Rockwell Automation 1503VC IntelliVAC Plus Contactor Control Module User Manual
Intellivac™ plus contactor control module
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Table of contents
Document Outline
- Important User Information
- TOC_1503-UM054
- Chapter 1_Product Description
- Chapter 2_Receiving and Storage
- Chapter 3_Installation
- Chapter 4_Description of Features_b
- These maximum times are inherent in the design of the Basic module and are programmable up to the maximums in Table 4.A. They are only valid when the TDUV feature is enabled.
- Time Delayed Under-Voltage Ridethrough (TDUV)
- Before a contactor has been commanded to close, this time will be set to 0mS. If a contactor does not close within the close time period, which is programmed as 200mS in the IB unit, then the contactor open routine will be initiated and a ‘Contactor ...
- Contactor Close Time
- To determine component wear of the contactor over its lifetime, the close time will be monitored as a wear indicator. To perform this measurement the close time will be averaged over the last 5 closures and when the present value has exceeded the tab...
- Re-Closing Control Features
- Temporary Jog Function
- Open Coil Test To check that there is a coil(s) connected to the IntelliVAC Plus unit a test is performed to confirm that the coil current is greater than 200mA. If the coil current measured is lower than this threshold then it can be assumed that th...
- Altitude/Air Pressure Compensation (400A Contactors)
- This parameter will calculate the average number of operations (valid Close commands) between the last reset time and the present RTC value. It can be viewed as an average over the number of hours, days or weeks, between the last operations reset tim...
- Dual Power Supply Operation
- The IntelliVAC Plus module is capable of operating on two different power sources. The first of these sources is from the input power at terminals TB1-TB2. This power source is used to generate the internal DC voltages required for operation of the ...
- Power Fail Operation
- Status Indicators
- The IntelliVAC Plus unit has five sets of status indicators:
- Two (2) red/green bi-colour type LEDs on the IB unit for Module/Contactor status
- One (1) red 7 segment LED display for Warning/Fault status
- Figure 4.1 – IB LEDs
- Table 4.E shows the Faults/Warnings conditions for the IB module only. These conditions are only valid for the IB module contained within the IntelliVAC Plus unit and not the IB modules within the other MC modules within an MC system.
- IB Faults / Warnings Healthy Module and Contactor OPEN
- Healthy Module and Contactor CLOSED
- This condition is valid for both Electrically Held and Mechanically Latched contactors.
- Invalid Command Present
- This condition is valid for both Electrically Held and Mechanically Latched contactors.
- This condition is valid for Mechanically Latched contactors only.
- The Contactor status LED is Yellow to indicate that the contactor is in a Closed condition and the Contactor status relay is closed to reflect the status of the contactor thus allowing externally connected circuits to function.
- This condition is valid for Electrically Held contactors only.
- The Contactor status LED is Yellow or off to indicate that the contactor is in a Closed or Open condition and the Contactor status relay is Closed or Open to reflect the status of the contactor thus allowing or preventing externally connected circuits...
- This condition is valid for both Electrically Held and Mechanically Latched contactors.
- The Contactor status LED is Yellow or off to indicate that the contactor is in a Closed or Open condition and the Contactor status relay is Closed or Open to reflect the status of the contactor thus allowing or preventing externally connected circuits...
- This condition is valid for both Electrically Held and Mechanically Latched contactors.
- The Contactor status LED is Yellow or off to indicate that the contactor is in a Closed or Open condition and the Contactor status relay is Closed or Open to reflect the status of the contactor thus allowing or preventing externally connected circuits...
- This condition is valid for Electrically Held contactors only.
- The Contactor status LED is Red to indicate that the contactor is in an Open condition and the Contactor status relay is Open to reflect the status of the contactor thus preventing externally connected circuits to function.
- This condition is valid for both Electrically Held and Mechanically Latched contactors.
- The Contactor status LED is off to indicate that the contactor is in an Open condition and the Contactor status relay is Open to reflect the status of the contactor thus preventing externally connected circuits from functioning.
- This condition is valid for both Electrically Held and Mechanically Latched contactors.
- The Contactor status LED is Red to indicate that the contactor has a severe fault and has not dropped out at all, or at least not within the maximum allowed time of 240mS and the Contactor status relay is Open to prevent externally connected circuits ...
- This condition is valid for both Electrically Held and Mechanically Latched contactors.
- The Contactor status LED is off to indicate that the contactor is in an Open condition and the Contactor status relay is Open to reflect the status of the contactor thus preventing externally connected circuits from functioning.
- This condition is valid for both Electrically Held and Mechanically Latched contactors.
- The Contactor status LED is Yellow or off to indicate that the contactor is in a Closed or Open condition and the Contactor status relay is Closed or Open to reflect the status of the contactor thus allowing or preventing externally connected circuits...
- This condition is valid for both Electrically Held and Mechanically Latched contactors (TDUV and <80Vrms during hole conditions do not apply for Mechanically Latched contactors).
- Table 4.F shows the Faults/Warnings conditions for the IntelliVAC Plus module only.
