MEDIUM VOLTAGE CONTROLLERS

CENTERLINE
MEDIUM VOLTAGE MOTOR CONTROL

Manufacturers share the challenge of efficiently controlling motors to improve performance, reduce power consumption and protect motor investment. Of all the motors in your manufacturing process, medium voltage motors can have a large impact on your continued success. Developing medium voltage motor control and protection has been a core discipline for Rockwell Automation for more than 100 years. Medium Voltage products, from across-the-line starters to soft starters and variable frequency AC drives, deliver enhanced protection in applications ranging up to several thousand horsepower. Bringing motors up to speed in a controlled manner, limiting wear on the motor and other mechanical components, and protecting your investment are key benefits of Rockwell Automation medium voltage systems.

O.E.M. frames and components provide OEMs and electrical equipment companies with custom-engineered solutions and high quality components. Both the medium voltage controller and SMC product lines offer smaller, more flexible individual components to reduce building and expansion costs. Open-frame style structures are also available with most medium voltage components already mounted within the frame. All OEM components are manufactured to meet UL, CSA, CE and IEC standards. Allen-Bradley medium voltage motor controllers are available
in a wide range of control formats allowing the flexibility to select the best match for the application. Medium voltage full-voltage controllers, reduced voltage controllers, solid-state reduced-voltage controllers, two-speed controllers, synchronous controllers and load break switches provide integrated intelligence and the lowest cost solution for starting motors.

A COMPLETE LINE OF INDUCTION AND SYNCHRONOUS CONTROLLERS

Solid-state reduced voltage controllers apply reduced voltage to a medium voltage

AC motor to allow soft starting and stopping, limitation of the inrush current, and reduction of the effects of water hammer in pumping systems. Allen-Bradley MV SMC Flex controllers include motor protection, communication and diagnostic capabilities and high flexibility, making it ideal for virtually any application.

IntelliCENTER provides MCC users with an integrated hardware, software and

communication solution. The IntelliCENTER features pre-configured software which shows real-time data, trending, component history, wiring diagrams, user manuals and spare parts. The IntelliCENTER reduces installation time with its plug-and-play set-up and minimizes facility downtime by quickly providing intelligent diagnostic and predictive failure information.

Arc resistant controllers Rockwell Automation has enhanced the safety of its world
recognized medium voltage control products to include an optional arc resistant class of medium voltage control equipment. ArcShield controllers provide the additional arc resistant safety features required by some industries. Most medium voltage control products can be provided with the ArcShield enclosure design which meets the arc resistant testing requirements of IEEE C37.20.7. ArcShield controllers use the same standard reliable internal components that continue to serve industries world wide.

Variable frequency AC drives Allen-Bradley medium voltage drives provide a single

solution for all medium voltage speed control requirements. The PowerFlex 7000 family of drives exceeds customer expectations by delivering superior reliability, ease of use and lower total cost of ownership. The advanced power semiconductor technology reduces component count to the lowest of any medium voltage drive available, translating to increased savings and reliability, less downtime and fewer spare parts.

INTELLICENTER
INTEGRATED INTELLIGENCE WITHIN AN MCC
Built-in DeviceNet
DeviceNet ports in horizontal wireway Simplifies installation Complex I/O interwiring is reduced to a single DeviceNet cable New 8 ampere, Class 1 DeviceNet cabling Tested for noise immunity

Power Monitor 3000

Displays volts, amperes, hertz, watts, demand watts, peak demand, kWH/kVARH, power factor Logs min/max values, snapshot values, harmonic waveforms Programmable outputs indicate over voltage, under voltage and phase imbalance, loss or reversal Communicates via Ethernet, ControlNet, DeviceNet, Remote I/O, RS-232 or RS-485

DeviceNet Starter Auxiliary (DSA)

Interface module fon non-intelligent devices Motor starter with eutectic alloy Feeders and mains 4 input points Ideal for monitoring contactor status, disconnect switch, overload trip and Hand-Off-Auto switch

E3 Solid-State Overload Relay

DeviceNet on-board 2 or 4 input points 1 or 2 output points Information: Time-to-trip, time-to-reset % thermal capacity utilized Cause of last five trips and warnings Phase and average current Protective functions Overload, underload Phase loss / imbalance Stall and Jam Ground fault (Plus version) Settings for protective functions Trip level, Warning level Time delay

825-P Modular Protection System

4 DeviceNet communications (optional card) Three output relays Two configurable inputs Ground fault CT input Metering capability RTD scanner module with 12 inputs (optional)

IntelliCENTER Software
Spare parts lists specific to each unit AutoCAD elevation and one-line drawings User manuals specific to each unit Event logging, warnings, faults, parameter edits

IntelliCENTER Software
Features pre-configured screens for each unit Allows MCC monitoring from anywhere in the users facility Contains Active X controls to allow easy integration into RSView

MV SMC FLEX
UNMATCHED INTELLIGENT MOTOR CONTROL
Why use Smart Motor Controllers (SMCs)
SMCs provide many features to benefit your system: Minimize mechanical damage resulting from full voltage starting of AC induction motors, enabling longer system life Limit line disturbances from inrush currents, resulting in reduced downtime Multiple Start/Stop modes increase functionality Diagnostic monitoring helps prevent problems before they occur Satisfy electrical distribution restrictions by reducing inrush currents SMCs are ideal for applications where: Belts, gears, and chains can be damaged by acrossthe-line starting Materials can be damaged by sudden starts and stops A step change in torque can damage equipment Power company line current restrictions are imposed With SMC soft starters you benefit from: Advanced diagnostics, increasing system performance Greater product functionality for increased system flexibility Decreased downtime due to advanced protection of motor winding, equipment, and materials

The MV SMC Flex controller furnishes as standard a full range of starting and stopping methods for a variety of applications. Its unique control options offer enhanced motor starting and stopping capabilities to satisfy your most demanding applications.

