Bulletin 1503VCIntelliVACTM

ContactorControl Module

User Manual

Important User Information

Solid state equipment has operational characteristics differing from those ofelectromechanical equipment. “Safety Guidelines for the Application,Installation and Maintenance of Solid State Controls” (Publication SGI-1.1available from your local Rockwell Automation Sales Office or online athttp://www.ab.com/manuals/gi) describes some important differences betweensolid state equipment and hard-wired electromechanical devices. Because of thisdifference, and also because of the wide variety of uses for solid state equipment,all persons responsible for applying this equipment must satisfy themselves thateach intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect orconsequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included soley for illustrative pur-poses. Because of the many variables and requirements associated with anyparticular installation, Rockwell Automation, Inc. cannot assume responsibility orliability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use ofinformation, circuits, equipment or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without writtenpermission of Rockwell Automation, Inc. is prohibited.

Throughout this manual we use notes to make you aware of safety considerations.

ATTENTION: Identifies information about practices or circum-stances that can lead to personal injury or death, property damage, oreconomic loss.

Attentions help you:• identify a hazard• avoid the hazard• recognize the consequences

Important: Identifies information that is especially important for successfulapplication and understanding of the product.

Shock Hazard labels may be located on or inside the product to alertpeople that dangerous voltage may be present.

DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation , Inc.

PLC is a registered trademark of Rockwell Automation, Inc.

1503-UM 051A-EN-P – June 2003

Table Of Contents

Product Description Chapter 1

Introduction ............................................................................................ 1-1Description ............................................................................................. 1-1

IntelliVAC Features ........................................................................ 1-2IntelliVAC Versions ......................................................................... 1-3

Specifications .......................................................................................... 1-3Mounting and Connections ............................................................... 1-3Configuration ................................................................................... 1-3Firmware ......................................................................................... 1-3

Electrical Ratings ................................................................................... 1-4Mechanical Ratings ................................................................................. 1-4Mechanical Dimensions .......................................................................... 1-5

Receiving and Storage Chapter 2

Receiving ............................................................................................... 2-1Storage ................................................................................................... 2-1

Installation and Wiring Chapter 3

General Precautions ............................................................................... 3-1Safety and Codes .................................................................................... 3-1Arrangements - Integral .......................................................................... 3-2Arrangements - OEM ............................................................................. 3-3Fuse Protection ....................................................................................... 3-5Grounding ............................................................................................... 3-5Connections ............................................................................................. 3-6Wiring Guidelines - Electrically Held Contactors ................................... 3-8

Two-Wire Control ............................................................................ 3-9Three-Wire Control ........................................................................ 3-10

Wiring Guidelines - Mechanically Latched Contactors ......................... 3-11Motor Jogging Control ........................................................................ 3-12Time Delay Under Voltage ................................................................... 3-13

Setup and Commissioning Chapter 4

IntelliVAC Configuration ...................................................................... 4-1

Monitoring & Troubleshooting Chapter 5

Module Status ........................................................................................ 5-1Contactor Status ...................................................................................... 5-1Troubleshooting ...................................................................................... 5-3

Spare Parts Chapter 6

Spare Parts List for IntelliVAC ............................................................. 6-1

1503-UM 051A-EN-P – June 2003

ii Table of Contents – IntelliVAC™ Contactor Control Module User Manual

Chapter 1

Product Description

This document contains information for the Allen-Bradley Bulletin 1503VCIntelliVAC™ control module. The Bulletin 1503VC is used to control theAllen-Bradley Bulletin 1502 vacuum contactors that are a significant compo-nent of the Bulletin 1500/1900 Centerline Medium Voltage Motor Controllersoffered by Rockwell Automation. An IntelliVAC control module may also beprovided as a loose component, for application with a Bulletin 1502 contactorby a third party (OEM).

IntelliVAC is an efficient and flexible solution for controlling medium voltagevacuum contactors used in motor starter and feeder applications. IntelliVACmay be used to control both 400 and 800 Amp contactors. Electrically heldand mechanically latched contactor types can be controlled with IntelliVAC.