- On a fault occurrence, of either the IB or IE units, the contactor will be opened either by removing power to the hold coil in an electrically held contactor or by pulsing the trip coil in a mechanically latched contactor.
- Figure 4.3 --Segment LED Address/Fault/Warning Display
- If only faults or warnings exist then the latest fault or warning will be annunciated. If faults and warnings both exist, then only the last fault occurrence will be displayed.
- For the 7-segment LED display, the ‘Watchdog Timeout’ and the ‘System Lock-Out State’ will have the highest priority with the ‘Watchdog Timeout’ being the higher of the two.
- Chapter 5_IntelliVAC Plus Basic Wiring
- Chapter 6_Wiring
- Chapter 7_Communications
- The communications systems implemented within the IntelliVAC Plus product can be divided into three sections:
- RS232 Communications
- This interface is used for factory programming of the CPU and is only to be used by factory authorized personnel.
- RS485 Communications
- This interface is used for three purposes:
- 1. For internal communications between the IntelliVAC Base and IntelliVAC Enhanced boards which are contained within the IntelliVAC Plus product.
- 2. For inter-module communications between the IntelliVAC Plus and the IntelliVAC MC products, to coordinate control actions amongst up to five medium voltage vacuum contactors.
- 3. For Flashing the IntelliVAC Base and IntelliVAC Enhanced boards in an IntelliVAC Plus product or Flashing the IntelliVAC Base board within an IntelliVAC MC product.
- The communications within the IntelliVAC Plus module, as well as within the IntelliVAC MC system, operates at a 125K baud rate. Extensive error checking is provided to prevent incorrect data from corrupting operation of the entire system. Various er...
- This interface is used for two purposes:
- For external communications to a DeviceNet network allow the IntelliVAC Plus and IntelliVAC MC product to be controlled and monitored by an external controller unit.
- For Flashing the IntelliVAC Plus using ControlFLASH.
- Compatibility with IntelliCENTER
- Chapter 8_Configuration_Programming
- Configuration IB Board DIP Switches
- Some of the functionality of the IntelliVAC Plus product is derived from the settings of the DIP switches on the IB board.
- The DIP switch settings are only read once after a power up sequence occurs. If changes are to be made to the DIP switch inputs, then control power must be recycled before the changes will take affect.
- Table 8.A – Altitude Settings
- DIP SW1
- ALTITUDE (m)
- 3
- 2
- OFF
- OFF
- OFF
- -1000 to 0
- 0 to 1000
- 1001 to 2000
- Table 8.B – Drop Out Time Settings
- DIP SW1
- DROP OUT TIME
- 6
- 5
- OFF
- OFF
- OFF
- 50 mS
- 75 mS
- 100 mS
- Table 8.C – Contactor Type
- DIP SW2
- DIP SW1
- CONTACTOR CONFIGURATION
- 2
- 1
- 8
- OFF
- OFF
- OFF
- 400A Mech. Latch (7.2kV)
- 400A Elec. Held (7.2kV)
- 800A Mech. Latch (7.2kV)
- OFF
- OFF
- OFF
- Table 8.D – TDUV Configuration
- DIP SW2
- TDUV Configuration
- 3
- OFF
- TDUV disabled
- ON
- TDUV enabled
- Table 8.E – TDUV Hold-Up Times
- DIP SW2
- TDUV Hold-up Time
- 5
- 0.2 Sec
- 0.5 Sec
- 1.0 Sec
- Table 8.F – Power-Up Safety Configuration
- DIP SW2
- Power-up Safety
- 6
- OFF
- Enabled
- ON
- Future Use
- These DIP switches are not used and are for future use.
- MC Board DIP Switches
- Some of the functionality of the IntelliVAC MC product is derived from the settings of the DIP switches on the MC board.
- The DIP switch settings are only read once after a power up sequence occurs. If changes are to be made to the DIP switch inputs, then control power must be recycled before the changes will take affect.
- The IE firmware revision will be made available through either RSNetWorx, in the General window under the Revision parameter, or by use of a HIM, under the Revision menu when the IE unit is selected. There is no special parameter made available on De...