SOFT START

SOFT STOP

CU

MV SMC Flex Smart Motor Controller offers:

Standard Control Module Soft start - with selectable kickstart Soft stop Current limit start - with selectable kickstart Linear speed acceleration * - with selectable kickstart Linear speed deceleration Full voltage Preset slow speed
* requires motor tachometer

Optional Control Module Pump control (eliminates water hammer) - Separate start and stop profiles Standard Features of SMC Flex Controller Electronic motor overload protection Metering Diagnostics Built-in DPI communications (other communication options available) Two-line, 16-character backlit LCD display keypad programming Three programmable auxiliary contacts MV SMC Flex Power Module Current loop gate drive (patent pending) Efficient heat sink profile

Bulletin 1560E

Bulletin 1562E

Retrofit Controller

Combination Controller

CURRENT LIMIT

PUMP CONTROL
(Optional)

FULL VOLTAGE

LINEAR SPEED 7

ARCSHIELD

ARC RESISTANT MEDIUM VOLTAGE CONTROLLERS

The Allen-Bradley Centerline ArcShield arc resistant controller provides rugged process control for applications requiring a higher level of personnel protection. ArcShield products are compliant to the IEEE C37.20.7 standard, and provide Type 2 protection. During an arc flash, the ArcShield controller safely redirects the arc flash energy out the top of the unit and away from personnel. This level of protection is also maintained when the low voltage door is open for maintenance purposes.

Actual photographs of successful ArcShield tests

Offering a wide variety of Centerline ArcShield products:

The ArcShield products are available in a number of different controller configurations. Here are just a few of the products available: Bulletin 1591A Incoming units Bulletin 1512A/AT One high controller Bulletin 1512B/BT Two high controller Bulletin 1562E MV SMC Flex controller Arc Pressure Relief Vent Safely vents arc gases and material away from personnel during an arc flash Arc gases are vented out the top of the enclosure through the plenum exhaust structure Heavy Duty Enclosure Design Reinforced side sheets, doors, roof, and back plates designed to contain arc flash energy while vents open Added support plates secured with multiple bolts provide increased rigidity and security Robust Power Cell Door Design Multi-point latching mechanism, reinforced cross bracing and gasket sealing provide arc containment A viewing window in the power cell door allows the operator to view the status of the isolation switch before opening the door Once the latching mechanism is engaged, the power cell door is bolted shut for added protection

Side view (common to all products)

Front

BUILDING BLOCKS
At Rockwell Automation, we are committed to providing the products and services that our customers demand. Over the past eighty years, Allen-Bradley medium voltage Centerline controllers have set the standard by which others are measured. Our unmatched quality and innovative designs have made us the leader in medium voltage motor control products.

ADVANCED DIGITAL CONTROL OF VACUUM CONTACTORS

The Allen-Bradley Bulletin 1503VC IntelliVAC controller offers a superior and efficient means of controlling vacuum contactors. IntelliVAC controllers are a quantum leap beyond traditional electromechanical control circuits. Here are just a few of the beneficial characteristics: The performance and flexibility of digital control, allowing the control of a wide array of contactor types (400A, 800A electrically held, and mechanical latch) Enhanced reliability as a result of embedded self diagnostics and better coordination between unit power fuses and the vacuum contactor drop-out time Increased productivity with features like power loss ride through (TDUV) and contactor anti-kiss, which were previously offered as optional features Motor and process protection with delayed restart built-in

NON-LOAD BREAK ISOLATION SWITCH

Electrical and mechanical interlocks prevent the switch from opening when the contactor is energized Ensures normal operation only when the switch is fully closed Allows for separate source testing when in the OFF position Grounded in the OFF position When in the open position, a visible barrier isolates the power cell from the power bus compartment Status of the isolation switch can be viewed through a window in the power cell door

HANDLE AND INTERLOCK MECHANISM

Simple direct drive mechanism improves reliability and ensures operator safety Mechanical interlock mechanism remains part of the enclosure to eliminate setup adjustment Power cell door is interlocked with the handle mechanism to prevent the door from being opened when the cell is energized

LOW VOLTAGE COMPARTMENT

Separate 120 volt source is required for Test position control power Allows testing and troubleshooting of the power cell without exposing personnel to medium voltage Prevents backfeeding medium voltage through the control transformer, in Test mode All low voltage components are located in the low voltage panel Low voltage panel interior painted white for better visibility