Figure 1.1 IntelliVAC Module

1503-UM051A-EN-P – June 2003

Introduction

Description

1-2 Product Description

1503-UM051A-EN-P – June 2003

Figure 1.2 IntelliVAC Block Diagram

IntelliVAC Features

· A wide range of supply voltage (100 – 240 V AC 50/60 Hz, 100 - 250 VDC) allows implementation in multiple applications

· Consistent vacuum contactor pick-up time ensures repeatable performance· Selectable vacuum contactor drop-out time improves coordination with

upstream power fuses· Electronic altitude compensation (400 A only) eliminates mechanical

compensation required for altitudes above 1,000 metres· Power loss ride-through (TDUV) allows the vacuum contactor to remain

closed during short power loss (may require an optional external capacitor,dependant on ride-through time)

· Anti-kiss and anti-pumping protection ensure that the vacuum contactorclose – open sequence occurs as expected, avoiding rapid re-closure due tofaulty control devices

· Delayed restart protects the vacuum contactor by ensuring that the ratedduty cycle is not exceeded

· Temporary jog function (electrically held contactors only) allows the motorto be positioned for process set-up

Micro Controller

Contactor C

oil(s) Interface

ConfigurationInputs

CommandInputs

CurrentRegulator

IGBT CoilSwitching

CC

InputPower

Conditioning

Coil C

urrent Transducer

Vacuum ContactorClose Coil

Vacuum ContactorTrip Coil

SupplyVoltage100-240

VAC100-250

VDC

CloseSignal

OpenSignal

Vacuum ContactorAuxiliary

CC

ExternalCapacitor(Optional)

ModuleStatus

ContactorStatus

Aux.

Feedback

Status

Outputs

c

AltitudeSelect

Drop-OutSelect

TDUVTime

Select

ContactorSelect

c

c

c

c

cc

c cc

c c

Flash EEPROMInterface

CoilPowerSupply

ControlPowerSupply

Descriptioncontinued...

Product Description 1-3

1503-UM051A-EN-P – June 2003

IntelliVAC Versions

There are two versions of IntelliVAC control. The first type is used tocontrol vacuum contactors that are electrically held, with a single electricalcoil that is economized electronically. The second is used to control mechani-cally latched vacuum contactors. See Chapter 6 for part numbers.

Mounting & Connections

The IntelliVAC control modules are mounted using two (2) screws (seeFigure 1.3). They are typically located in the low voltage control panel of themedium voltage controller (Bulletin 1500/1900 controllers, in the case ofRockwell Automation).

IntelliVAC is interfaced to the Bulletin 1502 vacuum contactors using a“quick” connector, located at the module, a wire harness and “quick” con-nector at the contactor. Control power and other control circuit connectionsare similarly achieved with “quick” connectors.

Configuration

IntelliVAC is easily configured for a wide variety of medium voltage motorand feeder control applications. It is configured using DIP switches, locatedwithin the enclosure (front side). Please refer to Chapter 4 for information.

Bulletin 1500/1900 controllers are shipped with IntelliVAC pre-configured forthe required application. Please refer to the documents provided with theorder.

Firmware

IntelliVAC has firmware stored in flash EEPROM; therefore, this may beupdated in the field (if necessary). The IntelliVAC board firmware isupdated using the mini-DIN connector, which is accessible inside theenclosure.

Specifications

1-4 Product Description

1503-UM051A-EN-P – June 2003

Table 1.A Electrical Ratings

TA = Ambient Temperature

Table 1.B Mechanical Ratings

Operating0 to 60 °C ambient at the control module

TemperatureNon-Operating

-40 to 85 °C

Altitude -1000 to 5000 metres

Pollution Pollution level II (as defined by UL 840 and IEC 60664-1)

Humidity Class II

Main Input Voltage (L1 to L2/N)

AC – 100 to 240 V rms, 50 to 60 Hz DC – 100 to 250 V

Inrush – 25 A peak (4 milliseconds maximum when contactor is energized) Idle - 125 mA rms (maximum without contactor coil energized)

Main Input Current (L1 to L2/N)

Sealed -1.0 A rms (maximum)

Command Inputs

AC – 100 to 240 V rms DC – 24 to 250 V Maximum on state current for open or close command:

9mAAC @ 250 V AC, 60Hz, TA=60°C 9mADC @ 250 V DC, TA=60°C Minimum on state current for open or close command:

2mAAC @ 100 V AC, 60Hz, TA=60°C 600µADC @ 24 V DC, TA=60°C Maximum off state current for open or close command:

400µAAC @ 11 V AC, 60Hz, TA=60°C 400µADC @ 15 V DC, TA=60°C

Status Output Contacts

AC – 250 V rms, 5 A, R load; 2 A (reactive), PF=0.4 DC – 30 V, 5 A, R load; 2 A (reactive), L/R=7 ms

Standards and Approvals

CE, cULus CSA, IEC pending

Specificationscontinued...

Product Description 1-5

1503-UM051A-EN-P – June 2003

Figure 1.3 Mechanical Dimensions

Inches (mm)

0.20(5.1) 1.17

(29.7)

.228(5.8)(2) PLACES

6.88(174.8)

7.29(185.3)

2.34(59.4)

6.53(165.9)

1-6 Product Description

1503-UM051A-EN-P – June 2003

This page is intentionally blank.

Chapter 2

Receiving and Storage

Receiving Upon receiving the controller, remove the packing and check for damage thatmay have occurred during shipping. Report any damage immediately to theclaims office of the carrier.

NOTE: If the IntelliVAC module is an integral component of a complete MVcontroller (Bulletin 1500/1900), special receiving and handling instructions willapply. For details, refer to the service manual provided with the equipment.

Storage It is important to consider the following storage requirements if you are notinstalling your controller immediately after receiving it.

• Store the controller in a clean, dry, dust-free environment.

• Storage temperature should be maintained between -40°C and 85°C (-40°Fand 185°F).

• Relative humidity must not exceed 95%, non-condensing.

1503-UM051A-EN-P – June 2003

2-2 Receiving and Storage

1503-UM051A-EN-P – June 2003

This page is intentionally blank.

Installation

In addition to the precautions listed throughout this manual, the followingstatements, which are general to the system, must be read and understood.

ATTENTION: The controller contains ESD (electrostaticdischarge) sensitive parts and assemblies. Static controlprecautions are required when installing testing, servicing, orrepairing the assembly. Component damage may result if ESDcontrol procedures are not followed. If you are not familiarwith static control procedures, refer to applicable ESDprotection handbooks.

ATTENTION: An incorrectly applied or installed controllercan damage components or reduce product life. Wiring orapplication errors, such as incorrect or inadequate AC supply, orexcessive ambient temperatures, may result in malfunction of thesystem.

ATTENTION: Only personnel familiar with the controllerand associated machinery should plan or implement the installa-tion, start-up, and subsequent maintenance of the system.Failure to do this may result in personal injury and/or equipmentdamage.

ATTENTION: The Canadian Electrical Code (CEC),National Electrical Code (NEC), or other local codes outlineprovisions for safely installing electrical equipment. InstallationMUST comply with specifications regarding wire type,conductor sizes, branch circuit protection, interlocking anddisconnect devices. Failure to do so may result in personalinjury and/or equipment damage.

Chapter 3

1503-UM051A-EN-P – June 2003

General Precautions

Safety and Codes

3-2 Installation

1503-UM051A-EN-P – June 2003

The IntelliVAC is offered in two arrangements, Integral (part of a Bulletin1500/1900 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-BradleyBulletin 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)

Arrangements

Installation 3-3

1503-UM051A-EN-P – June 2003

OEM

The IntelliVAC may be ordered as an OEM component. This allows theOEM to mount the components in a configuration most suitable to the motorcontroller equipment layout. Care must be exercised to ensure theIntelliVAC has adequate ventilation provided around it. Refer to Figure 3.3for 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 solidbarrier above or below.

The OEM is responsible for controller fusing, motor overload protection,control devices (eg. Start/Stop push buttons), and wiring between theIntelliVAC and 1502 vacuum contactor (using optional wire harness). Wiringand mounting for optional items, such as TDUV Capacitor are also theOEM’s responsibility. Refer to Fig. 3.2 for basic connections.

