rockwell Automation Publication 1503 UM053C EN P March 2015 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more informat
3. 4 Control Power p Open M IV 7 8 5G Overload Open Control Power Fuse M oY Capacitor M IV Mov 1 4 gt Tc e gt zl EC TCO C MOV foe DON AUX cco EP di du gt 7 L1 G L2 N Overload Close M IV es NX 9 40 See Table 5 on page 19 for recommended fuse sizing Close Motor J ogging Control IMPORTANT Jog functionality can work with electrically held contactor only 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 see Figure 15 on page 29 This method will bypass the standard six second motor restart delay for jogging purposes only Operations will be limited to two starts every twelve seconds programmed TDUV time has expired Therefore applications requiring an immediate removal of power during emergency stop conditions are not compatible with the TDUV feature ATTENTION If the TDUV feature is used the contactor will not open until the 28 Rockwell Automation Publication 1503 UM053C EN P March 2015 Installation and Wiring Chapter 3 Figure 15 Motor Jogging Control 4 C
4. REP BET t 12 5 L1 G L2 N 9 Emergency Stop when required Overload Stop Eu NE 9 10 M IV 1 Close See Table 5 on page 19 for recommended fuse sizing sH Status Figure 12 Timing Diagram 400A Electrically Held Contactor for IntelliVAC Control with three wire Control 15ms Close Command a to Micro JJ Debounce Selectable drop out time 5ms 0 190 ms Micro Output Clamp delay to close coil 200ms i Close level of current 7 to close coils Acknowledge window Contactor status relay output 1 Module status SJ i relay output i Contactor pick up 1 pome Natural contactor drop out gt t 30ms 120VAC Contactor auxiliary input to micro Contact status relay closes on request to close It will open if the contactor does not close withing 200 ms and module will fault opening module status relay For this example the 130 ms drop out time has been selected The drop out time is 50 ms The micro controller delay is 130 50 80 ms Rockwell Automation Publication 1503 053 March 2015 25 Chapter3 Installation and Wiring Wiring Guidelines IntelliVAC control can be used for mechanical latch contactors A momentary Mech ani cal Lat
5. ERU A EVE QUU CE ORE 19 Control PONE dCi s e nb ut acd 20 Status Relays 2522 e ut Re ed eeu e vec ITA 20 Interface Connections ees cure duod cn tiir EE Ca ou 21 Wiring Guidelines PH MelolouN cheated ne tate 22 Electrically Held Contactors ce 22 Control with Solid State 22 Two Wire Control o qat cc bea ub beides 23 Three Wire Control ec ied ce y v reed pews uoto tet oett 24 Wiring Guidelines Mechanical Latch 26 Mechanical Latch 27 Capacitor Trp reis aha Mad Che E a i Mel te 27 Motor Jogging ror e eer RR RAP E RR 28 Undervoltage Protection endo a het betta a oat 29 Time Delay Undesvoltage nr RH P P EE oie sas 29 Chapter 4 IntclhV AG VE RPHRRER HAT 31 Rockwell Automation Publication 1503 UM053C EN P March 2015 3 Table of Contents Monitoring and Troubleshooting Spare Parts Contactor Drop out Time Settings Chapter 5 Introd ctionz 243 3 Vedi 33 Moutle Status cratic pee WU C AS M Eu pata wen Id 33 Contactor Statusic cserssesisajess III ESTE PI 34 Chapter 6 Spare Parte Lists ortus sse ex xa spa EE Re EU ERRAT eis 99 Optional Equipment koe rt aie edo nepote se Ea RERO Rees 39 Appendix A
6. 4 Control Power gt Capacitor Optional M IV C Control Power Fuse X 1j 2p i h 22 qud gt 5 AUX cco lt lt M t alo L1 G L2 N Emergency Stop when required Overload Run M IV N 9 10 Close See Table 5 on page 19 for recommended fuse sizing Three Wire Control If using three wire control the CLOSE contactor input is maintained high using two contacts Momentarily opening this input will cause the IntelliVAC to open the contactor Momentarily closing the START contact will provide a CLOSE command to IntelliVAC given that all permissives are satisfied In this configuration the STATUS output acts as a seal in contact If a fault occurs in addition to cycling control power over to the IntelliVAC module the CLOSE command must be removed for a minimum of 4 seconds before being reapplied See Figure 11 on page 25 contact should be placed the L1 control power rung to the IntelliVAC If the TDUV feature is used the contactor will not open until the programmed TDUV time has expired ATTENTION For Emergency Stop applications requiring removal of power a 24 Rockwell Automation Publication 1503 UM053C EN P March 2015 Installation and Wiring Chapter 3 Figure 11 Three Wire Control 4 Control Power Capacitor Optional M IV Control Power Fuse E EC TCO 2 3 gt li MOV
7. Chapter3 Installation and Wiring Figure 4 Typical IntelliVAC Installation within a Bulletin 1500 1900 MV Controller Shown with optional external capacitor OEM The IntelliVAC can be ordered as an OEM component This allows the OEM to mount the components in a configuration most suitable to the control equipment layout Care must be exercised to ensure the IntelliVAC has adequate ventilation provided around it See Figure 5 on page 17 for mounting the IntelliVAC It is recommended that a minimum of 38 1 mm 1 5 in of free air space be provided between the IntelliVAC and any solid barrier above or below As well 6 4mm 0 25 in should be left between adjacent modules The OEM is responsible for controller fusing motor overload protection control devices for example Start Stop push buttons and wiring between the IntelliVAC and 1502 vacuum contactor using optional wire harness Wiring and mounting for optional items such as TDUV Capacitor are also the OEM s responsibility See Figure 6 on page 18 for basic connections 16 Rockwell Automation Publication 1503 053 March 2015 Installation and Wiring Chapter 3 Figure 5 Typical Mounting Configurations Minimum top clearance S l 38 1 5 1 er e e e Dimensions in mm in e e 38 1 s k 6 4 0 25 Additional Modules as required Minimum bottom clearance IMPORTANT Adjacent IntelliVAC modules may
8. Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures see applicable ESD protection handbooks ATTENTION 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 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 protection interlocking and disconnect devices Failure to do so may result in personal injury and or equipment damage gt el amp The IntelliVAC is offered in two arrangements Integral part of an Allen Bradley 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 see Figure 4 on page 16 Rockwell Automation Publication 1503 053 March 2015 15
9. 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 Fuse Rating Contactor Drop out Time Setting ms Voltage Designation 400A 800A 2R 3R 48 6R 9R 50 12R 18R 50 19R 5000 24R 100 32R 240 38R 48X 75 57X D 200 2x24R 100 2x32R 240 2x 38R 2x 48X 2x57X Rockwell Automation Publication 1503 053 March 2015 41 Appendix A 42 Contactor Drop out Time Settings IMPORTANT Fuse Rating Contactor Drop out Time Setting ms Voltage Designation 400A 800A 20E 30E 40E 50E 65E 80E 100E 50 50 125E 150E 175E 200E 250E 300E 350E 75 5000 400 100 450 130 500 240 600 240 75 750E D 200 900E 240 2x 250E 50 2x 300E b 75 2x350E 0 75 2 x 400E 0 100 2x450E D 130 2x 500E 240 2 x 600E 240 2x 750E D D 2x 900E 1 Fuse not suitable for use with contactor 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 Rockwell Automation Publication 1503 UM053C EN P March 2015 Contactor Drop out Time Settings Appendix A
10. Typical Settings umi E eS ER BER a lodi omn de 4l Rockwell Automation Publication 1503 UM053C EN P March 2015 Summary of Changes This manual contains new and updated information New and Updated This table contains the changes made to this revision Information Attention Table added for TDUV feature limitations 30 Added notations to table for DIP Switch explanation Table 22 Rockwell Automation Publication 1503 053 March 2015 5 Summary of Changes Notes 6 Rockwell Automation Publication 1503 UM053C EN P March 2015 Introduction Scope Description Rockwell Automation Publication 1503 053 March 2015 Chapter 1 Product Description 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 This document applies to the Series E version of IntelliVAC See publication 1503 UM051C EN P for information related to the Series A an
11. 0 0 0 0 0090 0 0000 OOOO0O0COO0OQO 14 15_ 16 CONTACTOR STATUS OUTPUT N O MODULE STATUS OUTPUT N O L1 12 AD POWER INPUT Rockwell Automation Publication 1503 053 March 2015 Interface Connections Installation and Wiring Chapter 3 All other control interface connections are made at a twelve pole connector located on the top of the module See Figure 8 on page 21 and Table 6 on page 21 for connections and page 11 for electrical ratings See Wiring Guidelines on page 22 for guidance in making connections to the control circuit Figure 8 Top side connections 12 4 5 6 7 8 9 1011 12 EX CAP CONTACTOR INTERFACE Table 6 Terminal Assignments for IntelliVAC Interface Connections See page 11 for electrical ratings Terminal Number Terminal Designation Description 1 External capacitor negative Power connection for TDUV or capacitor trip options onl 2 External capacitor positive 1 d y 3 Latch trip coil common m Output for mechanical latch contactor trip coil 4 Latch trip coil 5 Close coil common Output to close coil of electrically held amp d mechanical latch contactors ose coi 7 Open Jog command mao Input to open a mechanical latch contactor or mag 9 an electrically held contactor mutually 8 Open Jog command common exclusive 9 Close comman
12. 010 1 100 msec 0 1 0 150 msec 110 10 0 0 0 0 400A Mechanical Latch Note Remaining 175 msec 110 11 0 0 0 1 400A Electrical Latch Nm 200 msec 1 1 1 800A Mechanical Latch ii 240 msec 010 800A Electrical Latch 1 The altitude compensation by DIP switch settings applies to Series E or higher 400 amp vacuum contactors only All 800 amp contactors are adapted for altitude by altering the mechanical return springs see Contactor Manual 1502 UM050 800 amp contactors are to be set for 1 1000m 001 DIP setting 2 By pass contactors in MV SMC applications must be set for 50 ms drop out time See Chapter A for typical drop out time settings used when power fuses are provided by Rockwell Automation 3 Input Contactors in MV PF7000 applications with the Safe Torque Off Option 24STO 24STORK must not use the TDUV feature set to more than 0 2 sec 4 The lowest TDUV ride through time see Table 7 Rockwell Automation Publication 1503 053 March 2015 Introduction Module Status Chapter 5 Monitoring and Troubleshooting The IntelliVAC module has two light emitting diodes LEDs and relay outputs to indicate the status of the contactor and the IntelliVAC module The Status Indicator are visible on the front of the module and the relay outputs are accessed on the terminal block of the bottom front of the module Figure 18 IntelliVAC Status Indicator
13. 1502 800 A contactors include a user friendly mechanical altitude adjustment Rockwell Automation Publication 1503 053 March 2015 Product Description Chapter 1 e 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 e 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 e 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 Se
