Allen‑Bradley IntelliVAC ™ 1503VC contactor control module

Allen‑Bradley IntelliVAC ™  1503VC contactor control module

Product Description

1. Core functional features

Wide control power supply: AC 110-240 V (47-63 Hz)/DC 110-250 V.

The contactor has good consistency in the closing time and the action can be repeated; The opening (tripping) time of the contactor can be set to achieve protection coordination with the upstream power fuse.

Altitude compensation: 400A contactor electronic altitude compensation, no mechanical adjustment required for distances greater than 1000 meters; The 800A contactor adopts mechanical springs for altitude adaptation.

TDUV delayed undervoltage (power outage crossing): Short term control power supply drop/power outage, maintaining contactor closure; External electrolytic capacitors can be used to extend the duration of power outage.

Protection logic: prevent secondary bounce anti kiss, prevent repeated anti pumping; Delay restart to avoid exceeding the contactor operation cycle; Jog JOG function (electric hold only).

2. Hardware version

A series: divided into two independent models, which respectively control electrical holding and mechanical locking contactors.

B series: Single module compatible with both electrical holding and mechanical locking contactors; B can directly replace the old A series.

3. Hardware structure

The shell is fixed with two screws; The internal DIP dip switch has been fully configured; Mini DIN interface can upgrade Flash EEPROM firmware on-site.

Interface: Control power input, 12 pole contactor interface terminal, two-way status relay output (module status, contactor status, normally open contact); External capacitor EC terminal.

Mechanical dimensions: 185.3 × 165.9 × 59.4 mm.

Electrical/Mechanical Specifications

Status relay contact: 250   VDC maximum;

Environment: Storage -40~85 ℃; The working temperature decreases with altitude, decreasing by 2 ℃ for every 1000 meters increase; Humidity ≤ 95% without condensation; Resistance to shock and vibration.

CE compliance requires the selection of external EMI filters.

Reception and Storage

Open the box upon receipt and inspect for any transportation damage. If any damage is found, immediately report it to the freight forwarder.

Storage conditions: clean, dry, and dust-free; Temperature -40 ° C to 85 ° C; Relative humidity ≤ 95%, no condensation.

If it is a complete set of 1500/1900 medium voltage cabinet built-in modules, please refer to the complete equipment manual.

Installation and Wiring

Important: The module belongs to ESD electrostatic sensitive devices and must be operated with electrostatic protection; Only trained electrical personnel are required to carry out operations; Wiring shall comply with local electrical specifications of NEC and CEC.

3-1 Two application forms

Integrated form: As an internal original component of the 1500/1900 medium voltage controller.

OEM independent supply: external self installation. Installation requirements: A minimum ventilation gap of 38.1mm should be reserved above and below the module; Multiple modules installed side by side with a minimum gap of 6.4 mm; OEM is responsible for fuses, overload protection, start stop buttons, wiring harnesses, TDUV capacitors, and EMC filters.

3-2 Grounding

A series: The grounding pole is located at the top of the casing; The B-series grounding pole is located at the bottom of the casing.

It is necessary to connect the cabinet body PE common grounding terminal. Poor grounding can cause equipment damage and personal danger.

Selection of 3-3 fuses (external must be configured)

Recommended types of power supply voltage contactors: fuses

110‑120VAC 400A EH TRM 2~3.2A；800A EH TRM 2‑6.25A

220‑240VAC 400/800A TRM 2‑6.25A

DC 125V/250V EH/ML ATM series fast melting

AC uses TRM delay fuses; DC circuits must use ATM fuses that can break DC.

3-4 Terminal Interface Definition

Power terminals L1 (+), L2/N (-/N).

Status relay (normally open)

13-14: Module status; Disconnect during malfunction and close normally.

15-16: Contactor status; Connect the contactor after it is closed.

12 pole top interface: external capacitor EC, closing CCO, opening TCO, auxiliary feedback AUX; Closing input 9-10, opening input 7-8.

3-5 Electrical Holding Contactor Wiring Scheme

Two line control: Long signal maintains closing; To clear the fault, the closing signal needs to be removed for at least 4 seconds before reapplying. DIP can close the power on safety lock.

Three wire control (start stop button+self-locking): START instantaneous closing, STOP opening; Use contactor status relays for self-locking.