. Figure 3.2 IntelliVAC Typical Schematic (Electrically Held Vacuum Contactor)

* Refer to Table 3.A for recommended fuse sizing.

-+

3

2

12

11AUX

MOV

M

TCO

5

6

BLK BLK

-

+

1EC

CCO

4

9 10

15

16

M

CLOSE

INPUT POWERL N

G

STARTSTOPOVERLOAD

CONTROLPOWER

FUSE

CONTROL POWER

CONTACTORSTATUS

M

CAPACITOR(OPTIONAL)

M - INTELLIVAC

13

14MODULESTATUS

CONFIGURATIONDIP SWITCHES

-+7 8OPEN

*

3-4 Installation

1503-UM051A-EN-P – June 2003

Figure 3.3 Typical Mounting Configurations

Note:Adjacent IntelliVAC modules may be mounted with a minimum of 0.25inches separation.

MINIMUM TOPCLEARANCE

1.50(38.1)

1.50(38.1)

MINIMUMBOTTOMCLEARANCE ADDITIONAL MODULES

(AS REQUIRED)

0.25 (6.4)

Arrangementscontinued...

Installation 3-5

1503-UM051A-EN-P – June 2003

The IntelliVAC module requires external fuse protection to coordinate withthe power supply and contactor. The fuse ratings shown in Table 3.A allowthe passage of inrush currents expected when the contactor is closed, or fromrecommended external capacitors for the TDUV option. They will alsoprotect the contactor coils in the event of a module malfunction.

The recommended fuses have been tested to ensure realiable protection ofthe module. If the supply voltage is DC, the module must be used with anexternal fuse that is approved for and rated to interrupt the DC voltagesupply. The types listed are Ferraz-Shawmut Midget Fuses (1-1/2" X 13/32").The TRM is a time-delay type, rated 250 VAC. The ATM is a fast-actingtype, rated 500 VDC.

Table 3.A IntelliVAC Fuse Protection

The IntelliVAC module must be connected to a common ground terminal(PE) on the controller panel. The ground terminal is located on top of themodule enclosure (refer to Figure 3.5)

ATTENTION: It is important that IntelliVAC isproperly grounded using the ground connection provided .Failure to do so may result in damageto equipment or personal injury.

Recommended fuse Rated supply voltage Contactor type

(minimum) (maximum)

400A EH TRM 2 TRM 3.2 800A EH TRM 2 TRM 6.25 120 VAC

400/800A ML TRM 2 TRM 3.2

400A EH TRM 2 TRM 6.25 800A EH TRM 2 TRM 6.25 240 VAC

400/800A ML TRM 2 TRM 6.25

400A EH ATM 3 ATM 3 800A EH ATM 3 ATM 6 125 VDC

400/800A ML ATM 3 ATM 3

400A EH ATM 3 ATM 6 800A EH ATM 3 ATM 6 250 VDC

400/800A ML ATM 3 ATM 6

Fuse Protection

Grounding

3-6 Installation

1503-UM051A-EN-P – June 2003

There are three green connectors on the IntelliVAC module for connectionsto the control 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 Table1-A for acceptable input power and control signal ratings.Control power is applied to the module with a two-pole connector located atthe bottom rear portion of the module. Refer to Figure 3.4 for connections.The ‘L1’ connection is intended to be the ‘Hot’ or ‘+’ side of the controlpower, 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 atthe bottom front portion of the module. Refer to Figure 3.4 for connections.There are two status relays, each with one normally-open contact:

Module Status: Terminals 13 and 14Contactor Status: Terminals 15 and 16

Refer to Chapter 5 Monitoring and Troubleshooting for a description ofoperation for the relays.Refer to Table 1.A for electrical ratings of the status relays.

Figure 3.4 Bottom side connections

L2/NL1CONTACTOR STATUS OUTPUT (N.O.) MODULE STATUS OUTPUT (N.O.) POWER INPUT

13 161514

Connections

Installation 3-7

1503-UM051A-EN-P – June 2003

Interface connections

All other control interface connections are made at a twelve-pole connectorlocated on the top of the module. Refer to Figure 3.5 and Table 3.B forconnections. Refer to the Wiring Guidelines section in this chapter forguidance in making connections to the control circuit.