14. chc ontactors control signal is required to close the contactor and a second momentary control signal is required to open the contactor The momentary open close commands must be at least 50 ms in duration See Figure 13 on page 26 for a typical mechanical latch control scheme IMPORTANT mechanical latch contactor may be closed when power is applied to the IntelliVAC control module IMPORTANT Itis permissible to apply an open command to the IntelliVAC module as power is reapplied Figure 13 Mechanical Latch Contactor Control 4 Control Power p T s MeV MOV T HAS Control Power Fuse EC TCO 2 M MOV ft 14 CC as 9 745273 L1 G L2 N M IV Overload Close NE o 0 9 10 1 Close Open M IV 71 8 See Table 5 on page 19 for recommended fuse sizing Overload Open 26 Rockwell Automation Publication 1503 053 March 2015 Mechanical Latch Contactors Installation and Wiring Chapter 3 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 to provide this capability The capacitor provides control power for the IntelliVAC and
15. input must receive a maintained voltage high to keep the contactor closed IMPORTANT 1 When used with electrically held contactors the IntelliVAC allows close commands every six seconds This is to ensure the rated contactor duty cycle is not exceeded 2 If IntelliVAC powers up configured for an electrically held contactor and the vacuum contactor is detected as being closed the module will not respond to a close command until the vacuum contactor auxiliary contact input is in the correct closed state and module power is removed and reapplied See Chapter 5 3 In general a Close command should only be applied 4 seconds after energizing IntelliVAC contact should be placed in the L1 control power rung to the IntelliVAC If the TDUV feature is used the contactor will not open until the programmed TDUV time has expired ATTENTION For Emergency Stop applications requiring removal of power Control with Solid State Devices When control devices that employ electronic or suppressed output circuits are used in the rung s that control the inputs to the IntelliVAC alternate arrangements may be required Devices employing transistor or triac output circuits have finite impedance and allow a leakage current to flow in the blocking or off state Some PLC and I O modules with relay outputs have R C snubber circuits across the contact to suppress voltage transients generated during contact opening The impedance of these snubber circu
16. will respond to the control inputs The input command must be toggled before the module will respond to a new command rising edge triggered For Series D E the Module Status indicator is also used to indicate various Warning conditions related to the contactor performance see Table 11 on page 36 The Module Status output relay has a normally open contact The contact is open during a Fault condition status indicator red and closed during a healthy condition status indicator green The relay is open for some warning conditions but closed for less severe issues The module states are summarized in Table 10 on page 35 and Table 11 on page 36 The Contactor Status is indicated with a yellow status indicator that is off until a CLOSE command is received The yellow status indicator will stay on if the contactor closes properly until the contactor is opened If the processor has an internal fault the status indicator will be red Contactor Status output relay has a normally open contact The contact is open when the contactor is open status indicator off and closed when the contactor has received a close command for 200 ms or if it is closed status indicator on IMPORTANT The Contactor will only respond to close command reapplications after the restart delay timer has expired The contactor states are summarized in Table 10 on page 35 and Table 11 on page 36 IMPORTANT The status indicators are red green types with
17. 1 L2 N DC 110 250V 10 15 Description Contactor Control Voltage ACRating DCRating Minimum Voltage Ratings Amps AC or DC VAC 47 63 Hz Inrush Current 400 800 120 240 25Apeak 25A peak 1 2 cycle Idle Current 400 800 120 240 125mA 35mA Maximum without contactor coil energized Hold Current maximum 400 800 120 240 300mA 100mA Close Current 400 120 4 6A 3 64 0 2 sec Main Input Current 240 34A 33A L1 L2 N 800 120 113A 4 8 A 240 8 9 A 4 5 A Trip Current latch 400 120 70A 37 0 2 sec 240 3 6A 2 0A 800 120 7 0A 3 3A 240 43 9 Minimum IntelliVAC Pick Up 400 800 95 Operational Supply Voltages Drop Out 400 800 75 Trip Mechanical Latch 400 70 Command Inputs AC 70 240V rms DC 70 250V Maximum on state current for open or close command 11 276V AC 60 Hz T 60 C 2 4 276V DC T 60 C Minimum on state current for open or close command 2 5 70V AC 60 Hz T 60 C 1 2 mA 68V DC T 60 C Maximum off state current for open or close command 1 9 LA 60V 60 Hz T 60 C 900 60V DC T 60 C Status Output Contacts AC 250V rms 5 A R load 2 A reactive PF 0 4 DC 30V 5 A R load 2 A reactive L R 7 ms Standards and CE cULus CSA IEC pending Approvals 1 Ta Ambient Temperature 2 Ensure compatibility of IntelliVAC input ratings with those of circuit components activating these inpu
18. Closed Off Yellow 2 Open Closed 12 Warning Long Contactor Drop Out Time Yellow R3 9 Closed Off Yellow 2 Open Closed 12 Fault Microcontroller Malfunction Red Open Red Open Fault Power Up with Invalid Dip Switch Configuration Red Flash 1 10 Open Off Open Warning Undervoltage with a CLOSE Command Present 6 Yellow Flashing Open Closed 11 off Yellow 2 Open Closed 12 1 Warnings will be cleared when a change of input state occurs and the condition has been resolved 2 Faults require control power to be removed until the unit resets 3 Invalid Command Types 1 Close Jog or Trip commands present during power up sequence 2 Close or Jog command reapplied too quickly before contactor opening sequence is verified Allow at least 60 msec plus drop out delay time before reapplying these signals NOTE Contactor will only respond to a close command reapplications after the restart delay timer has expired 3 Close and Trip commands present simultaneously valid with Mechanical Latch contactors only 4 Only for Electrically Held Contactor 5 Undervoltage conditions are defined on page 3 17 6 Flash 2 2 Consecutive Red status indicator flashes followed by a pause 7 Yellow R1 Yellow with 1 Red status indicator flash followed by a pause 8 Yellow R2 Yellow with 2 consecutive Red status indicator flashes followed by a pause 9 Yellow R3 Yellow with 3 consecutive Red status indicator flashes f
