oem products: medium voltage applications

oem products: medium voltage applications
OEM PRODUCTS: MEDIUM VOLTAGE APPLICATIONS
BULLETIN 1502 / 1503 / 1901
Important User
Information
Because of the variety of uses for the products described in this publication, those responsible
for the application and use of this control equipment must satisfy themselves that all necessary
steps have been taken to assure that each application and use meets all performance and
safety requirements, including any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this guide are intended
solely for purposes of example. Since there are many variables and requirements associated
with any particular installation, Rockwell Automation does not assume responsibility or liability
(to include intellectual property liability) for actual use based upon the examples shown in this
publication.
Table of Contents
Overview
1502
Medium Voltage 3-Pole Vacuum Contactors
Description ..................................................................................................... 1
Specifications ................................................................................................ 2
Typical IntelliVAC Control Circuit (400 A) ...................................................... 4
Typical Electromechanical Control Circuit (400 A) ...................................... 4
400A 3-Pole Vacuum Contactor • Dimension Drawing ............................... 5
800A 3-Pole Vacuum Contactor • Dimension Drawing ............................... 5
Contactor Description ................................................................................... 6
Mechanical Latch Kit .................................................................................... 6
Altitude Code/Derating Table ....................................................................... 6
1503F/C/S
OEM Controllers and Components
Description .................................................................................................... 7
Power Fuses ................................................................................................ 7
Assembled Power Cell and Frame .............................................................. 8
Typical Schematic • 120 V Control Circuit ............................................ 8
Dimension Diagram • 400 A ................................................................... 9
Dimension Diagram • 600 A ................................................................ 10
Frame Options ..................................................................................... 11
Relay Control Panel ....................................................................................12
Non-Load-Break Isolation Switch ...............................................................13
400 A (Clip-on Fuses) ...........................................................................14
400 A (Bolt-on Fuses) ...........................................................................15
600 A (Clip-on Fuses) ..........................................................................16
600 A (Bolt-on Fuses) .......................................................................... 17
800 A (Bolt-on only Fuses) .................................................................. 18
Isolation Switch Handle Module .................................................................19
1503VC
IntelliVAC™ Control Module for MV Vacuum Contactors
Advanced Digital Control of Vacuum Contactors .......................................20
IntelliVAC Control Module ...........................................................................20
Control Power Selector Assembly ...............................................................20
Specifications .............................................................................................21
Catalog Numbers ........................................................................................21
Dimensions .................................................................................................21
Table of Contents (cont.)
1503E
MV SMC Flex OEM Kits
Description ..................................................................................................22
Optional Control Module ............................................................................22
Features ......................................................................................................22
Optional Communication Modules ........................................................... 22
Product Selection Guide ............................................................................22
Typical Power System Diagram – 3300/4160V ..........................................23
Typical Control Circuit • Standard Module .................................................24
Functional Design Specifications ..............................................................25
OEM Controller and Components ..............................................................26
Assembled Frame ...............................................................................26
Power Stack .........................................................................................28
Voltage Sensing Board ........................................................................34
Interface Board ....................................................................................35
SMC Flex Control Module .................................................................. 36
Fiber Optics .........................................................................................38
Gate Driver Test Power Supply ............................................................39
Relay Control Panel .............................................................................40
Bypass Contactor .................................................................................41
1901
SyncPro™ Field Application and Protection System
Features ..................................................................................................... 42
Protection/Control .......................................................................................42
Display/Metering .........................................................................................42
Specifications .............................................................................................43
Options and Catalog Numbers ...................................................................43
Dimension Drawings ..................................................................................44
DTAM Dimensions ..................................................................................... 44
Overview
Rockwell Automation has produced quality Medium Voltage products to meet the requirements
of all types of industries for well over six decades.
From the original oil-immersed contactor to air break and vacuum contactors, to solid-state controllers
such as Smart Motor Controllers and AC Variable Frequency Drives, Rockwell Automation has
developed and built a medium voltage product line that satisfies industries who are demanding more
safety, less maintenance, longer life and reliability in motor control equipment.
Added to those demands is the need for smaller, more flexible medium voltage products that are more
efficient and reduce building and expansion costs.
OEM frames and components leverage the existing family of motor controllers built by Rockwell
Automation. They also incorporate some of the most fundamental, high volume components available
in our OEM product line for Original Equipment Manufacturers and electrical equipment companies.
Bulletin 1502 vacuum contactors are a comprehensive line of vacuum contactors used as isolating
contactors or as bypass contactors. Light weight and maintainability are but two of the features of this
fixed-mounted design.
Bulletin 1503F OEM components are a series of medium voltage frame-mounted components
designed to mount into new or existing structures or enclosures. These assemblies can also be
used to retrofit existing motor controllers. These products are available as a complete OEM frame or
sold individually as components.
Bulletin 1503E MV SMC™ Flex OEM kits are a series of solid-state reduced voltage components
designed to mount into new or existing structures or enclosures. These assemblies can also be used to
retrofit existing motor controllers. These products are available as an OEM frame and components.
Bulletin 1901 SyncPro™ is a field application and protection system for squirrel-cage, brush-type
synchronous motors.
Rockwell Automation also offers standard motor controllers, solid-state reduced voltage starters,
and variable speed drives with standard, yet flexible, product configurations for all product lines.
Rockwell Automation offers several OEM programs, such as customer-specific program
(custom engineered options and configurations with a standard quick-ship delivery). Contact your local
Rockwell Automation office for more information on these programs and other OEM products.