Figure 3.5 Top side connections

Table 3.B Terminal Assignments for IntelliVAC Interface Connections

* No connection required if option is not used.

Note: Refer to Table 1.A for electrical ratings.

CONTACTOR INTERFACE11 128 9 105 6 72 3 41

EX. CAP.

Ground connection

Terminal No. Terminal Designation Description

1 External capacitor (negative)

2 External capacitor (positive)

Power connection for TDUV or capacitor trip options only *

3 Latch trip coil (common)

4 Latch trip coil

Output for mechanical latch contactor trip coil *

5 Close coil (common)

6 Close coil

Output to close coil of electrically held & mechanical latch contactors

7 Open / Jog command

8 Open / Jog command (common)

Input to open a mechanical latch contactor or jog an electrically held contactor (mutually exclusive) *

9 Close command

10 Close command (common)

Input to initiate the closure of electrically held & mechanical latch contactors

11 Contactor auxiliary contact

12 Contactor auxiliary contact

Input to indicate the state of the contactor (typically wired to a normally closed auxiliary contact)

3-8 Installation

1503-UM051A-EN-P – June 2003

The IntelliVAC can be applied with two- or three-wire control circuits. Thecontrol system utilized will determine the configuration of the input wiring.Consider the following input and output for the type of control used:

• Terminals 9&10 Close Contactor• Terminals 15&16 Contactor Status

In either case, the CLOSE input must receive a maintained voltage high tokeep the contactor closed.

Note:1. When used with electrically held contactors, the IntelliVAC allows closecommands every six seconds. This is to ensure the rated contactor duty cycleis not exceeded.2. If a contactor close command is applied and then removed in less than 500milliseconds the IntelliVAC may fault and the module status LED will turnred. To clear the fault, module power has to be removed and reapplied.3. If IntelliVAC powers up configured for an electrically held contactor, andthe vacuum contactor is detected as being closed, the module will not respondto a close command until the auxiliary contact input is in the correct (open)state (see Chapter 5).

Wiring GuidelinesElectrically Held Contactors

Installation 3-9

1503-UM051A-EN-P – June 2003

Two Wire Control

If using two-wire control, the CLOSE contactor input is maintained high usinga single contact. Momentarily opening this input will cause the IntelliVAC toopen the contactor. Maintaining the contact will provide a CLOSE commandto IntelliVAC (given that all permissives are satisfied). If a fault occurs, inaddition to cycling control power to the IntelliVAC module, the CLOSEcommand must be removed for a minimum of 25 milliseconds, before beingre-applied. Refer to Figure 3.6.

Figure 3.6 Two Wire Control

* Refer to Table 3.A for recommended fuse sizing.

-+

3

2

12

11AUX

MOV

M

TCO

5

6BLK BLK

-

+

1EC

CCO

4

9 10

M

CLOSE

INPUT POWERL N

G

RUNOVERLOAD

CONTROLPOWER

FUSE

CONTROL POWER

M

M-IV

M-IV

CAPACITOR(OPTIONAL)

*

3-10 Installation

1503-UM051A-EN-P – June 2003

Three Wire Control

If using three-wire control, the CLOSE contactor input is maintained highusing two contacts. Momentarily opening this input will cause the IntelliVACto open the contactor. Momentarily closing the START contact will providea CLOSE command to IntelliVAC (given that all permissives are satisfied).In this configuration, the STATUS output acts as a seal-in contact. If a faultoccurs, in addition to cycling control power to the IntelliVAC module, theCLOSE command must be removed for a minimum of 25 milliseconds beforebeing re-applied. Refer to Figure 3.7.

Figure 3.7 Three Wire Control

* Refer to Table 3.A for recommended fuse sizing.

-+

3

2

12

11AUX

MOV

M

TCO

5

6BLK BLK

-

+

1EC

CCO

4

9 10

15 16

M

CLOSE

INPUT POWERL N

G

STOPOVERLOAD

CONTROLPOWER

FUSE

CONTROL POWER

CONTACTORSTATUS

M

M-IV

M-IV

M-IV

CAPACITOR(OPTIONAL)

START

*

Wiring GuidelinesElectrically Held Contactorscontinued...