19. Trip commands present during power up sequence 2 Close or Jog command reapplied too quickly before contactor opening sequence is verified Allow at least 60 msec plus drop out delay time before reapplying these signals 3 Close and Trip commands present simultaneously valid with Mechanical Latch contactors only 4 Only for Electrically Held Contactor 5 Undervoltage conditions are defined on page 26 6 Flash 2 2 Consecutive Red status indicator flashes followed a pause 7 Flash 1 1 Red status indicator flash followed by a pause 8 Flash 3 3 Consecutive Red status indicator flashes followed a pause Rockwell Automation Publication 1503 UM053C EN P March 2015 35 Chapter 5 36 Monitoring and Troubleshooting Table 11 IntelliVAC Status Indication Series D only Conditions Description Module Status Contactor Status ne Status Status Relay Status Indicator Status Relay Indicator Color Color Normal Healthy Module and Contactor OPEN Green Closed Off Open Normal Healthy Module and Contactor CLOSED Green Closed Yellow Closed Warning Invalid Command Present 3 Yellow Closed Off Open Warning Mechanical Latch Fail to Trip Yellow Closed Yellow Closed Fault Power Up with Contactor CLOSED 0 Red Flash 2 9 Open Yellow Closed Warning Contactor Fails to Pick Up Yellow R17 Closed Off Yellow 2 Open Closed 12 Warning Contactor Drop Out During Hold Yellow R2 9
20. User Manual Allen Bradley IntelliVAC Contactor Control Module Catalog Number Bulletin 1503VC Series E 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
21. ation Publication 1503 UM053C EN P March 2015 Chapter 2 Receiving and Storage Receiving Upon receiving the controller remove the packing and check for damage that may have occurred during shipping Report any damage immediately to the claims office of the carrier IMPORTANT Ifthe IntelliVAC module is an integral component of a complete MV controller Bulletin 1500 1900 special receiving and handling instructions will apply For details see the service manual provided with the equipment Storage Consider theses important storage requirements if you are not installing your controller immediately after receiving it Store the controller in a clean dry dust free environment e Storage temperature should be maintained between 40 85 C 40 185 F Relative humidity must not exceed 95 non condensing Rockwell Automation Publication 1503 UM053C EN P March 2015 13 Chapter2 Receiving and Storage Notes 14 Rockwell Automation Publication 1503 UM053C EN P March 2015 General Precautions Safety and Codes Arrangements Chapter 3 Installation and Wiring In addition to the precautions listed throughout this manual the following statements which are general to the system must be read and understood ATTENTION The controller contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing the assembly
22. be mounted with a minimum separation of 6 4mm 0 25 in Rockwell Automation Publication 1503 053 March 2015 7 Chapter 3 Installation and Wiring Figure 6 IntelliVAC Typical Schematic Electrically Held Vacuum Contactor Control Power Control M IntelliVAC Power Fuse 8 9 Close 110 Start Overload Stop NE 16 Contactor Status 15 La Module 14 Status G 13 Capacitor Optional Ec 2 as MoV ans 11 6 M AUX CCO Med 12 5 Configuration DIP Switches Input Power L1 G L2 N Control Power Fuse The IntelliVAC module requires external fuse protection to coordinate with the power supply and contactor The fuse ratings shown in Table 5 on page 19 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 suppl
23. both sections ON to produce yellow If viewed from a sharp angle you may see only green or red Please view from directly in front of the module to ensure accurate color recognition Rockwell Automation Publication 1503 UM053C EN P March 2015 Monitoring and Troubleshooting Chapter 5 Table 10 IntelliVAC Status Indication Series C only Conditions 1 2 Description Module status Contactor Status Status Indicator Relay Status Indicator Relay Color Color Normal Healthy Module and Contactor Green Closed Off Open OPEN Normal Healthy Module and Contactor Green Closed Yellow Closed CLOSED Warning Invalid Command Present 3 Yellow Closed Off Open Warning Mechanical Latch Fail to Trip Yellow Open Yellow Closed Fault Up with Contactor CLOSED Red Flash 2 6 Open Yellow Closed Fault Contactor Fails to Pick Up Green Open Red Flash1 Open Fault Contactor Drop Out During Hold Green Open Red Flash2 9 Open Fault Long Contactor Drop Out Time Green Open Red Flash3 8 Open Fault Microcontroller Malfunction Red Open Red Open Fault Power Up with Invalid Dip Switch Red Flash 1 Off Open Configuration Fault Undervoltage with a CLOSE Red Open Off Open Command Present 1 Warning Recoverable Condition Remove and retry offending signal 2 Fault Non recoverable condition Module power must be removed and reapplied 3 Invalid Command Types 1 Close Jog or