POWER CELL COMPARTMENT

Power cell, low voltage panel, and bus compartment are isolated from each other for better fault containment Swing out low voltage panel for easy access to install load cables Isolated load cable compartments between top and bottom power cell Easy access for cable installation and stress cones Bar type current transformers are supplied as standard for overload protection and metering

POWER BUS COMPARTMENT

Centerline bus designed as an integral part of the structure Dissipates heat more efficiently Edge-to-edge configuration maximizes resistance to magnetic forces and minimizes moisture or dust collection Molded bus brace reduces maintenance and provides better distribution of forces during a fault Accessible without a ladder, for installation and maintenance Allows for incoming line cables to enter through the top or bottom of the compartment

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INTELLIGENT MOTOR CONTROL

MEETING TOMORROWS MANUFACTURING NEEDS...TODAY
We understand that you need to control performance, reduce downtime, improve safety, increase productivity, and perform diagnostics. Thats why weve combined leading-edge motor control and protection devices with the advanced networking and diagnostic capabilities of Rockwell Automations Integrated Architecture to provide you with Intelligent Motor Control.

PROTECTION
Thanks to integrated I/O and advanced diagnostic and protection capabilities, all Intelligent Motor Control products constantly monitor the motor operation to help you follow performance trends and take remedial action before potential failures occur. Reduce unwanted downtime by 75% while increasing overall production efficiency by 10% or more. 12

COMMUNICATIONS
Because you have a wide range of application needs, Intelligent Motor Control offers a variety of motor control technologies. Simplified control technologies are designed to suit your needs DeviceLogix component technology increases the control PowerFlex 7000 One-High MV SMC Flex IntelliCENTER possibilities with function block Controller Controller AC Drive Controller diagrams that operate at the device level SCALABLE FUNCTIONALITY DriveLogix offers embedded Login control for application programmability and control of auxiliary functions in one package Integrated Architecture enables you to reduce your total cost of ownership by using a single control infrastructure for the entire range of factory automation applications, large or small Reuse engineering designs and practices to reduce development time and cost Quickly respond to customer or market demands Reduce maintenance costs and downtime Easily access plant and production data from business systems or better management decision-making

COMMUNICATIONS
The key to intelligence in motor control... Utilize open networked architecture to enhance motor protection, share diagnostic information and speed troubleshooting for a more productive, intelligent process. From simple I/O to complex power monitoring tasks, DeviceNet lets your cost effectively integrate many low-level manufacturing functions NetLinx open network technology provides seamless communications throughout your enterprise (DeviceNet, ControlNet, and EtherNet/IP) Flexibility and commonality of communications across the product offering makes Intelligent Motor Control easy to use

O.E.M. PRODUCTS
QUALITY COMPONENTS FOR THE OEM MARKET
From the original oil-immersed contactor to air break and vacuum contactor, 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 solidstate 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.

General Features

Medium Voltage Motor Controllers

Description of Features
Designed for Safety, Convenience and Reliability
The Allen-Bradley medium voltage controller offers: Three isolated compartments: - Power bus - Low voltage - Power cell Large swing-out low voltage panel painted white for high visibility Test circuit and plug for remote control power supply External operating handle to operate the isolation switch Bolted power cell door(s) Centerline horizontal power bus with removable cover plates for accessibility 1/4 x 2 continuous copper ground bus Line, load and control wire conduit openings with removable cover plates at the top or bottom of the structure Base mounting sill channels with mounting holes and removable lifting means Hybrid epoxy powder paint nish

IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Universal input voltage (110-240V AC, 50/60 Hz or 100-250V DC) Selectable vacuum contactor drop-out time and consistent pickup time Altitude compensation Power loss ride-through (TDUV) may require additional hardware (external capacitor) Anti-kiss and anti-plugging protection Delayed motor re-start and temporary motor jog function One device is suitable for all contactors and control schemes

Input Voltage
2400V, 3300V, 4200V, 6600V or 6900V AC (+5/-10%) 3 phase 50/60 Hz ( 3%)

Ambient Temperature
0C to 40C (32F to 104F) with relative humidity of up to 95% (non-condensing)

Enclosure Types
NEMA Type 1 General purpose (IP10) NEMA Type 1 w/g General purpose with gasket (IP21) NEMA Type 12 Dust-tight and drip proof (IP52) NEMA Type 3R Non walk-in weatherproof (IP34) Arc Resistant (NEMA Type 12) Accessibility Type 2 Tested per IEEE C37.20.7-2001

Controller Standard Features

NEMA Class E2 design Removable lifting angles or brackets Non-removable sill channels Removable backplates Top or bottom plates to accommodate cable entry/exit Tin-plated copper horizontal power bus located in an isolated compartment A x 2 continuous bare copper ground bus A main non-load break isolation switch with visible blades and shutter mechanism, and operating handle Mechanical and electrical interlocks between isolation switch, vacuum contactor and MV door Vacuum contactor(s) Three (3) current limiting power fuses for NEMA Class E2 operation Three (3) current transformers Control circuit transformer with primary and secondary fuses A low voltage control panel Space for necessary auxiliary control and metering devices Polycarbonate viewing window in power cell door