1502
3-POLE VACUUM CONTACTOR
Medium Voltage
400 and 800 A Contactors
400 A
800 A
Description
The Allen-Bradley Medium Voltage 400 and 800 ampere vacuum
contactors offer:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Lightweight, compact design
High interrupting capability
Low chopping current
Visual contact wear indicator
Field adjustable altitude setting (800 A only)
Provision for mechanical interlocking
Excellent dielectric recovery allowing for high switching frequency
Single coil/core magnet assembly (800 A only)
Control power transformer primary fuse holders (400 A only)
Quiet DC coil operation
Minimal maintenance required
Mechanical latch design (Optional)
CSA, CE and IEC Approved
UL Recognized to 7200 V
1502
3-POLE VACUUM CONTACTORS
Specifications
1502
3-POLE VACUUM CONTACTOR
Bulletin 1502 Medium Voltage Contactor Ratings
400 A
800 A
200
00
000
00
0
20
00
20
00
0
Operational Characteristics
Mechanical Life (Operations) x 000
Electrically Held
Mechanical Latch
Electrical Life (Operations) x 000
Switching Frequency
Electrically Held
(Operations per hour)
Mechanical Latch
Opening and Closing Times (Series E)
Electro-Mechanical (Relay) Control (Mechanical Latch Only)
Maximum Closing Time (20 VAC)
0 or 0 Hz (milliseconds)
0
Maximum Opening Time (20 VAC)
0 or 0 Hz (milliseconds)
0
IntelliVAC Control (Electrically Held & Mechanical Latch)
Maximum Closing Time
0/0 Hz or DC (milliseconds)
00 / 70
Maximum Opening Time – without delay  0/0 Hz or DC (milliseconds)
0
Opening and Closing Times (Series D) 
Maximum Closing Time
0 or 0 Hz (msec)
0
Maximum Opening Time (Normal Drop Out)
0 or 0 Hz (msec)
0
Maximum Opening Time (Fast Drop Out)
0 or 0 Hz (msec)
0
Capacitor Switching
2400 V
800 KVAR
System Voltage
40 V
400 KVAR
00 V
2000 KVAR
General
-000 to 000 meters
Standard Altitude Rating
(-00 to 00 lbs) 
Contactor Weight
2.8 kg (48 lbs)
Auxiliary Contact Rating
A00
Auxiliairy Contacts on the Vacuum Contactor
2 N.O. / 2 N.C.








N/A
NA
0
0
200
240
0
2000 KVAR
000 KVAR
4000 KVAR
-000 to 000 meters
(-00 to 00 lbs) 
4 kg (00 lbs)
A00
2 N.O. / 2 N.C.
The voltage and current ratings listed are valid up to ,000 m (,00 feet).
Please refer to the Altitude Derating Chart on page for ratings above this altitude.
The IEC rating at 7200 V (RMS Sym.) is 00 Amps / MVA.
Control voltage, as measured at the input of the IntelliVAC control module (when Series E data entered)
A contactor drop-out delay may be configured with the IntelliVAC control module (refer to publication 0-UM0_-EN-P).
The full altitude range is available with the IntelliVAC control module only, and the IntelliVAC is to be configured accordingly (refer to
publication 0-UM0_-EN-P). The standard mechanical latch contactors, if used with electro-mechanical control, are designed
for -000 to 000 meters (-00 to 00 feet). Higher altitudes are possible by changing the contactor return spring.
Altitude adjustment (manual) is required to support full altitude range.
The number of contactor auxiliary contacts depends on the contactor type. Some of the contactors are used in the typical control
schemes used.
Series D contactors are suitable for electro-mechanical (relay) control only.
1502
3-POLE VACUUM CONTACTORS
Typical IntelliVAC Control Circuit (400A, Electrically Held)
CONTROL POWER
*
CONTROL
POWER
FUSE
M-INTELLIVAC
7 +
+
OVERLOAD
- 0
CLOSE
START
STOP
- 8
OPEN
CONTACTOR
STATUS
4
MODULE
STATUS
CAPACITOR
(OPTIONAL)
EC
2 +
TCO
AUX
2
CCO
4
MOV
M
M
CONFIGURATION
DIP SWITCHES
L
INPUT POWER
G
L2/N
Typical Electromechanical Control Circuit (400A, Electrically Held)
MOV
M
M
FU
CR
CR
CR2
CR2
CR2
CR2
MOV
C
D
BLK
CC
Y
N
B
A
M
HC
Y
B
CR2
STOP
START
OVERLOAD
CR
CR
M
CR
CR2
CC
HC
– MV Vacuum Contactor
– Control Relay
– Economizing Relay
– Closing Coil
– Holding Coil
Note: Some of the control circuit devices shown in addition to “M” (MV vacuum contactor) are available as optional equipment.
(See Control Panel Specifications on pages 12 and 20.)
1502
3-POLE VACUUM CONTACTOR
Dimension Drawings
400 A Vacuum Contactor:
2 (8.)
(.70)
48 (7.2)
27 ()
to Center
Front View
Side View
800 A Vacuum Contactor:
4.2 (.4)
2. (20.7)
470.4 (8.2)
8.2 (.2)
to Center
Front View
Side View
Approximate dimensions in millimeters (inches)
1502
3-POLE VACUUM CONTACTORS
Bulletin 1502 Vacuum Contactors
Contactor
Current
Rating
400 Amp

Control Circuit
Electromechanical
IntelliVAC™ 
Electromechanical
800 Amp
IntelliVAC™ 








Contactor Description
Fixed Mounted, Electrically Held  
Fixed Mounted, Electrically Held (fast drop-out)   
Fixed Mounted, Mechanical Latch 
Fixed Mounted, Electrically Held  
Fixed Mounted, Mechanical Latch 
Fixed Mounted, Electrically Held  
Fixed Mounted, Electrically Held (fast drop-out)   
Fixed Mounted, Mechanical Latch 
Fixed Mounted, Electrically Held  
Fixed Mounted, Mechanical Latch 
Catalog Number
02-V4DBDA-__
02-V4DBDD-__
02-VC4DBDB-__
02-VC4DBDA-0
02-VC4DBDB-0
02-V8DXDA-__
02-V8DXDD-__
02-V8DXDB-__
02-VC8DXDA-__
02-VC8DXDB-__
Wire Harness
Catalog Number

0-WHE4D
0-WHM4D
0-WHE4V
0-WHM4D
0-WHE8D
0-WHM8D
0-WHE8V
0-WHM8D
Complete the catalog numbers by selecting the altitude rating from the Altitude Code/Derating Table on this page, e.g. 02-V4DBDA-2.