24. ctions There are three green connectors on the IntelliVAC module for connections to the control circuitry Connector plugs are provided with the module If replacement plugs are required see Chapter 6 Spare Parts Rockwell Automation Publication 1503 053 March 2015 19 Chapter 3 20 Installation and Wiring Control Power The IntelliVAC can accept either AC or DC control power See Table 1 on page 11 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 See Figure 7 for connections The 1 1 connection is intended to be the or side of the control power and the L2 N connection is intended to be the Neutral Return or side of the control power Status Relays Status relay connections are accessed with a four pole connector located at the bottom front portion of the module See Figure 7 for connections There are two status relays each with one normally open contact e Module Status Terminals 13 and 14 e Contactor Status Terminals 15 and 16 See Monitoring and Troubleshooting on page 33 for a description of operation for the relays See Table 1 on page 11 for electrical ratings of the status relays Figure 7 Bottom side connections Ground Connection 00 0 0000 O O O 0 00
25. ctor has or opened for other reasons Module status indicator Yellow R2 and Contactor status indicator Off See Table 10 Table 12 Both status indicators Off See Table 10 Table 12 Check control voltage and internal control fuse see Figure 17 for location Contactor does not open Module status indicator Yellow and Contactor status indicator Trip mechanism is damaged Inspect and replace if required mechanical latch Yellow See Table 10 Table 12 Check for loose connections in the control circuit Contactor does not open electrically held 38 Series C Module status indicator Green and Contactor status indicator Red Flash 3 Series D Module status indicator Yellow R3 and Contactor status indicator Yellow See Table 10 Table 12 Contactor welded closed or mechanisms binding Inspect and repair if required See Table 10 on page 35 Series C or Table 11 on page 36 Series D for definition of Module status indicator states Rockwell Automation Publication 1503 053 March 2015 Spare Parts Spa re Pa rts List IntelliVAC electrically held Series A m Chapter 6 1503VC BMC1 Order 1503VC BMC4 IntelliVAC mechanical latch Series A 1 1503VC BMQ Order 1503VC BMC4 IntelliVAC electrically held and mechanical latch Series B 9 1503VC BMC3 Order 1503 IntelliVAC electrical
26. d 0 Input to initiate the closure of electrically held i d di and mechanical latch contactors ose command common 11 Contactor auxiliary contact 0 Input to indicate the state of the contactor T cat a typically wired to a normally closed auxiliary 1 No connection required if option is not used contact 2 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 required 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 on page 22 3 For electrically held contactor this command will energize the close coil output For mechanically held contactor this command will energize the trip coil output TCO Rockwell Automation Publication 1503 053 March 2015 21 Chapter3 Installation and Wiring Wiring Guidelines 22 Electrically Held Contactors The IntelliVAC can be applied with two wire or three wire control circuits The control system used will determine the configuration of the input wiring Consider the following input and output for the type of control used e Terminals 9 and 10 Close Contactor e Terminals 15 and 16 Contactor Status In either case the CLOSE
27. d B designs and 1503 UM052C EN P for information related to Series C and D designs 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 Intelli VAC Chapter1 Product Description External Capacitor optional Supply voltage 110 240V AC or 110 250V DC 7 Close Signal Open Signal Altitude Select Dropout Time Select Contactor Type Select TDUV Select Power Up Safety Enable Unused Figure 2 IntelliVAC Block Diagram Current I Input Regulator Power Conditioning Control Power Supply i j Command Inputs IGBT Coil Switching DIP Sw 1 Status Outputs DIP Sw 2 Flash EEPROM Interface IntelliVAC Features e range of supply voltage 110 240V AC 50 60 Hz 110 250V DC allows implementation in multiple applications 2 Vacuum Contactor Trip Coil Vacuum Contactor Close Coil Contactor 7 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 Bulletin 1502 400 A only eliminates mechanical compensation required for altitudes above 1000 meters Bulletin
28. eld contactors closed during a voltage dip or brief power loss This option may require the addition of a capacitor see below See Chapter 6 for typical capacitor sizing The capacitor is connected to terminals 1 and 2 of the IntelliVAC see Figure 16 programmed TDUV time has expired Therefore applications requiring an immediate removal of power during emergency stop conditions are not compatible with the TDUV feature ATTENTION If the TDUV feature is used the contactor will not open until the Rockwell Automation Publication 1503 053 March 2015 29 30 Chapter3 Installation and Wiring Table on page 32 ofthe Setup and Commissioning chapter has the dip switch settings to provide TDUV from 0 2 2 seconds IntelliVAC can provide TDUV protection without the use of an external capacitor see Table 8 on page 30 ATTENTION The TDUV feature has limitations if used for an input contactor on a PF7000 drive with the Safe Torque Off option See Table on page 32 Table 8 Maximum TDUV Time without Capacitor Control Voltage Max TDUV Time s 400A 800A 110 120V 0 2 0 2 220 240V 1 0 1 0 If the undervoltage condition persists beyond the set delay time the contactor will be opened and an undervoltage fault or warning condition will occur see Chapter 5 Figure 16 TDUV Control Circuit