Standards Canadian Standards Association (CSA),

Industrial Control Equipment C22.2 No. 14 and TIL D-21 American Nation Standards Institute (ANSI), Instrument Transformers C57.13 Institute of Electrical & Electronic Engineers (IEEE) National Electrical Code (NEC) Occupational Safety & Health Act (OSHA) Guide for Harmonic Control and Reactive Compensation of Static Power Converters (IEEE 519-1992) National Electrical Manufacturers Association (NEMA), Medium Voltage Controllers Rated 1501 to 7200 V AC ICS 3-2 (formerly ICS 2-324) Underwriters Laboratories, Inc. (UL), High Voltage Industrial Control Equipment 347 European Directives for EMC

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General Features

Medium Voltage Motor Controllers

Description of Features (cont.)
Paint Finishes
Description Color Procedure Preparation Hybrid epoxy power paint ANSI 49 medium light grey (standard) ANSI 61 light grey (optional) Continuous paint line. All parts are painted before assembly Alkaline wash/rinse/iron phosphate rinse/iron-chrome sealer rinse/recirculated de-ionized water rinse and virgin de-ionized water rinse Air-atomized electrostatic spray Total paint thickness 0.002 (0.051 mm) minimum Natural gas oven at 179C (355F) minimum

Painting

Baking

Power Bus (Optional)

Located at the center rear of the structure Mounted on the edge to a molded bus support insulator in a common vertical plane Centerline horizontal tin-plated copper bus optional silver-plated or insulated 1200/2000/3000 A Front/rear access

Ground Bus
Continuous bare copper ground bus 6 x 52 mm (1/4 in x 2 in) as standard #8 - #1/0 AWG or #6 250 MCM mechanical lug supplied at the incoming end of the lineup

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Bulletin 1500

Medium Voltage Controller Components

Description of Features
The Rockwell Automation Medium Voltage Controller, Bulletin 1500, is comprised of three core elements: Power cell compartment Low voltage compartments Power bus compartments

Operating Handle and Interlock Mechanism

Simple direct drive mechanism improves reliability and ensures operator safety Mechanical interlock mechanism remains part of the enclosure to eliminate setup adjustment Power cell door is interlocked with the handle mechanism to prevent the door from being opened when the cell is energized

Power Cell Compartment Isolation Switch

Electrical and mechanical interlocks prevent the switch from opening when the contactor is energized Ensures normal operation only when the switch is fully closed Allows for separate source testing when in the OFF position Grounded in the OFF position

Current Transformers
Three (3) current transformers are supplied as standard for overload protection and metering Five (5) amp secondary output

Visible Isolation
When in the open position, a visible barrier isolates the power cell from the power bus compartment Status of the isolation switch can be viewed through a window in the power cell door

Isolated Cable Ducts

Easy access for cable installation Ample room for stress cones Provides isolated load cable compartments between top and bottom power cells

Control Power Transformers

110/120 or 220/240 V AC 500 VA as standard with 350 VA extra capacity Appropriately sized primary and secondary fuses 1000 VA, 2000 VA, and 3000 VA CPTs (optional)

Vacuum Contactor
Modular design for simplied maintenance and reliability Fixed mounted design eliminates hot spots and reduces maintenance Visible contact wear indicator eliminates the need for special tools

Swing-out Low Voltage Panel (for 2-high structure)

Allows for easy access to install load cables Maximizes low voltage panel space

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Bulletin 1500

Medium Voltage Controller Components

Description of Features (cont.)
Power Bus Compartment Centerline Bus Design Low Voltage Compartment
Designed as an integral part of the structure Dissipates heat more efciently Edge-to-edge conguration maximizes resistance to magnetic forces and minimizes moisture or dust collection Molded bus brace reduces maintenance and provides better distribution of forces during a fault Accessible without a ladder, for installation and maintenance Allows for incoming line cables to enter through the top or bottom of the compartment

Low Voltage Compartment Control Panel

Separate 120 volt source is required for Test position control power Allows testing and troubleshooting of the power cell without exposing personnel to medium voltage Prevents backfeeding medium voltage through the control power transformer, in Test mode

Isolated Compartment
All low voltage components are located in the low voltage panel Low voltage panel interior painted white for better visibility Power cell, low voltage panel, and bus compartment are isolated from each other for better fault containment IntelliVAC control module

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Bulletin 1500

Medium Voltage Controller Components IntelliVAC Controller

IntelliVAC Control Module
The IntelliVAC control module has a universal input voltage range (110 - 240 VAC, 50/60 Hz or 110 - 250 VDC) Consistent vacuum contactor pick-up time, ensures optimal synchronization Selectable and repeatable vacuum contactor drop-out times (50, 75, 100, 130, 150, 175, 200 or 240 msec) for tighter coordination with power fuses Altitude compensation ( -1,000 to 5,000 meters) eliminates mechanical hardware changes at high altitude (400 Amp vacuum contactors) Power loss ride-through logic (TDUV) with selectable drop out time (0.2, 0.5, 1.0 or 2.0 sec) requires only an external capacitor Anti-kiss and anti-plugging protection Status indication (LEDs and relay outputs) allows integration in control system and aids troubleshooting Temporary motor jog function (separate input) to allow process set-up

Description of Features
The Allen-Bradley IntelliVAC controller offers a superior and efcient means of controlling vacuum contactors. IntelliVAC controllers are a quantum leap beyond traditional electromechanical control circuits. Here are just a few of the benecial characteristics: The performance and exibility of digital control, allowing the control of a wide array of contactor types (400 A, 800 A, Electrically Held and Mechanical Latch) Enhanced reliability as a result of embedded self diagnostics and better coordination between unit power fuses and the vacuum contactor drop-out time Increased productivity with features like power loss ride through (TDUV) and contactor anti-kiss, which were previously offered as optional features Motor and process protection with delayed restart built in IntelliVAC controllers are designed to perform with Bulletin 1502 vacuum contactors. These industry-proven contactors are available in 400 A and 800 A ratings up to 7,200 volts.