Electrical holding limit: The minimum interval between normal closing instructions is 6 seconds to prevent exceeding the rated operating cycle of the contactor at 600 times per hour; If the closing input signal is less than 500 ms, a fault will be triggered and a power-off reset is required; If the module is powered on and the contactor is detected to be closed and the power on safety is turned on, the closing command is rejected and a power outage and restart are required. After powering on, it is recommended to wait for 4 seconds before giving the closing command.

3-6 mechanical lock contactor wiring

Both closing and opening require a pulse signal of at least 50ms, without the need to maintain a voltage level.

Capacitor Trip function: When power is lost, the external capacitor energy storage output trips the contactor to disconnect the trip pulse.

The maximum capacitance of the 120V system is 1650 µ F; the maximum capacitance of the 240V system is 330 µ F; the capacitor withstand voltage is 120V ≥ 200VDC and 240V ≥ 400VDC.

After power failure, the OPEN disconnection command must be given within a few seconds, and the capacitor cannot be tripped after the energy is exhausted.

3-7 inch jog JOG (electric hold only)

Use the OPEN terminal to achieve jog, input the effective contactor to close, and immediately disconnect upon cancellation; Bypass the 6-second restart delay, specifically designed for debugging and alignment.

3-8 TDUV delay undervoltage crossing

Short term voltage drop maintains contactor closure.

External capacitance: 110-120V maximum 0.2 seconds; 220-240V maximum 1.0 seconds.

External EC capacitors (terminals 1-2) with DIP settings can achieve up to 2 seconds of power-off maintenance.

Judgment criteria: Start timing when the voltage drops to 90V after closing for 200 ms; Drop to 72V and take immediate action; Exceeding the set delay, the contactor trips and reports an undervoltage fault.

Setting and Debugging (DIP DIP DIP configuration)

To modify the DIP switch, the module power must be disconnected first, and the modification will only take effect when it is powered back on; Remove the casing and place the 12 position DIP on the front edge of the circuit board, with the No.1 located near the Mini DIN programming port.

DIP switch function

DIP bit function

1-3 altitude compensation (only 400A electric holding contactor)

4-6 contactor dropout time (50-190 ms), fuse timing coordination

7-8 contactor type: 400/800A; electrical holding EH/mechanical locking ML

Enable/disable TDUV delay undervoltage function

10-11 external capacitor mode TDUV time: 0.2/0.5/1.0/2.0 seconds

12 Power Up Safety enabled/disabled

Factory default: altitude 0-1000   m; trip 130   ms; 400A electrical hold; TDUV is turned off; Power on safety activation.

The complete set of 1500/1900 has been pre configured before leaving the factory; Use default parameters for individual ordering modules and verify DIP before powering on. The firmware upgrade is done through the Mini DIN debugging port.

Monitoring and Troubleshooting

1. LED indicator light

Green: Module status light: Green=Module normal; Red=Fault; The B series supports flashing fault codes.

Yellow: Contactor status light: It lights up when the closing command is received and the contactor is closed.

2. Relay output

Module status relay: Fault (red light) disconnected; Normal (green light) closure.

Contactor status relay: After the contactor is closed, it closes.

3. B series flashing fault code

1 Flash: DIP dip configuration error; Power off and switch to DIP restart. 2 flashes: The auxiliary feedback loop is abnormal.

Differentiation: Recoverable Warning: Cancel input signal retry; Unrecoverable fault: The module must be powered off and restarted to clear.

Common fault phenomena

The contactor does not operate at all: there is no control power supply; The internal fuse is blown; DIP configuration error; External protection (overload, emergency stop) action.

The contactor does not close after a short period of time: the coil is damaged; Auxiliary contact adjustment error; Control voltage drop under voltage fault; Foreign objects obstructing the armature; Power off reset is required.

Unjustified disconnection during operation: overload protection, stop command triggered; TDUV timeout undervoltage; The auxiliary feedback signal is abnormal.

Mechanical lock cannot be opened: insufficient control power supply; Damage to the release mechanism; Loose wiring.

Minimum operating voltage: suction 95VAC; Release 75VAC; Mechanical lock release 400A minimum 70VAC, 800A minimum 80VAC.

Spare Parts and Options

Module model

1503VC-BMC1: A series electric hold

1503VC-BMC2: A series mechanical lock buckle

1503VC-BMC3: B series (EH+ML universal)

Internal insurance: 6.3A/250V Littlefuse   21506.3.

Connector spare parts: 2-pole power supply, 4-pole status output, 12 pole I/O connector.

option

TDUV electrolytic capacitor: 120V (1650 µ F)/240V (330 µ F).

EMC filter FN670-10/06, used for CE EMC compliance.