29. igate and reset Check Control Power and control fuse power Loose connections in control circuit Verify IntelliVAC power input plug is in place and properly seated Verify internal control fuse has not opened See Figure 17 for location Module status indicator Red upon power up IntelliVAC faulted Cycle control power to reset Replace IntelliVAC if unsuccessful Module status indicator Red Flash 1 upon power up See Table 10 Table 12 Improper setting of dip switches Check settings and cycle control power Loose connection in control circuit Verify contactor auxiliary installation See Publication 1502 0 052 or 1502 UM051 EN P Auxiliary Contact Set up Procedure Verify circuit continuity is contactor plug connected properly Contactor closes momentarily and will not reclose or Module status indicator Red Series C and Contactor status indicator Off Module status indicator Yellow Flashing and Contactor status indicator Off Series D Undervoltage fault no TDUV control voltage dipped below trip point Verify voltage levels are 110 240V AC 110 250V DC Contactor fails to close or Module status indicator Green and Contactor status indicator Red Flash 1 Series C Module status indicator Yellow R1 Series D and Contactor status indicator Off Check internal control fuse Verify IntelliVAC operation in test
30. input state occurs and the condition has been resolved 2 Faults require control power to be removed until the unit resets 3 Yellow R3 Yellow with 3 consecutive Red flashes followed by a pause 4 Flash 2 2 Consecutive Red status indicator flashes followed by a pause 5 Flash 3 3 Consecutive Red status indicator flashes followed by a pause 6 Yellow R1 Yellow with 1 Red status indicator flash followed by a pause 7 Yellow R2 Yellow with 2 consecutive Red status indicator flashes followed by a pause 8 Will reflect actual status ofthe contactor 9 Invalid Command Types 1 Close Jog or Trip commands present during power up sequence 2 Close or Jog command reapplied too quickly before contactor opening sequence is verified Allow at least 60 msec plus drop out delay time before reapplying these signals NOTE Contactor will only respond to a close command reapplications after the restart delay timer has expired 3 Close and Trip commands present simultaneously valid with Mechanical Latch contactors only 10 Open during undervoltage Closed if voltage restored Rockwell Automation Publication 1503 UM053C EN P March 2015 37 Chapter 5 Problem or Trip Indicated Contactor does not energize Monitoring and Troubleshooting Table 12 Module Troubleshooting Indication of the following conditions Motor Protection device Trip contact activated Both status indicators Off Possible Solutions Invest
31. ion contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium V
32. its also allows leakage current to flow when the contacts are open The IntelliVAC input circuits have been designed such that typical output leakage currents should not create unintended operation of the contactor The vast majority of control devices can be directly connected to the IntelliVAC without any inappropriate operation occurring Rockwell Automation Publication 1503 053 March 2015 Installation and Wiring Chapter 3 This situation can be prevented by consideration of the control devices when designing the control system With control devices that have excessive leakage current that is PLC or similar control devices consider using relay outputs with now suppression across the contacts If this cannot be done consider the leakage current of the device to see if it is compatible with the IntelliVAC inputs see Electrical Ratings on page 11 If the control device is not compatible consider using interposing relay connected as shown in Table 9 Figure 9 Control with Solid State Devices 4 Control Power gt M IV Control Power Fuse 2 1 EC A ads MOV M eo 81 la 2 12 5 Input Power T L G i Solid State Overload Output CR M IV NK Wo P 9l Close t01 See Table 5 on
33. ly held and mechanical latch Series C and 1503VC BMCA Order 1503 IntelliVAC electrically held and mechanical latch Series 1 1503VC BMC5 Internal Fuse 6 3 A 250V Littlefuse 21506 3 Multi pole connectors 80174 902 14 R 2 pole module power 80174 014 01 R 4 pole status outputs 80174 014 03 R 12 pole coil and connections 80174 014 11 R 1 Series Letter is printed on the large label on the right hand side of the enclosure beside the part number Optional Equipment TDUV Capacitor 110 120V AC control 1650 pF 80158 779 51 R 220 240V AC control 330 pF 80158 779 52 R 1 Includes mounting bracket and terminal guards Rockwell Automation Publication 1503 UM053C EN P March 2015 39 Chapter6 Parts Notes 40 Rockwell Automation Publication 1503 053 March 2015 Typical Settings Appendix A Contactor Drop out Time Settings The contactor drop out time settings shown in the following table are typical minimum 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 The IntelliVAC module DIP switches are designed to provide the minimum drop out times shown see Chapter 4 Table 13 Typical Contactor Drop Out Time Settings IMPORTANT
34. 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 gt 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 E
35. mode before applying Medium Voltage See Figure 17 for location See Table 10 Table 12 Coil damaged or connections are loose Repair and cycle control power Series Q Auxiliary Contact Assembly improperly adjusted See Publication 1502 052 or 1502 0 051 Auxiliary Contact Set up Procedure Cycle control power to reset Series C Armature Plate obstructed from closing to coil face Verify no foreign material behind the armature plate Cycle control power to reset Both status indicators Off See Table 10 Table 12 Check internal control fuse Verify IntelliVAC operation in test mode before applying Medium Voltage see Figure 17 for location Contactor opens during Motor Protection activated Investigate and reset operation e Module status indicator Red Series C Undervoltage fault TDUV control voltage dipped below trip point or Verify voltage levels 110 240V AC 110 250V DC Yellow Flashing Series D See Table 10 Table 12 With external capacitor and TDUV feature activated undervoltage condition for longer than programmed TDUV time Undervoltage fault activated e Module status indicator Green and Contactor status indicator e Contactor Status feedback between Terminals 11 and 12 on the IntelliVAC has Red Flash 2 Series C See Table 10 Table 12 closed The IntelliVAC will de energize the coil thinking the conta