The contactors listed include fuse clips for .0 kV max. control power transformer primary fuses. Change the fifth (th) position of the catalog number from “B” to “C” for
contactors with 7.2 kV max. fuse clips, e.g. 02-V4DCDA-. No extra charge applies.
The electrically held contactors are also available with 20 VDC coils (20 VDC coils are not available for mechanical latch contactors). Change the sixth (th) position
of the catalog number from “D” to “E”, for e.g. 02-V4DCEA-. No extra charge applies.
For use as bypass contactors with Bulletin 0E MV SMC-Flex controllers, see page 40.
When IntelliVAC™ control is used, select altitude code zero (0) which allows the same contactor to be used from -,000 to ,000 metres; however, the contactor current
must be derated per the Altitude Code/Derating Table on this page
02-VC electrically held contactors are provided as fast drop out type, and drop out delays are controlled by the IntelliVAC™ control module.
If a 0F OEM Power Cell and Frame, a 0C or 0E control panel are ordered, a wire harness is provided.
IntelliVAC™ control can be selected on page 20. Select an appropriate wire harness above, for use with IntelliVAC™ control.
Mechanical Latch Kit
Electrically-Held, 400 Amp, Vacuum Contactors (Series E and later) can be retro-fitted with a mechanical
latch assembly using this kit (1502-4MLK). The kit is suitable for use with vacuum contactors 1502-VC4DBDA-0,
as listed in the above table.
The kit comes with all required components and instructions.
NOTE: The kit must be installed by qualified personnel.
1502-4MLK
If a mechanical latch contactor is known to be required, it is recommended that a suitable contactor be
ordered direct from the factory (i.e. 1502-VC4DBDB-__ ).
1503F
OEM CONTROLLERS AND COMPONENTS
Assembled Power Cell
and Frame
Description
The 1503F OEM controller is an open-frame-style structure that consists of a bolted construction frame
housing the vacuum contactor, non-load-break isolation switch, and the isolation switch handle module.
A control panel is also included and connects to the vacuum contactor to provide the necessary control
functions for operating the controller. Available for voltages ranging from 2400 to 7200 volts.
The 1503F OEM controller requires additional components in order to fully construct a complete motor
starter such as current transformers, power fusing, a control power transformer, overload protection,
appropriate control circuitry for the application, and a suitable enclosure.
The OEM frame includes as standard:
• Non-load-break fused isolation switch 
(See Switch Specifications, page 13)
400 Amp
• Isolation switch operating handle
(See Handle Specifications, page 19)
• 2 N.O./2 N.C. auxiliary contacts on the isolator switch
•
Two options:
– IntelliVAC control module (see page 20 and Product Profile 1503-PP400_-EN-P)
– Control panel and 10-ft (3.05-m) wire harness for 120 or 230 V AC control power
(See Control Panel Specifications, page 12)
• Vacuum contactor
(See Vacuum Contactor Specifications, page 2, Bulletin 1502)
• Power cell door
• Factory tested
• Installation Manual
Power Fuses
Ferraz-Shawmut medium voltage power fuses are recommended for the Bulletin 1503F. These motor
fuses have been tested and meet the co-ordination requirements for the Bulletin 1502 vacuum contactor.
1503F
OEM CONTROLLERS AND COMPONENTS
Assembled Power Cell and Frame (cont.)
Typical Schematic • 120 V Control Circuit, 400A Electrically Held Contactor with IntelliVAC Control (including option 1503C-CPSx)
ISOLATING SWITCH
IS
DOOR INTERLOCK
L
CUSTOMER
INCOMING LINE
L2
MOTOR
CT
T
F
M
CURRENT LIMITING
POWER FUSES
(CUSTOMER SUPPLIED)
GRD
CT2
T2
F
L
CT
T
F
4
OVERLOAD
CUSTOMER SUPPLIED
20V AC
(L)
(N)
GRD
ISa
8
X
ISb
OFF
7
()
()
(7)
NORMAL
(8)
X
0
TEST SUPPLY POINT
TS
20V
TEST
X ()
(2)
()
(4)
0Hz
X
2
M-IV
F 4.0A
2.0A
F7
A
M
B
4
EC
2 +
TCO
AUX
2
HCO
L
A
B
STOP
START
2
7
N
C
M
20
M-IV
CONTACTOR
STATUS
M
MOV
G
M-IV
LEGEND
CUSTOMER WIRING
REMOVE JUMPER WHEN CONNECTING REMOTE EQUIPMENT
"IEEE" NUMBER FOR PROTECTIVE DEVICE
REMOTE EQUIPMENT
4
+ - 0
CLOSE
4
OVERLOAD
2
1503F
OEM CONTROLLERS AND COMPONENTS
• 400 A
606 (23.85)
546 (21.50)
4 × ø.515
Mounting
Holes
127 (50.36)
538 (21.17)
61 (27.22)
7 (3.83)
25 (0.7)
Front View
556 (21.8)
Bottom View
Approximate dimensions in millimeters (inches).