Delayed motor re-start prevents rapid cycling of vacuum contactor, protecting the connected motor

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Bulletin 1500

Medium Voltage Controller Components IntelliVAC Controller

Specications

Typical Control Schematic 400A Electrically Held Vacuum Contactor

CONTROL POWER

CONTROL POWER FUSE

M-INTELLIVAC 7 + OPEN 8

9 + OVERLOAD STOP START 16 15

CLOSE

- 10

CONTACTOR STATUS

MODULE STATUS CAPACITOR (OPTIONAL) 1 EC 2 + M 11 AUX 12 CCO TCO

14 13

4 3 6 5

MOV M

CONFIGURATION DIP SWITCHES

L1

INPUT POWER G L2/N

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Bulletin 1500

Medium Voltage Controller Components Vacuum Contactors

Applications
Medium Voltage (1,000 to 7,200 V) vacuum switching for: Motor Starters (asynchronous, synchronous) Full voltage Reduced voltage Variable frequency drives Transformer feeder units Capacitors

Product Approvals
UL347 CSA 22.2 No. 14 and TIL D-21 IEC 60470 CE Mark

Modular Construction

Description of Features
The Allen-Bradley vacuum contactors are designed as xed mounted devices for heavy-duty industrial performance. This design eliminates the worries typically associated with drawout contactors. The compact design of the contactor eliminates the need for it to be removed from the power cell. Also there are no drawout stab and nger assemblies, which require routine maintenance. The Series E contactors are designed for operation with Rockwell Automations IntelliVAC control module.

Designed to be interchangeable with other contactors of the same rating Horsepower rated devices are located elsewhere in the power cell, not on the contactor Easily removed for maintenance and repair

Vacuum Bottles
Designed to industry specications Arcing conned inside vacuum bottle for ionized gas protection Mounted on the front of the contactor for visible inspection Contact wear indicators located on the bottle eliminates the need for special tools Excellent dielectric recovery provides high switching frequency

Advantages
Lightweight, compact design High interrupting capability Low chop current Visual contact wear indicator (no measurement tools required) Provisions for mechanical interlocking (to isolation switch) 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) Minimal maintenance required All major components are easily accessed from the front Mechanical latch design (optional) Easily integrated into control circuit with quick connector and wire harness (optional) Designed to complement the advanced features of the IntelliVAC contactor control module

Long Electrical and Mechanical Life

1,000,000 electrical operations (400 A) 2,500,000 mechanical operations (400 A)

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Bulletin 1500

Medium Voltage Controller Components Vacuum Contactors

Specications

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Bulletin 825-P

Key Rockwell Automation Options Modular Protection System

Description of Features
System Overview Basic Unit
0.5 to 5000A Current Range Suitable for Low- and Medium-Voltage Applications Built-in Keypad and Backlit 2-Line LCD Test / Reset Button Status LEDs Front accessible RS 232 port Wide Supply Voltage Range (110...240V AC/DC) Three Output Relays Two Congurable Inputs PTC thermistor Input Core Balance Current Transformer Input Fiber Optic Port for Remote RTD Scanner Three option card slots NEMA 12 (IP65) Housing The Bulletin 825-P Modular Protection System for motors offers a compact, modular design that uniquely allows an installer to congure a devices functional capabilities to match the application requirements. Flexibility is also afforded by accommodating future expansion of the system as the application requirements grow. Ease of installation is provided through pluggable options and accessories. Finally, this next generation design offers greater capabilities with the option of full metering for line voltage and power monitoring in addition to expanded RTD monitoring. The 825-P Modular Protection System is a key component to Bulletin 1500 medium voltage controllers.

Converter Modules
Compact Three-Phase current transformer modules Provides electrical isolation Six current ranges 0.5 to 2.5 A 2.5 to 20 A 20 to 180 A 160 to 630 A Compatibility with MCS PLUS Bulletin 100-D contactors

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Bulletin 825-P

Key Rockwell Automation Options Modular Protection System

System Overview (cont.) Core Balance Current Transformer
Sensitive, low level ground fault detection 100:1 ratio 110 mm window opening Note: The 825-P is compatible with core balance current transformer ratios of 1:1 to 2000:1.