- Chapter 9_DeviceLogix
- DeviceLogix
- Logical Masks
- Important Terms for Logical Masks
- START
- STOP
- FORWARD
- REVERSE
- JOG
- Direct Commands
- 1 – Logical Mask 0 (Mask Local)
- 2 – Logical Mask 1 (Mask Network)
- 3 – Logical Mask 2 (Mask DeviceLogix)
- 4 – Logical Mask 3 (Mask HIM/PC)
- The selection of the Logic Mask in DeviceNet is as follows:
- Inputs and Outputs
- Input and Output Bits
- Local Function Block Logic
- RSNetworx for DeviceNet Software Operating Modes
- DeviceLogix Operating Modes
- Launching the DeviceLogix Editor
- Figure 9.1 – Launching DeviceLogix Editor
- Figure 9.2 – Select Logic Editor Type
- Figure 9.3 – DeviceLogix Editor Screenshot
- DeviceLogix Function Block Elements
- I/O Components
- Digital Input Point (DIP)
- Figure 9.4 – Digital Input Point
- Digital Output Point (DOP)
- Figure 9.5 – Digital Output Point
- DLX Function Blocks
- Boolean
- Bi-stable Function blocks
- Timers
- Counters
- Bistable Function Blocks
- Timers
- Pulse Timer
- Figure 9.6 – Timing diagram for the Pulse Timer
- On Delay Timer
- Figure 9.7 – Timing Diagram for the On-Delay Timer
- Off Delay Timer
- Figure 9.8 – Timing Diagram for the Off-Delay Timer
- Up Counter
- Figure 9.9 – Timing Diagram for the Counter Function with a Preset Value = 3
- Up Down Counter
- Figure 9.10 – Timing Diagram for the Up/Down Counter with a Preset Value = 3
- Offline Operations
- Online Operations
- Go Online
- Change Function Block Attribute Values
- Figure 9.11 – Modify Function Block Attributes
- Online Animation
- Change Logic
- Add a Logical Element
- Add a digital input point (DIP)
- Add a digital output point (DOP)
- Bit Negation
- Figure 9.12 – Bit Negation
- Assume Data Available
- Figure 9.13 – Assume Data Available
- Assume Data Available (alternate method)
- Figure 9.14 – Assume Data Available Alternate Method
- Forcing
- Figure 9.15 – Forcing
- Tip: You cannot use the Force Function in offline mode.
- Tip: You do not have to be in the Edit mode to use forces.
- Forcing Inputs
- The following list describes the input force options.
- Figure 9.16 – Input Forced Indication
- Forcing Outputs
- The following list describes the output force options.
- Figure 9.17 – Output Force Indication
- Dual Function Inputs
- Figure 9.18 – Dual Function Bit Behavior
- List of bits which are dual function:
- Customized Logic Mode:
- Available Inputs:
- Hardware Boolean inputs
- Status Inputs
- IBX- Aux.
- IBX-Input1
- IBX-Input2
- Stop Status
- Interim 1-5
- MC Start Status
- Start
- Stop
- FWD
- REV
- JOG
- Protection Status
- Speed SW FWD Status
- Speed SW REV Status
- Isolation SW Status
- Remote Mode Status
- Local mode status
- Normal Mode Status
- Test Mode Status
- IBX Out A Status
- IBX Out B Status
- Fault Status
- IBX- Healthy Module Contactor open
- IBX-Healthy Module Contactor closed
- IBX-Invalid Command Present
- IBX-Mechanical latch Fail to Trip
- IBX-Power up with contactor closed
- IBX- Contactor Fails To Pick UP
- IBX-Contactor drop out during hold
- IBX- Long Contactor Drop Out Time
- IBX- CPU malfunction
- IBX - Power Up With Invalid Dip Configuration
- IBX-Under voltage with close command present
- Network Boolean Inputs
- Net In 1-10
- Dedicated Network command bits
- Net In 11/Net Start
- Net In 12/Net Stop
- Net In 13/Net FWD, Net In 14/Net Rev, Net In 15/Net Jog
- Output bits/tags
- Hardware Boolean Outputs
- Net out A
- Net Out B
- Network Boolean Outputs
- Net Out 0/Reset All Faults
- Net out 1, 2
- Net Out 3-7/ Interim 1-5
- Net Out 8/Protection Status
- This is the output portion of the Protection status dual function bit.
- Net Out9/Speed SW FWD Status
- Net out 10/Speed SW REV Status
- This is the output portion of the Speed SW REV Status dual function bit.
- Net Out 11/Isolation SW status
- This is the output portion of the Isolation SW status dual function bit.
- Net Out 12/Remode Mode Status
- This is the output portion of the Remote Mode Status dual function bit.
- Net Out 13/Local Mode Status
- This is the output portion of the Local Mode Status dual function bit.
- Net out 14/ Normal Mode Status
- This is the output portion of the Normal Mode Status dual function bit.
- Net Out 15/Test Mode Status
- This is the output portion of the Test Mode Status dual function bit
- Net out 16, 18, 20, 22, 24/ IBX Trip Coil
- Net Out 17, 19, 21, 23, 25/ IBX Close coil
- Net Out 26/Stop Status
- This is the output portion of the “Stop Status” dual function bit.
- Net Out 27/Start
- This is the output portion of the “Start” dual function bit.
- Net Out 28/Stop
- This is the output portion of the “Stop” dual function bit.
- Net Out 29/FWD
- This is the output portion of the “FWD” dual function bit.
- Net Out 30/REV
- This is the output portion of the “REV” dual function bit.
- Net Out 31/Jog
- This is the output portion of the “Jog” dual function bit.
- Hardware set up for this example:
- Figure 9.19 – Basic Logic Program
- Pre configured Logic Mode:
- Figure 9.20 – Select Pre-Configured Logic Program
- Chapter 10_Troubleshooting
- Appendix A_Fuse Protection
- Appendix B_Parameters_b
- Appendix C_Maintenance
- Appendix D_Spare Parts
- Appendix E_DeviceNet Info
- Appendix F_IntelliVAC Plus Firmware
- Back Cover_1503-UM054C