Net Shipping Weight (400A): 127 kg (280 lbs)
1503F
OEM CONTROLLERS AND COMPONENTS
Assembled Power Cell and Frame (cont.)
• 600 A
4 [2.7]
48
[8.]
78
[0.22]
4
[24.7]
2 [24.8]
8 [2.88]
Front View
Approximate dimensions in mm [inches]
10
Side View
1503F
OEM CONTROLLERS AND COMPONENTS
Frame
Options and Catalog Numbers
Current
Rating
(Amps) 
Voltage
(kV)
Contactor
Type
Fuse
Clip
Control Circuit

Electro-mechanical
Clip-on
IntelliVAC
Electrically
Held
Electro-mechanical
Bolt-on
2. – .0
IntelliVAC
Electro-mechanical
Clip-on
Mechanical
Latch
IntelliVAC
Electro-mechanical
Bolt-on
400
IntelliVAC
Electro-mechanical
Clip-on
IntelliVAC
Electrically
Held
Electro-mechanical
Bolt-on
. – .
IntelliVAC
Electro-mechanical
Clip-on
Mechanical
Latch
Electro-mechanical
Bolt-on
Bolt-on
Mechanical
Latch
Bolt-on
Electrically
Held
Bolt-on
Mechanical
Latch
Bolt-on
IntelliVAC
Electro-mechanical
600
IntelliVAC
Electro-mechanical
. – .

IntelliVAC
Electro-mechanical
Electrically
Held
2. – .0


IntelliVAC
IntelliVAC
Electro-mechanical
IntelliVAC
Control Voltage
Catalog Number
20 to 20 VAC
220 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
220 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
220 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
220 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0 to 20 VAC
0 to 240 VAC or
0 to 20 VDC
0F-E4GCD
0F-E4GCE
0F-E4GCU
0F-E4GBD
0F-E4GBE
0F-E4GBU
0F-M4GCD
0F-M4GCU
0F-M4GBD
0F-M4GBU
0F-E4KCD
0F-E4KCE
0F-E4KCU
0F-E4KBD
0F-E4KBE
0F-E4KBU
0F-M4KCD
0F-M4KCU
0F-M4KBD
0F-M4KBU
0F-EGBD
0F-EGBU
0F-MGBD
0F-MGBU
0F-EKBD
0F-EKBU
0F-MKBD
0F-MKBU
Refer to current derating chart on page for use above ,000 m (,00 ft.).
Electro-mechanical Control includes a complete 0C-xxx control panel assembly, for mounting by customer.
IntelliVAC Control includes an IntelliVAC module and suitable 0-WHxxx wire harness.
A control power selector assembly, 0C-CPSx, may be ordered separately (if required).
11
INSTALLED
1503C
OEM CONTROLLERS AND COMPONENTS
Relay Control Panel
Description
Control panel and 10-ft (3.05 m) wire harness for connecting to the vacuum contactor. Control panel
includes control relays, rectifier, MOV, terminal blocks (1492-W4), test switch and plug.
Note: A control panel for 110/120 V, 50/60 Hz shown.
A control panel for 220/240 V, 50/60 Hz does not include test plug. A control panel without a test
switch and plug is available for multiple contactors. See page 39.
Specifications
2 (8.8)
Approximate dimensions in millimeters (inches).
224 (8.8)
To Contactor
22 (.0)
42 (.8)
Front View
(120 V AC)
Side View
Options and Catalog Numbers
The IntelliVAC controller is offered as a substitute for electro-mechanical control circuits,
with numerous additional benefits. OEMs have a more flexible means of unit control
that results in reduced overall panel space and enhanced control functionality.
12
INSTALLED
1503S
OEM CONTROLLERS AND COMPONENTS
Non-Load-Break Isolation Switch
Description
The isolation switch is a non-load-break type switch, and is available in clip-on or bolt-on fuse versions.
The isolation switch works in conjunction with the contactor and the isolation switch handle to isolate the
power cell when the isolation switch handle is moved to the OFF position.
Standard features:
• Clip-on or bolt-on fuse versions
• Line and load fuse clips
• Electrically and mechanically interlocked when used with the Allen-Bradley handle module and
contactor
• Shutter mechanism isolates power cell from medium voltage
Specifications
•3 pole, gang operated
• 400, 600 or 800 Amp full load current
• Auxiliary contacts:
– Provisions for 3 N.O./3 N.C.
– 2 N.O./2 N.C. auxiliary contacts included
Contact type:
– Cat. No. 700-CPM
Contact rating:
– NEMA 2 x A600 and 2 x P600
• Net shipping weight:
– 400A: 25 kg (55 lbs)
– 600A: 35 kg (77 lbs)
– 800A: Consult factory
Options and Catalog Numbers
13
INSTALLED
1503S
OEM CONTROLLERS AND COMPONENTS
Isolation Switch (cont.)
Mounting Surface
• 400 A (Clip-On Fuses)
. [2.2]
47 [8.]
Line Terminals
0 [2.]
27 [2.8]
442.7
[7.4]
88
[27.0]
2.2 [4.2] 
08 [20]
Terminals v
0 [.7]
22 [.0]
 Assumes a 40.4 mm [.88 in.] fuse is used.
v Includes terminal connection hardware.
Front View
Approximate dimensions in millimeters [inches]
14
Side View
1503S
OEM CONTROLLERS AND COMPONENTS
Mounting Surface
• 400 A (Bolt-On Fuses)
. [2.2]
(2.2)
47 [8.]
Line Terminals
0 [2.]
(2.)
(2.8)
27 [2.8]
442.7 [7.4]
(7.4)
8.2 [2.88]
(2.88)
274. [0.80] 
4 [7.]