36. ollowed by a pause 10 Flash 1 1 Red status indicator flash followed by a pause 11 Open during undervoltage Closed if voltage restored 12 Will reflect actual status of the contactor Rockwell Automation Publication 1503 UM053C EN P March 2015 Monitoring and Troubleshooting Chapter 5 IntelliVAC Status Indication Series E only Conditions Description Module status Contactor Status M Status Indicator Relay Status Indicator Relay Color Color Normal Healthy Module and Contactor OPEN Green Closed Off Open Normal Healthy Module and Contactor CLOSED Green Closed Yellow Closed Warning Invalid Command Present Yellow Closed Off Open Warning Mechanical Latch Fail to Trip Yellow Closed Yellow Closed Fault Power Up with Contactor CLOSED Red Flash 29 Open Yellow Closed Warning Contactor Fails to Pick Up Yellow R1 9 Closed Off Yellow 19 Open Closed Warning Contactor Drop Out During Hold Yellow R2 9 Closed Off Yellow Open Closed Warning Long Contactor Drop Out Time Yellow R3 0 Closed Off Yellow Open Closed Fault Microcontroller Malfunction Red Open Red Open Fault Power Up with Invalid Dip Switch Configuration Red Flash 1 c Open Off Open Fault Contactor Fails to Drop Out Red Flash 3 9 Open Red Open Warning Undervoltage with a CLOSE Command Present Yellow Flashing Open Closed Off Yellow Open Closed 1 Warnings will be cleared when a change of
37. oltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page 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 NV Pegasus Park De Kleetlaan 12a 1831 Diegem 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 Publication 1503 UM053C EN P March 2015 Supersedes Publication 1503 UM053B EN P June 2013 Copyright O 2015 Rockwell Automation Inc All rights reserved Printed in Canada
38. ontrol Power IV Control Power Fuse 1 4 z e FC TCO 3 oL Undervoltage Protection Time Delay Undervoltage YN A NY 2 gt lt e e o 5 QF lt Y 12 5 L1 L2IN Emergency Stop when required I o Overload Stop Start M IV NE olo 9l M T MV el Close 15H Contactor Status Jog M IV go 71 8 See Table 5 page 19 for recommended fuse sizing Open The IntelliVAC controller protects the contactor from control voltage dips and loss of power It provides undervoltage release and prevents attempts to close the contactor when insufficient power is available to guarantee reliable closing of the contacts The undervoltage protection will be initiated under the following conditions regardless of nominal control voltage 1 Ifthe supply voltage drops below 90V AC or DC during the first 200 ms after a Close command is received This applies to electrically held and mechanical latch contactors 2 Ifthe supply voltage drops below 72V AC or DC after the 200 ms close sequence electrically held contactors only The IntelliVAC can be configured to provide time delay undervoltage TDUV protection The feature is available to keep electrically h
39. ors Status Relay Outputs 1503WC BMC IntelliVAC unit shipped separately from the factory will have a default configuration per Table 9 on page 32 Rockwell Automation Publication 1503 UM053C EN P March 2015 31 Chapter 4 32 Setup and Commissioning Table 9 DIP Switch Factory Default Settings Description 112 3 4 5 6 17 8 112 3 4 5 6 7 8 Altitude 0 1000 0 0 1 Drop out time 130 msec 0 1 1 Contactor config 400 A EH 00 0 1 TDUV config No TDUV 0 Ext cap TDUV time 0 2 sec 0 0 Power Up Safety Enable 0 IntelliVAC units shipped in a complete MV controller Bulletin 1500 1900 are configured for the installed application contactor type The user must verify the settings before energizing the equipment Table defines the switch settings IntelliVAC DIP Switch Explanation UP 1 DIP switch SW1 DIP Switch SW 2 Down 0 112 Altitude Power up Safety 1000 0 0 Enable 1 1000 0 01 Disable 1001 2000 0 1 0 2001 3000 10 1 1 4 Ext cap TDUV time 3001 4000 1 0 0 0 Noext capacitor 4001 5000 1 0 1 0 1 1 0 Seconds Not defined 1 1 0 1 0 1 5 Seconds Not defined 1 2 0 Seconds Y 1 TDUV configuration B 50 msec 0 0 NoTDUV 75 msec
40. page 19 for recommended fuse sizing or CR KO Two Wire Control If using two wire control the CLOSE contactor input is maintained high using a 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 reapplied See Figure 10 on page 24 Some two wire control schemes may be configured such that a close command is present when IntelliVAC is energized In this case the Power Up Safety feature may be disabled by setting DIP switch 12 accordingly See Table on page 32 ATTENTION Only disable the Power Up safety feature when absolutely necessary Doing so can create unsafe operating conditions Rockwell Automation Publication 1503 053 March 2015 23 Chapter3 Installation and Wiring contact should be placed the L1 control power rung to the IntelliVAC If the TDUV feature is used the contactor will not open until the programmed TDUV time has expired ATTENTION For Emergency Stop applications requiring removal of power a Figure 10 Two Wire Control
41. quipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Product Description Receiving and Storage Installation and Wiring Setup and Commissioning Table of Contents Chapter 1 Introd ction EE A Eoo en Rees 7 SCOPE enaA Lot el CIA DI 7 Descriptio RR Ke E RE y IntelliVAC Features ve Iu cames E ached Ue Eo Is valde ated 8 IntelliVAC Versions 9 Specifications scored cae dA et EEEE 10 Mounting and Connections 4i qu ER OE EM 10 CO PULA ORs cea euer bici Sane eret eens 10 idis CEPR EMT 10 Chapter 2 m 13 13 Chapter 3 General 15 Safetyand Ciodesss 2h fuk Mh ae hel gelo Melk uf 15 Arrangements ss er oss Sel E 15 Integral to an Allen Bradley MV Controller 15 CRI que 16 Control Power Buse eisai ese ein a etit 18 GroUndllg s as se pedes id d ARR ak tua ouseas PERENNE ER 19 Connectiolls ooe veces EV pe