Option Cards
Voltage Input Input terminations for VA, VB, VC and VN Enables voltage and power measurement and related protection functions Accommodates potential transformers for levels exceeding 250V AC DeviceNetor Modbus Communications Direct network access for control and monitoring DeviceNet communications card features DeviceLogix component technology for enhanced control capability DeviceNet communication card provides compatibility with the IntelliCENTER software Expansion I/O Three Congurable Inputs Four Auxiliary Relay Outputs 4 to 20mA Isolated Analog Output

RTD Scanner Module

12-channel inputs Compatible with 100 Platinum, 100 Nickel, 120 Nickel, and 10 Copper type RTDs Can be remote mounted near the motor, simplifying wiring Class 1, Division 2, Group T4A rated Noise immune ber optic connection to the Basic Unit Channels are individually congurable for RTD type and location (winding, bearing, ambient, or other).

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ArcShield

The ArcShield products have a robust enclosure design which contain the arc ash energy and exhaust materials until vents on top of the enclosure open. Once opened, the vents provide a path for materials to exit the enclosure. An overhead plenum is used to direct the materials to a safe location, away from personnel near the equipment. The low voltage panel is reinforced and sealed, to prevent arc ash exhaust materials from entering this compartment. As standard, a plenum exhaust section is provided with each new ArcShield order. The plenum exhaust section can be mounted on either the left or right end of the line-up, and it extends 40 inches (or 1016 mm) past the end of the line-up. As the ArcShield may have an impact on horsepower ratings, please contact your Rockwell Automation ofce to conrm. Engineered Features Reinforced cabinet and power cell door closure mechanism

Description of Features
The Allen-Bradley Centerline ArcShield arc resistant controller provides rugged process control for applications requiring a higher level of personnel protection. ArcShield products are compliant to the IEEE C37.20.7 standard, and provide Type 2 protection during an arc ash. The ArcShield controller safely redirects the arc ash energy out the top of the unit and away from personnel. This level of protection is also maintained when the low voltage door is open for maintenance purposes.

Multi-point latching mechanism, reinforced cross bracing and gasket sealing Reinforced back plates added support plates secured with multiple bolts provide increased rigidity and security Reinforced low voltage panel to withstand arc ash energy and shield maintenance personnel while working in the isolated low voltage compartment Arc Pressure Relief vent to safely vent arc gases and material away from personnel during an arc ash Available with removable arc exhaust plenum

Specications

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Bulletin 1506

Medium Voltage Controller Full Voltage Reversing Starter

Description of Features
Fixed mounted vacuum contactors (FORWARD and REVERSE) Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) R-rated current-limiting power fuses Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks Available for motor loads Plugging or anti-plugging duty Mechanically and electrically interlocked contactors

400 amp

Specications

Power Circuit Schematic 1506

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Bulletin 1512A

Medium Voltage Controller Full Voltage Non-Reversing (One-High) Starter

Description of Features
Fixed mounted vacuum contactor Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) R-rated current-limiting power fuses (R-rated power fuses used for 450 A, 600 A and 800 A starters) Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks 1-high structure design for one complete motor controller Available in optional ArcShield enclosure Also available as Prepared Space (Bulletin 1512AP, 200A and 400A only) or Starter Kits (Bulletin 1512AS)

400 Amp

Specications

Power Circuit Schematic 1512A

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Bulletin 1512AT

Medium Voltage Controller Full Voltage Transformer Feeder Unit Starter

Description of Features
Fixed mounted vacuum contactor Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) E-rated current-limiting power fuses (R-rated power fuses used for 450 A, 600 A and 800 A starters, and for 400 A 6600V/6900V starters) Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks 1-high structure design for one complete transformer controller Available in optional ArcShield enclosure Also available as Prepared Space (Bulletin 1512AP, 200 A and 400 A only) or Feeder Kits (Bulletin 1512AU)

400 Amp

Specications

Power Circuit Schematic 1512AT

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Bulletin 1512B

Medium Voltage Controller Full Voltage Non-Reversing (Two-High) Starter

Description of Features
Fixed mounted vacuum contactor Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) R-rated current-limiting power fuses Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks 2-high structure design for two complete motor controllers Available in optional ArcShield enclosure Also available as Prepared Space (Bulletin 1512BP) and Starter Kits (Bulletin 1512BS)

400 Amp

Specications

Power Circuit Schematic 1512B

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29

Bulletin 1512BT

Medium Voltage Controller Full Voltage Transformer Feeder Unit (Two-High) Starter
Description of Features
Fixed mounted vacuum contactor Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) E-rated current-limiting power fuses Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks 2-high structure design for two complete transformer controllers Available in optional ArcShield enclosure Also available as Prepared Space (Bulletin 1512BP) or Starter Kit (Bulletin 1512BU)

400 Amp

Specications

Power Circuit Schematic 1512BT

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Bulletin 1522E/F/G

Medium Voltage Controller Two-Speed Non-Reversing Starter

Description of Features
Fixed mounted vacuum contactor HIGH and LOW speed settings for two-speed separate winding, Bulletin 1522E starter HIGH/LOW speeds and HIGH SPEED SHORTING settings for two-speed consequent pole, Bulletin 1522F/G starter Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) R-rated current-limiting power fuses Six (6) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks Constant or variable torque, and constant horsepower applications

400 A

Specications

Power Circuit Schematic 1522E

Power Circuit Schematic 1522F

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31

Bulletin 1560E / 1562E

Medium Voltage Controller SMC Flex Smart Motor Control Starter

Metering
Access locally using the controllers built-in LCD display, or remotely through the communication port Three-phase voltage Three-phase current Three-phase power (MW, MWh, power factor) Elapsed time Motor thermal capacity usage Motor speed (with optional use of tachometer input)