Installation 3-11

1503-UM051A-EN-P – June 2003

IntelliVAC control may be used for mechanically latched contactors. Amomentary control signal is needed to close the contactor, and a secondmomentary control signal is needed to open the contactor. The momentaryopen/close commands must be at least 50 milliseconds in duration.Refer to figure 3.8 for a typical mechanical latch control scheme.

Note:1. A mechanically latched contactor may already be closed when power isapplied to the IntelliVAC control module.2. It is permissable to apply an open command to the IntelliVAC module aspower is re-applied.

Figure 3.8 Mechanically Latched Contactor Control

* Refer to Table 3.A for recommended fuse sizing.

-+

3

2

1211

AUX

MOV

CC

TCO

56

BLK BLK

-+

1EC

CCO

4

9 10

M

CLOSE

INPUT POWERN

G

OVERLOAD

CONTROLPOWERFUSE

CONTROL POWER

M

M-IV

M-IV

L

-+7 8OPEN

M-IVOPEN

CLOSE

MOV

TCBUWH

M - IV

*

Wiring GuidelinesMechanically LatchedContactors

3-12 Installation

1503-UM051A-EN-P – June 2003

When used with electrically held contactors, the IntelliVAC allows closecommands every six seconds. This is to ensure the rated contactor duty cycleof 600 operations per hour is not exceeded. For motor jogging operations, thesecond control input, or OPEN command, will close the contactor for as longas the input is present, and open the contactor when the input is removed.(Refer to Figure 3.9). This method will bypass the standard six second motorre-start delay for jogging purposes only.

Fig. 3.9 Motor Jogging Control

* Refer to Table 3.A for recommended fuse sizing.

-+

3

2

1211

AUX

MOV

M

TCO

56

BLK BLK

-+

1EC

CCO

4

9 10

15 16

M

CLOSE

INPUT POWERN

G

STOPOVERLOAD

CONTROLPOWER

FUSE

CONTROL POWER

CONTACTORSTATUS

M

M-IV

M-IV

M-IV

START

L

-+7 8OPEN

M-IVJOG

*

Motor Jogging Control

Installation 3-13

1503-UM051A-EN-P – June 2003

The IntelliVAC can be configured to provide time delay under voltage(TDUV) protection. The feature is available to keep electrically held contac-tors closed during a voltage dip or brief power loss. This option may requirethe addition of a capacitor (see below). Refer to Chapter 6 for typicalcapacitor sizing. The capacitor is connected to terminals 1(-) and 2(+) of theIntelliVAC. (Refer to Figure 3.10).

Table 4.B of the “Setup and Commissioning” chapter has the dip switchsettings to provide TDUV from 0.2 to 2 seconds. For 120VAC controlpower, a 0.2 second delay can be provided without an external capacitor.For 240VAC control power, delays of up to 1 second can be providedwithout an external capacitor. An external capacitor is required for longerdelays.

If the undervoltage condition persists beyond the set delay time, the contac-tor will be opened and an undervoltage fault condition will occur.

Figure 3.10 TDUV Control Circuit

* Refer to Table 3.A for recommended fuse sizing.

-+

3

2

12

11AUX

MOV

M

TCO

5

6BLK BLK

-

+

1EC

CCO

4

9 10

15 16

M

CLOSE

INPUT POWERL N

G

STOPOVERLOAD

CONTROLPOWER

FUSE

CONTACTORSTATUS

M

M-IV

M-IV

M-IV

CAPACITOR(OPTIONAL)

START

*

Time Delay Under Voltage

3-14 Installation

1503-UM051A-EN-P – June 2003

This page is intentionally blank.

Setup and Commissioning

The IntelliVAC module is configured for a specific application by setting DIPswitches. They are accessed by loosening the two screws on the front of theunit, and removing the cover by sliding it forward. The switches are found onthe front edge of the IntelliVAC circuit board (see Figure 4-1). There are 12switches, with number 1 being at the top next to the mini DIN connector.(Refer to Table 4.B)

IMPORTANT: Remove power from the modulebefore removing the cover and before changingthe DIP switch settings. The new settings arerecognized only on power-up.