42. ries 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 Series Dor EIntelliVAC module can be used to replace a Series A or Series 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 Rockwell Automation Publication 1503 053 March 2015 9 Chapter1 Product Description Specifications Mounting and Connections The IntelliVAC control 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 Cont
43. rol 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 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 IntelliVAC has firmware stored in flash EEPROM This may be updated in the field if necessary The IntelliVAC board 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 Rockwell Automation Publication 1503 UM053C EN P March 2015 Product Description Chapter 1 Table 1 Electrical Ratings Main Input Voltage AC 110 240V rms 10 15 47 63 Hz L
44. s CONTACTOR STATUS MODULE STATUS IMPORTANT Thisuser manual contains information for Series C and Series D IntelliVAC versions See Module Status for information about the IntelliVAC series in use The Module Status is indicated with a Green status indicator if the module is functioning properly and has a valid configuration If the module powers up with an invalid configuration the status indicator will be Red flashing once 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 e Series C the status indicator will be Red Fault If the contactor does not close properly a Fault is generated the status indicator turns Red and inputs are inhibited until the module power is removed and reapplied Series D E the status indicator will be yellow flashing once If the undervoltage condition is corrected during the selected TDUV interval as set via DIP switch then normal operation resumes Rockwell Automation Publication 1503 UM053C EN P March 2015 33 Chapter5 Monitoring and Troubleshooting Contactor Status 34 If the processor has an internal fault the status indicator will be Red the outputs will be cleared and the processor must be reset input power must be cycled If the reset is successful the status indicator will be Green and the module
45. stored energy to trip the contactor Maximum recommended capacitor size is 1650 uF for 120V control or 330 pF for 240V control Use of larger capacitors is not recommended 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 Table 7 If the 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 required to provide the OPEN command This can be taken from the external capacitor as shown in Figure 14 on page 28 Table 7 Mechanical Latch Contactor Capacitor Trip Times after loss of control power Contactor Nominal Voltage Actual Ext Capacitor Max time Rating Vac Vinput Vac uF for trip sec o hs 7 120 110 1650 27 400 Amp 100 17 240 140 330 75 200 47 IMPORTANT Minimum capacitor voltage ratings e 120V applications 200V DC 250V DC preferred e 240V applications 400V DC 450V DC preferred Rockwell Automation Publication 1503 UM053C EN P March 2015 27 Chapter3 Installation and Wiring Figure 14 Mechanical Latch Contactor with Capacitor Trip Option
46. ts Consider means of isolating loading these signals as required using interposing relays or load resistors Consult factory for assistance if required The Series C and D IntelliVACs are compatible with most PLC outputs and have been verified with Rockwell Automation type 120V triac outputs See Wiring Guidelines on page 22 3 Includes idle current Rockwell Automation Publication 1503 UM053C EN P March 2015 11 Chapter1 Product Description Table 2 Table 3 Mechanical Ratings Temperature Operating 0 60 C ambient at the control module 1 Non Operating 40 85 Altitude 1000 5000 meters Pollution Pollution level as defined by UL 840 and IEC 60664 1 Humidity 95 non condensing Shock Operational 15 g peak 11 ms Vibration operational 10 57 Hz 0 015 inch displacement peak to peak 57 150 Hz 2 5 g acceleration 1 Ambient temperature is derated at altitudes above 1000 meters 3300 feet See Chapter 1 Table 4 Altitude Derating Altitude Maximum Operation Ambient at the control module 1000 0 60 1 1000 60 1001 2000 58 2001 3000 56 3001 4000 54 4001 5000 52 1 Derate by 2 C 1000 m for high altitude operation Figure 3 Mechanical Dimensions 5 1 0 20 174 8 6 88 185 3 7 29 oo me 5 8 0 228 Dimensions in mm in 12 Rockwell Autom
47. y The types listed are Ferraz Shawmut Midget Fuses 1 1 2 in X 13 32 in The TRM isa time delay type rated 250V AC The ATM is a fast acting type rated 500V DC Rockwell Automation Publication 1503 053 March 2015 Installation and Wiring Chapter 3 Table 5 IntelliVAC Fuse Protection Rated Supply Voltage Contactor Type 1 Recommended Fuse minimum maximum 400A EH 2 TRM 3 2 110 120V AC 800A EH TRM 2 TRM 6 25 400 800A ML TRM 2 TRM 3 2 400A EH 2 6 25 220 240V 800A TRM 2 TRM 6 25 400 800A ML TRM 2 TRM 6 25 125V DC 400A EH ML ATM3 3 800A EH ML 5 6 250V DC 400A EH ML ATM3 5 800A EH ML ATM5 ATM6 1 Electrically Held vacuum contactor EH Mechanical Latch vacuum contactor ML IMPORTANT _ Ifexternal capacitors are connected or more than one IntelliVAC module is protected by a 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 to a common ground terminal PE on the controller panel The ground terminal is located on the bottom of module enclosure see Figure 7 on page 20 ground connection provided Failure to do so may result in damage to ATTENTION It is important that IntelliVAC is properly grounded using the equipment or personal injury Conne

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