Diagnostics
Bulletin 1562E Combination Controller Line Fault Power Loss Voltage Unbalance Current Unbalance Ground Fault Communication Fault Phase Reversal Undervoltage Jam Overtemperature Stall Open Gate Overload Underload Extensive Starts per hour

Communication (optional)
DeviceNet ControlNet EtherNet/IP Probus DP Remote I/O RS485-DF1

Description of Features
Optimized Performance, Safety, Convenience and Reliability
The Rockwell Automation MV SMC Flex Smart Motor Controller offers:

Programming
Three-level menu structure (using standard languages) Built-in LCD display and keypad Multiple languages: English, French, German, Italian, Mandarin, Portuguese, Spanish Optional Human Interface Modules (DPI-based) Congurable with DriveTools programming software

Standard Control Module

Soft Start with Selectable Kickstart Soft Stop Current Limit Start with Selectable Kickstart Linear Speed Acceleration* with Selectable Kickstart Linear Speed Deceleration* Dual Ramp with Selectable Kickstart Full Voltage Preset Slow Speed
* requires motor tachometer

Vacuum Contactor
Fixed mounted vacuum contactor is standard Main contactor for unit isolation (1562E) Bypass contactor removes SCR Power Stack from circuit, once at full voltage Eliminates heat generated by SCRs - improves efciency Protects SCRs from voltage and current transients Contactor can be provided with IntelliVAC solid-state control

Optional Control Module

Pump Control (eliminates water hammer) separate start and stop proles

Complete Package
Quick shipment of several standard congurations Bulletin 1560E retrot controller (does not include isolation switch, main contactor, power fuses and control transformer) Bulletin 1562E combination controller Available with optional equipment Ready for immediate installation Complete installation documentation Built to Rockwell Automation quality standards and ISO9001:2000 Fully load tested with a three-phase MV motor

Motor Protection
Electronic motor overload protection Class 10, 15, 20 and 30 or OFF

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Bulletin 1560E / 1562E

Medium Voltage Controller SMC Flex Smart Motor Control Starter

Specications

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33

Bulletin 1560E / 1562E

Medium Voltage Controller SMC Flex Smart Motor Control

Power Circuit Schematic 1560E

Power Circuit Schematic 1562E

34

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Bulletin 1572/1576

Medium Voltage Controller Reduced Voltage Autotransformer Starter

Description of Features
Fixed mounted vacuum contactor (1S, FORWARD, REVERSE and RUN) settings, with closed transition operation, Bulletin 1576 Reversing starter (1S, 2S and RUN) settings, with closed transition operation, Bulletin 1572 Non-reversing starter Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) R-rated current-limiting power fuses Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks NEMA medium duty, dry type, three (3) winding autotransformer with 50, 65 and 80% taps. The 65% tap shall be used unless otherwise specied.

400 Amp

Specications

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35

Bulletin 1572/1576

Medium Voltage Controller Reduced Voltage Autotransformer Starter

Power Circuit Schematic 1572

Power Circuit Schematic 1576

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Bulletin 1582

Medium Voltage Controller Reduced Voltage Reactor, Non-reversing Starter

Description of Features
Fixed mounted vacuum contactors (START and RUN) with closed transition operation Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) R-rated current-limiting power fuses Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks NEMA medium duty, dry type, three (3) winding reactor with 50, 65 and 80% taps. The 65% tap shall be used unless otherwise specied.

Specications

Power Circuit Schematic 1582

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37

Bulletin 1591A/B

Medium Voltage Incoming Line Units

1591A

Description of Features (1591A)

Incoming bus arrangement for top or bottom cables Provision for low voltage panel and door Lug pad with provision for incoming cable lug terminations

Description of Features (1591B)

Incoming bus arrangement for top or bottom incoming cables Provisions for the low voltage panel and door Lug pad with provision for incoming cable lug terminations Comes as a 2-high structure

Specications

Note: A 44-inch incomer is only available when a 3000A power bus is used.

Power Circuit Schematic 1591A/1591B

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Bulletin 1592BF/M, 1594F/M

Medium Voltage Feeders Fused and Non-Fused Load-Break Switch

Description of Features
Main load break switch for switching primary power source Feeder load break switch for switching other loads Isolation between upper and lower power cells The operating handle is fully interlocked with the power cell door Provisions on the operating handle for key interlocking A polycarbonate viewing window in the power cell door to view the position of the isolation handle Protective guard over the line terminals, inside the power cell, to barrier off medium voltage when the power door is open Feeders for 2-high structures Bulletin 1592BF fused load break switch, designed as a feeder for 2-high structures Bulletin 1592F/M fused load break switch, designed for feeder and mains Bulletin 1594F/M non-fused load break switch, designed for feeder and mains

Specications 1592BF

Specications 1592F/M / 1594F/M

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Bulletin 1592BF/F/M, 1594F/M