(7.)
08 [20]
 Assumes a 48 mm [.2 in.] fuse is used.
Front View
Terminals
22
[.0]
(.0)
0 [.7]
Side View
Approximate dimensions in millimeters [inches]
15
1503S
OEM CONTROLLERS AND COMPONENTS
Isolation Switch (cont.)
87 [7.]
47 [8.]
27 [2.8]
88.8 [2.24]
442.7 [7.4]
8.8
[7.24]
0 [2.]
Mounting Surface
• 600 A (Clip-On Fuses)
2.2 [4.] 
08 [20]
0 [.7]
47. [.8]
 Assumes a 40.4 mm [.88 in.] fuse is used.
Front View
Approximate dimensions in millimeters [inches]
16
Side View
1503S
• 600 A (Bolt-On Fuses)
87 [7.]
0 [2.]
27[2.8]
[2.8]
27
274.
[0.8]

08[20]
[20]
08
7.
7. [8.]
[8.]
442.7
442.7 [7.4]
[7.4]
8.8
[7.24]
47 [8.]
Mounting Surface
OEM CONTROLLERS AND COMPONENTS
0 [.7]
47. [.8]
 Assumes a 48 mm [.2 in.] fuse is used
Front View
Side View
Approximate dimensions in millimeters [inches]
17
1503S
OEM CONTROLLERS AND COMPONENTS
Isolation Switch (cont.)
Mounting Surface
• 800 A (Bolt-On only Fuses)
7.0 [4.]
0.2 [.]
0.2 [24.04]
7
[.]
. [4.4]
0. [2.02]
. [7.8] 
02.4 [40.7]
20 [0.24]
7. [0.0]
4.2 [8.08]
 Assumes a 48 mm [.2 in.] fuse is used.
Front View
Approximate dimensions in millimeters [inches]
18
Side View
1503S
INSTALLED
OEM CONTROLLERS AND COMPONENTS
Isolation Switch
Handle Module
Description
Standard handle and mechanical interlock assembly complete with provisions for key interlocking.
Specifications
• Padlocking provision: up to 3 padlocks in open position, 1 padlock in closed position
• Interlock with the power cell door
• Provision for key interlocking
[2.2]
7 [22.7]
7
[4.]
Connection to
Isolation Switch
0
[.]
0
[.00]
Rear Mounting Surface
[0.2]
Clearance
required for
installation
Front Mounting Surface
Handle in
OFF position
Left Side View (400A)
Contactor
Interlock Rod
Front View (400A)
(Cut away to show lower mounting holes)
Approximate dimensions in millimeters [inches]
Options and Catalog Numbers
19
1503VC
INTELLIVAC™ CONTROL MODULE FOR MV VACUUM CONTACTORS
Advanced Digital Control of Vacuum Contactors
The Allen-Bradley Bulletin 1503VC IntelliVAC™ control module offers a superior and efficient means of
controlling Bulletin 1502 vacuum contactors. The same controller is used for both 400 and 800 A vacuum
contactors, as well as both electrically held or mechanically latched contactors.
IntelliVAC™ Control Module
• The IntelliVAC™ control module is available with a universal input voltage
(110 - 240 V AC, 50/60 Hz or 110-250 V DC)
• Consistent vacuum contactor pick-up time
• Selectable and repeatable vacuum contactor drop-out times for better coordination with power fuses
• Altitude compensation (-1,000 to 5,000 meters)
IntelliVAC™
• Power loss ride-through (TDUV) allowing the vacuum contactor to remain closed during brief power
loss (up to 2 sec.)
• Anti-kiss and anti-pumping protection
• Temporary motor jog function
• Status indication
• Delayed restart
The IntelliVAC controller is offered as a substitute for electro-mechanical control circuits with numerous
additional benefits (see pages 12 and 40). OEMs have a more flexible means of unit control that results
in reduced overall panel space and enhanced control functionality.
Each IntelliVAC module comes with all required “quick connect” style connectors. A wire harness is
required to connect the module to Bulletin 1502 vacuum contactors (see page 6).
Control Power Selector Assembly
A selector switch and power receptacle are provided to allow “Normal”, “Off” and “Test” sources of control
power for the IntelliVAC control Module. A 115 V AC receptacle, suitable for use in North America, is
provided as part of the 1503C-CPS1.
Control Power
Selector Assembly
20
1503VC
INTELLIVAC™ CONTROL MODULE FOR MV VACUUM CONTACTORS
. [0.20]
2.7
[.7]
. [.]
.8 [0.228]
(2) places
8.
[7.2]
74.8
[.88]
.4 [2.4]
21
1503E
MV SMC™ FLEX OEM KITS
Description
Features
The MV SMC Flex controller provides microprocessor controlled
starting for standard three-phase, squirrel-cage induction motors.