Figure 4.1 DIP Switch and Connector Locations

An IntelliVAC unit shipped separately from the factory will have a defaultconfiguration per Table 4.A.

Table 4.A DIP Factory Default Settings

Chapter 4

1503-UM051A-EN-P – June 2003

Interface connections

EEPROM programming port(mini DIN connector)

DIP switches

Status relay outputs Supply power input

Ground stud

Internal control fuse

DIP switch Description 1 2 3 4 5 6 7 8 9 10 11 12

Altitude: 0 – 1000m 0 0 1 Drop-out time: 130 msec 0 1 1

Contactor config.: 400A EH 0 1 TDUV config.: No TDUV 0

Ext. cap TDUV time: 0.2 sec 0 0 (not used) 0

IntelliVAC Configuration

4-2 Setup and Commissioning

1503-UM051A-EN-P – June 2003

IntelliVAC units shipped in a complete MV controller (Bulletin 1500/1900)will be configured to suit the installed application (i.e. contactor type). Theuser should verify the settings before energizing the equipment. Table 4.Bdefines the settings for each switch.

Table 4.B DIP Switch Definitions

* The altitude compensation by DIP switch settings applies to Series E 400amp vacuum contactors only. Series C and D 400 amp contactors and all 800amp contactors are adapted for altitude by altering the return springs.800 amp contactors are to be set for 1 to 1000m (001 DIP setting).

UP = 1 DOWN = 0 DIP switch SW1

1 2 3 4 5 6 7 8 9 10 11 12

| | | |

Altitude * 1 2 3 12 Not used

-1000 to 0 0 0 0

1 to 1000 0 0 1 10 11 Ext. cap. TDUV time

1001 to 2000 0 1 0 0 0 0.2 sec

2001 to 3000 0 1 1 0 1 0.5 sec

3001 to 4000 1 0 0 1 0 1.0 sec

4001 to 5000 1 0 1 1 1 2.0 sec

Not defined 1 1 0

Not defined 1 1 1 9 TDUV config.

0 No TDUV

Drop out time 4 5 6 1 TDUV Enabled

50 msec 0 0 0

75 msec 0 0 1 7 8 Contactor Config.

100 msec 0 1 0 0 0 400A Mech. Latch

130 msec 0 1 1 0 1 400A Elec. Held

150 msec 1 0 0 1 0 800A Mech. Latch

175 msec 1 0 1 1 1 800A Elec. Held

200 msec 1 1 0

240 msec 1 1 1

IntelliVAC Configurationcontinued...

Chapter 5

Monitoring & Troubleshooting

The IntelliVAC module has two light emitting diodes (LEDs) and relayoutputs to indicate the status of the contactor and the module.The LEDs arevisible on the front of the module and the relay outputs are accessed on thebottom front of the module.

Figure 5.1 IntelliVAC LEDs

The Module Status is indicated with a Green LED if the module is functioningproperly and has a valid configuration. If the module powers up with aninvalid configuration the LED will be Red, indicating a Fault condition whichwill not allow the contactor to close. If the module powers up properly andexperiences an undervoltage condition when attempting to close the contactoror while the contactor is closed, the LED will be Red (Fault). If the contac-tor does not close properly, a Fault is generated, the LED turns Red, andinputs are inhibited until the module power is removed and reapplied. If theprocessor has an internal fault, the LED will be Red, the outputs will becleared, and the processor will be reset. If the reset is successful, the LEDwill be Green and the module will respond to the control inputs. The inputcommand must be toggled before the module will respond to a new command(rising edge triggered).

Module Status output relay has a normally open contact. The contact is openduring a Fault condition (LED red), and closed during a healthy condition(LED green).

1503-UM051A-EN-P – June 2003

Module Status

5-2 Monitoring and Troubleshooting

1503-UM051A-EN-P – June 2003

Table 5.A IntelliVAC Status Indication

The Contactor Status is indicated with a yellow LED that is off until aCLOSE command is received. The LED will stay on if the contactor closesproperly, until the contactor is opened.

Contactor Status output relay has a normally open contact. The contact isopen when the contactor is open (LED off), and closed when the contactorhas received a close command or if it is closed (LED on).