Several standard modes of operation are available within a single
controller:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Soft Start – with selectable kickstart
Soft Stop
Current Limit Start – with selectable kickstart
Linear Acceleration* – with selectable kickstart
Linear Deceleration*
Dual Ramp – with selectable kickstart
Full Voltage
Preset Slow Speed
* requires motor tachometer
Optional Control Module
• Pump Control (eliminates water hammer)
– separate start and stop profiles
SMC Flex
Control Module
22
Electronic motor overload protection
Metering (MW, MWh, Power Factor, V, I)
Build-in DPI communication
Three-line, 16-character backlit LCD display
Keypad programming
Four programmable auxiliary contacts
Fiber optic SCR gate firing
Self-powered current loop gate driver boards (patent pending)
Optional Communication Modules
The following communication boards mount within the control module:
• DeviceNet (20COMM-D)
• ControlNet (20COMM-C)
• Ethernet/IP (20COMM-E)
• Profibus DP (20COMM-P)
• Remote I/O (20COMM-R)
• RS485 (DFI) (20COMM-S)
1503E
MV SMC™ FLEX OEM KITS
Typical Power System Diagram – 3300/4160 V
(Requires input disconnection [optional], as well as main and bypass vacuum contactors)
B
ISOLATING SWITCH
IS
DOOR INTERLOCK
00:
GFCT
(OPTIONAL)
CT
CT2
CT
CURRENT LIMITING
POWER FUSES
M
RS
S
4200V
H
H2
CPT
00 VA
X
20V
OV
OV2
OV
CURRENT LIMITING
PRIMARY FUSES
CS
+
-
OV S
TEST
C2
+
C
-
OV S
TEST
CLGD
RS2
C
+
-
OV S
TEST
CLGD
CS2
MTR
T
S4
C
CT
CT
X2
T2
OV4
S
S2
C
TO SMC-FLEX
(27, 28)
T
RR2
RR
C
C4
+
-
OV S
TEST
CLGD
C
CLGD
CT
CT
CL
RX TX G
C
T
RX TX G
C
T
C
RX TX G
RX TX G
C
T
4
2
TO CONTROL CIRCUIT
T
ISa
L
L2
L
A
WIRE CONNECTIONS FOR PHASE A
B
WIRE CONNECTIONS FOR PHASE B
C
CONNECTIONS SHOWN FOR PHASE C
G
CONNECT TO GROUND ONLY IF POWER SYSTEM IS GROUNDED
CURRENT LOOP CONDUCTORS PASS THROUGH THE C.T.'S
ON THE GATE DRIVER BOARDS (CLGD)
REMOTE EQUIPMENT
A
B
FROM
CONTROL
CIRCUIT
U
U8
U20
TB
L
L2/N
G
PHASE B
GATE TRANSMITTERS
PHASE A
TX
TX4
TX
TX
TX7
TX8
C
TB
FROM CLT
GDPS
CT INPUTS
MAXIMUM TWO STARTS PER HOUR WITH A
MINIMUM OF FIVE MINUTES BETWEEN STARTS.
G
Vcom
TB
AA+
BB+
CC+
J
POWER
OUT
CAUTION:
TX7
TX8
TX
TX0
TX
TX2
PHASE C
B
24C
VOLTAGE SENSING BOARD
VSB
L
B
T
2B
J
L2
A: 4800-7200V
B
B: 200-47V
T2
C: 40-24V
4B
L
D: 800-44V
B
T
B
GND GND2
TEMP.
A
SMC-FLEX INTERFACE BOARD
SMCFLEXIB
TX
TB2
TX2
VSB
TX
TX4
TX
TX
POWER
IN
40V AC, Ø, 0Hz
L L2 L GRD
TO SMC-FLEX
(, 2)
23
1503E
MV SMC™ FLEX OEM KITS
Typical Control Circuit – Standard Module
(Requires optional Main and Bypass control panels, as well as control relays and pilot devices)
OFF
NORMAL
TEST
X
FROM
CPT
TEST SUPPLY POINT
TS
20V
0Hz
ISb
X
X
X
20V
H
H
H2
H4
CLT
CURRENT LOOP TRANSFORMER
X
TO
SMCFLEXIB-TB
0.V
R
EC
2 +
A
# AWG 00V
M
ØA
ØB
TCO
4
M
B
ØC
MOV
N
AUX
2
# AWG 0kV
CL

M-IV
X2
L
CCO
G
C
M
MAIN CONTACTOR
L2/N
B-IV
A B
EC
2 +
TCO
AUX
2
CCO
M-IV
B-IV
4
MODULE
STATUS
MOV
N
G
C
B
BYPASS CONTACTOR
L2/N
START
STOP
4
CR
M-IV
MODULE
STATUS
MCX
BCX
M
B
L
4
CONTROL RELAY
CR
B-IV
CONTACTOR
STATUS
CR
SS
BCX
CONTACTOR
STATUS
B-IV
BYPASS CONTACTOR
AUXILIARY RELAY
+ - 0
FROM
SMCFLEXIB-J
2
CLOSE
4
7
8
SMC FLEX TM
CONTROL TERMINALS
20
2
22
AUX.
EXT. BYPASS
DPI
PTC
INPUT
2
24
TACH
INPUT
2
2
GROUND
FAULT
28
27
AUX.2
FAULT
2
0
AUX.
ALARM
2
SMC FLEX TO BE
PROGRAMMED BY
THE CUSTOMER
BEFORE START-UP
AUX.4
NORMAL
4
SS
MCX
FROM GFCT
(OPTIONAL)
M-IV
+ - 0
SMCFLEXIB
INPUT POWER
 IntelliVAC control modules
24
CLOSE
MAIN CONTACTOR
AUXILIARY RELAY
1503E
MV SMC™ FLEX OEM KITS
25
1503E
OEM CONTROLLERS AND COMPONENTS - SMC™ FLEX FRAME
Assembled Frame
Description
The Bulletin 1503 MV SMC Flex OEM frame is a self-contained power unit that can be easily installed.
To fully install the frame, the OEM must complete the following:
• Connect power cables from the power stacks in the frame to the input power disconnection mechanism,
bypass contactor, and motor;
• Mount the SMC Flex control module on the interface board and connect the interface board to the
voltage sensing board with wires, and the gate driver boards with fiber optic cables;
• Connect the interface board to OEM-supplied current transformers.
The vacuum bypass contactor is connected in parallel with the SCRs and is controlled by a contact on
the SMC Flex control module that opens and closes the vacuum contactor.
The frame includes:
• Three Power Stacks, comprised of heat sinks, SCRs, snubber caps and resistors, and gate driver boards
• Voltage sensing circuit board
• Installation Manual
26
1503E
OEM CONTROLLERS AND COMPONENTS - SMC™ FLEX FRAME
40 [2.]
00 [.42]
80
[.04]
Front View
Side View
Approximate dimensions in millimeters [inches].
27
1503E
OEM CONTROLLERS AND COMPONENTS
Power Stack
Description
The Bulletin 1503 MV SMC Flex OEM Power Stack consists of three modular power stacks that provide
excellent mounting flexibility. To fully install the power stacks, the OEM must complete the following:
• Connect power cables from the power stacks to the input power disconnection mechanism, bypass
contactor, and motor;
• Mount the SMC Flex control module on the interface board and connect interface board to the voltage
sensing board and the gate driver boards with fiber optic cables;
• Mount voltage sensing board and connect to the line and load terminals;
• Connect the interface board to OEM-supplied current transformers.
The vacuum bypass contactor is connected in parallel with the SCRs and is controlled by a contact on
the SMC Flex control module that opens and closes the vacuum contactor.
The power stacks include:
• Three power stacks, comprised of heatsinks, SCRs, snubber caps and resistors
• Gate driver boards and mounting hardware
• Installation Manual
28
1503E
OEM CONTROLLERS AND COMPONENTS
• 1000/2300 V, 180/360 A
8.4 [7.4]
42.7
[.80]
Front View
44. [7.0]
47.7 [8.02]
Side View
47.7 [8.02]
24.4 [8.44]
Note: All dimensions
include mounting bracket.
2.7 [0.0]
.7
[.0]
Bottom View
Dimensions in millimeters [inches]
29
1503E
OEM CONTROLLERS AND COMPONENTS
Power Stack (cont.)
0.2 [.7]
• 2300 V, 600 A
0.8 [2.20]
88.
[.0]
4.4 [8.7]
8.
[.88]
2.
[4.]
444.
[7.4]
0.8
[2.00] 02.
[4.04]
44.2
[.]
0.8
[2.00]
20. [8.0]
Mounting Holes for
M0 (/8”) hardware
(4 places)
Side View
Front View
[.4]
4.74.7
[.4]
• 3300/4160 V, 600 A
20. [8.0]
[8.0]
20.
88.
[.0]
4.4 [8.7]
8.
[.88]
8.8
[7.47]
0.8
[2.00]
8.
[22.88]
20.2
[8.08]
.2
[24.0]
0.8
[2.00]
Dimensions in mm [inches]
Front View
30
Mounting holes for
M0 (/8”) hardware
(4 places)
Side View
1503E
OEM CONTROLLERS AND COMPONENTS
• 3300/4160 V, 180/360 A
8.7 [7.]
82.2
[22.2]
Front View
44. [7.4]
44.4 [7.8]
Side View
Note: All dimensions
include mounting bracket.
44.4 [7.8]
24.4 [8.44]
2.7 [0.0]
.7
[.0]
Bottom View
31
1503E
OEM CONTROLLERS AND COMPONENTS
Power Stack (cont.)
4. [7.7]
20. [0.2]
88.
[.0]
• 6900 V, 180/360A
. [.72]
0.8
[4.0]
22.
[8.7]
7.0
[24.2]
0.8
[2.00]
87.
2.]
.
[7.2]
0.8
[2.00]
Mounting holes for
M0 (/8”) hardware
(4 places)
Front View
Side View
4. [.4]
• 6900 V, 600 A
20.2 [8.00]
88.
[.0]
4.4 [8.7]
8.
[.88]
2.
[.2]
0.8
[2.00]
.
[2.4]
.
[7.2]
2.
[24.4]
0.8
[2.00]
Dimensions in mm [inches]
32
Front View
Mounting holes for
M0 (/8”) hardware
(4 places)
Side View
1503E
OEM CONTROLLERS AND COMPONENTS
33
1503E
OEM CONTROLLERS AND COMPONENTS
Voltage Sensing Board
Description
The Voltage Sensing Board steps the voltage down from the system voltage to a voltage level compatible with the SMC Flex control module. Includes mounting instructions.
20.0
[.42]
20.0
[.42]
7.
[.]
270.2
270.2[0.4]
[0.4]
4.0 [.8]
8.0 [.]
Voltage Sensing Board
. [0.4]
Approximate dimensions in mm [inches]
34
1503E
OEM CONTROLLERS AND COMPONENTS
Interface Board
Description
Converts digital signals from the SMC Flex control module to drive the gate driver boards via fiber
optics. It also provides voltage, current and temperature feedback to the control module. Includes
mounting instructions.
Specifications
Control Voltage
0/20 to 220/240 V – 0/0 Hz, VA
Gate Drive
Via Fiber Optics
SCR Overtemperature
Via Fiber Optics
241.3 [9.50]
Interface Board and Mounting Brackets
27.6
27.6
[1.09]
[1.09]
256.2 [10.09]
Interface Board
241.3 [9.50]
Top mounting holes
for SMC Flex
Control Module
285.8
[11.25]
241.3
[9.50]
Mounting holes (4)
7.14 mm [0.281 in.) dia..
Front View
Bottom mounting holes for
SMC Flex Control Module
Side View
Approximate dimensions in mm [inches]
Note: Dimensions shown include mounting bracket assembly which is included with the interface board.
35
1503E
OEM CONTROLLERS AND COMPONENTS
SMC Flex Control Module
Description
The SMC Flex control module provides microprocessor controlled starting for standard three-phase,
squirrel-cage induction motors. The SMC Flex control module provides the following modes of operation
as standard:
• Soft Start – with selectable kickstart
• Soft Stop
• Current Limit Start – with selectable kickstart
• Linear Acceleration* – with selectable kickstart
• Linear Deceleration*
• Dual Ramp – with selectable kickstart
• Full Voltage
• Preset Slow Speed
* requires motor tachometer
The SMC Flex control module provides motor protection, including overload, underload, stall, jam, etc.,
during starting and while the bypass contactor is energized.