Notes: u Applies only to power-up conditionv Fault is reset by cycling control powerw If a contactor close command is applied and then removed in less than 500 milliseconds the IntelliVAC may fault and the module status LED will turn red. To clear the fault, module power has to be removed and reapplied.x For mechanical latch contactors a close command does not need to be maintained for the contactor to remain closed (resulting in a yellow state for contactor status).

Parameter Conditions LED State Relay Contact State

• rated supply voltage and • valid configuration

Green Closed

• undervoltage or • contactor fault or • invalid configuration u or • internal fault

Red v

Open

Module Status w

• insufficient supply voltage Off Open • rated supply voltage and • close command presentx and • contactor closed

Yellow Closed

Contactor Status • insufficient supply voltage

or • close command absentx or • contactor open

Off Open

Module Statuscontinued...

Contactor Status

Monitoring and Troubleshooting 5-3

1503-UM051A-EN-P – June 2003

Table 5.B Module Troubleshooting

Problem or Trip indicated Indication of the following conditions Possible solutions

Contactor does not energize • Motor Protection activated. • Investigate and reset.

• Both Status LEDs off • 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 Fig. 4.1 for location)

• Module Status LED 'Red' upon power up. • IntelliVAC faulted. Cycle control power to reset.

• Improper setting of dip switches. Check settings and cycle control power.

• Loose connection in control circuit.• Verify contactor auxiliary set up. Reference Publication 1502-5.0 (400A) or 1502-5.1 (800A) - Auxiliary Contact Set-Up Procedure.

• Verify circuit continuity (is contactor plug connected properly).

Contactor closes momentarily and will not reclose. • Module status LED red contactor status LED off. • Coil damaged or connections are loose. Repair and cycle control power.

• Auxiliary Contact Assembly improperly adjusted. Reference Publication 1502-5.0 (400A) or 1502-5.1 (800A) - Auxiliary Contact Set-Up Procedure.Cycle control power to reset.

• Armature Plate obstructed from closing to coil face. Verify no foreign material behind the armature plate. Cycle control power to reset.

• Undervoltage fault(no TDUV), control voltage dipped below trip point. Cycle control power to reset. Verify voltage levels are 100 to 240VAC, 100 to 250VDC.

• Both status LEDs OFF • Check internal control fuse. Verify IntelliVAC operation in test mode, before applying Medium Voltage. (Refer to Fig. 4.1 for location).

Contactor opens during operation. • Motor Protection activated. • Investigate and reset.

• Stop command initiated. • Verify circuit.

• Module Status LED 'Red' • Undervoltage fault(no TDUV), control voltage dipped below trip point. Cycle control power to reset. Verify voltage levels are 100 to 240VAC, 100 to 250VDC.

• With external capacitor and TDUV feature activated, undervoltage condition for longer than programmed TDUV time. Undervoltage fault activated. Cycle control power to reset.

• Contactor Status feedback between Terminals 11 & 12 on the IntelliVAC has closed. The IntelliVAC will de-energize the holding coil, thinking the contactor has opened for other reasons.

• Both status LEDs off • Check control voltage and internal control fuse. (Refer to Fig. 4.1 for location).

5-4 Monitoring and Troubleshooting

1503-UM051A-EN-P – June 2003

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Chapter 6

Spare Parts

Spare Parts List

1503-UM051A-EN-P – June 2003

1503VC-BMC1 IntelliVAC (electrically held) 80158-665-53-R1503VC-BMC2 IntelliVAC (mechanical latch) 80158-665-55-R

Internal Fuse: 6.3 A, 250 V (Littlefuse 21506.3) 80174-902-14-R

Multi-pole connectors:2 pole (module power) 80174-014-01-R4 pole (status outputs) 80174-014-03-R12 pole (coil and I/O connections) 80174-014-11-R

Optional Equipment

TDUV Capacitor*For 110/120 V AC control (1650 µF) 80158-779-51-RFor 220/240 V AC control (330 µF) 80158-779-52-R

*Includes mounting bracket and terminal guards

6-2 Spare Parts

1503-UM051A-EN-P – June 2003

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www.rockwellautomation.com

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Publication 1503-UM051A-EN-P –June 2003