Starting and Stopping Options
The following option is available in the MV SMC Flex controller:
• Pump Control 36
1503E
OEM CONTROLLERS AND COMPONENTS
NET B
NET A
MOD
PORT
240.7
[.]
Esc
Sel
Allen-Bradley
SMC Flex
2 24 2 2 27 28 2 0 2 4
2 4 7 8 20 2 22
27. [.0]
Front View
70.
[2.78]
Side View
Approximate dimensions in mm [inches]
37
1503E
OEM CONTROLLERS AND COMPONENTS
Fiber Optics
Description
Fiber optic cables connect the interface board to gate driver boards mounted on power stacks. They
are also used to connect thermistors in the power stacks to interface boards. Two lengths are available
to aid the design and manufacture of a new controller, or to retrofit into an existing enclosure. Includes
mounting instructions.
38
1503E
OEM CONTROLLERS AND COMPONENTS
Gate Driver Test Power Supply
Description
The test power supply is used to provide power for the gate driver board during commissioning and/or
troubleshooting. Includes operating instructions.
39
1503E
OEM CONTROLLERS AND COMPONENTS
Relay Control Panel
Description
The control panel is available for maximum flexibility. It connects to the Bulletin 1502 vacuum bypass
contactor, and the SMC Flex control module. It lets the SMC Flex control module close the contactor
once the motor is up-to-speed, and open the contactor under stop control. It is also used to control
contactors in a multiple contactor application (autotransformers, reactor starters, etc.) The control panel
connects the auxiliary contact on the contactor directly to the terminal blocks.
28 [.0]
22 [.00]
240 [.4]
Front View
Side View
Approximate dimensions in millimeters [inches]
The IntelliVAC controller is offered as a substitute for electro-mechanical control circuits,
with numerous additional benefits. OEMs have a more flexible means of unit control
that results in reduced overall panel space and enhanced control functionality.
40
1503E
OEM CONTROLLERS AND COMPONENTS
Bypass Contactor
Description
Bulletin 1502 contactors are available for use as bypass contactors. They are required to bypass or
short out the SCRs once the motor is up to speed. The SMC Flex control module will control the closing
of this contactor when the auxiliary contact is programmed for the up-to-speed setting.
Bulletin 1502 contactors (fast dropout only) are used with the 800 to 6900 V AC frames and power
poles. Select the appropriate current, line voltage and control voltage to suit your application.
Note: The SCRs must be bypassed once up to speed. They are not rated for continuous duty.
Failure to bypass the SCRs will result in component failure.
Specifications
Refer to Bulletin 1502 description on page 1, and Specifications on page 2.
Selection
Refer to Bulletin 1502 selection table on page 6.
41
1901
SYNCPRO™ FIELD APPLICATION AND PROTECTION SYSTEM
The Bulletin 1901 SyncPro is a programmable field application and protection system for squirrel-cage,
brush-type synchronous motors.
The SyncPro system is designed to provide supervisory protection and field control to a brush-type synchronous motor controller, proper field application timing, squirrel-cage protection against long acceleration and stall conditions, as well as running pull-out protection by monitoring motor power factor. When
combined with a suitable induction motor overload protection relay, the SyncPro provides the necessary
protection for the brush-type synchronous motor.
User interface (DTAM) shown on page 43.
Features
Protection/Control
• Programmable motor parameters and setpoints
• Squirrel-cage winding protection
• Wide range of settings for greater user flexibility
• Field winding application control
• Monitors field contactor coil condition
• Incomplete sequence
• Stores data from last 10 trips
• Field voltage failure
• Digital user interface with a high visibility two-line,
back-lit display
• Auto load
• Stall protection
• Displays trip and alarm conditions
• Pull-out protection (power factor)
• Terminal block assembly for simple interwiring
• Restart lockout
• Modular concept
• Ideal for retrofit applications
Display/Metering
• Suitable for low voltage and medium voltage slip ring
synchronous motor applications
• Detected fault conditions
• Self diagnostics
• Slip frequency and starting time during start-up
• Power factor
• Enter/view setpoints through the DTAM
42
1901
SYNCPRO™ FIELD APPLICATION AND PROTECTION SYSTEM
Specifications
Operating Power
Temperature and Humidity
Input Line Voltage
•120 Volts AC 50/60 Hz
• 230 Volts AC 50/60 Hz
Operating Temperature (Max. ambient)
• 0°C to 40°C (32°F to 104°F)
Input Power Requirements
•50 VA
Input Current
• 0-5 Amps
Configurations
• Open Frame controller
• Modular components
• Integral to synchronous controller
Storage Temperature
• -20°C to 65°C (-4°F to 149°F)
Humidity
•5 to 95% (non condensing)
At 95% humidity, maximum temperature is 35°C (95° F)
Approvals
• UL
• CSA
• Integrated with synchronous motor starter package
43
1901
SYNCPRO™ FIELD APPLICATION AND PROTECTION SYSTEM
1901-AND, Open Frame
48 [8.02]
0 [0.8]
42 [.7]
08
[20.00]
48
[8.]
[0.]
8
[.2]
4 [.7]
Front View
Approximate dimensions in millimeters [inches]
DTAM Dimensions
44
[0.] dia.
(4) Mounting Holes
[.2]
SideView
Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb
Publication 1503-BR010D-EN-P – March 2007
Supersedes Publication 1503-BR010C-EN-P – April 2005
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. Printed in Canada.
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