Medium Voltage Feeders Fused and Non-fused Load-break Switch

Power Circuit Schematic 1592BF/F

Power Circuit Schematic 1592M

Power Circuit Schematic 1594F

Power Circuit Schematic 1594M

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Bulletin 1906B/1912B

Medium Voltage Controller Brush-Type Synchronous Starter

Description of Features
Fixed mounted vacuum contactor for Non-reversing Bulletin 1912B Fixed mounted vacuum contactors (FORWARD and REVERSE) for reversing Bulletin 1906B For constant speed applications Available with or without static exciter Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) R-rated current-limiting power fuses Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: control circuit fusing NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks Synchronous control package: Field application and protection relay (SyncPro standard) Field application control pilot relays Field excitation switch (2-pole contactor standard, when optional Exciter is not provided as part of the unit) Field discharge resistor bank

Specications 1906B

Specications 1912B

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41

Bulletin 1906B/1912B

Medium Voltage Controller Brush-Type Synchronous Starter

Power Control Schematic 1906B

Power Control Schematic 1912B

42

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Bulletin 1906L/1912L

Medium Voltage Controller Brushless Synchronous Starter

Description of Features
Fixed mounted vacuum contactor for Non-reversing Bulletin 1912L Fixed mounted vacuum contactors (FORWARD and REVERSE) for reversing Bulletin 1906L For constant speed applications Three-pole, gang-operated, non-load break isolating switch with an external operating handle, fully interlocked with main contactor and power cell doors A polycarbonate viewing window in the power cell door to view the position of the isolating switch Three (3) R-rated current-limiting power fuses Three (3) current transformers Control power transformer with primary and secondary fuses Segregated low voltage panel to house standard and optional hardware for unit control and monitoring IntelliVAC control module for each vacuum contactor, mounted in low voltage panel, with advanced features: Additional low voltage control panel accessories including: control circuit fusing NORMAL-OFF-TEST circuit receptacle for external test power supply set of control circuit terminal blocks Provisions for optional factory or customer supplied eld exciter (contact Cambridge to ensure low voltage panel space is available for customer supplied eld exciter.)

Specications 1906L

Specications 1912L

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43

Bulletin 1906L/1912L

Medium Voltage Controller Brushless Synchronous Starter

Power Control Schematic 1912L

Power Control Schematic 1906L

44

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Bulletin 1901

Synchronous Control Package SyncPro

Protection/Control
Squirrel-cage winding protection Field winding application control Incomplete sequence Field voltage failure Auto load Stall protection Pull-out protection (power factor) Restart lockout

Display/Metering
Detected fault conditions Slip frequency and starting time during start-up Power factor Enter/view setpoints through the DTAM

Description of Features
The Bulletin 1901 SyncPro is a programmable eld application and protection system for squirrel-cage, brush-type synchronous motors. The SyncPro system is designed to provide supervisory protection and eld control to a brush-type synchronous motor controller, proper eld 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.

Designed for Safety, Convenience and Reliability

Programmable motor parameters and setpoints Wide range of settings for greater user exibility Monitors eld contactor coil condition Stores data from last 10 trips Digital user interface with a high visibility two-line back-lit display Displays trip and alarm conditions Terminal block assembly for simple interwiring Modular concept Ideal for retrot applications Suitable for low voltage and medium voltage slip ring synchronous motor applications Self diagnostics

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45

Bulletin 1901

Synchronous Control Package SyncPro

Specications
Approximate Dimensions (1901-AND, Open Type)
18.02 [458] .38 [10] 16.75 [425]

20.00 18.95 [508] [481] 13.29 [338]

.63 [16]

13.75 13.75 [349] [349]

.36 [9] dia. (4) Mounting Holes

6.12 [155]

Front View
Note: Dimensions are in inches [millimeters].

Side View

DTAM Dimensions

5.5 (139.7)

2.5 (63.2)

B R

PRE 9 NEXT ACC 6 I PREV

LEN INC POS DEC

6.0 (152.4)

1 ESC

.
2 3

ENTER

F( )

SHIFT

Front View
Note: A ten-foot cable is provided.

Side View

46

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825-P

MODULAR PROTECTION SYSTEM

The Bulletin 825-P Modular Protection System for motors offers a compact, modular design that uniquely allows an installer to configure a devices functional capabilities to match the application requirements. Flexibility is also afforded by accommodating future expansion of the system as the application requirements grow. Ease of installation is provide through pluggable options and accessories. Finally, this next generation design offers greater capabilities with the option of full metering for line voltage and power monitoring in addition to expanded RTD monitoring.

Basic Unit

Converter Modules

Option Cards

RTD Scanner Module

Core Balance Current Transformer

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SUPPORT AND MAINTAIN YOUR INVESTMENT

You can maximize the life of your investment by aligning your Medium Voltage solutions with a strategic approach to maintenance. By including the right combination of predictive, preventive and reactive methods and Rockwell Automation Services & Support, you can get the most out of your automation assets.

Protect Your System

Condition Monitoring Control maintenance needs by leveraging technology and predictive expertise Remote Monitoring & Diagnostics Communicate and access information locally or through remote support center

Improve Efficiency

Asset Management Products and services which maximize the efficiency of your storeroom Start-U Up & Commissioning Installation and continuous support for your motor control applications Training Instructors and self paced materials for troubleshooting and programming

Decrease Time To Install

Ease Troubleshooting

Network Validation DeviceNet configuration and diagnostics for networked products Technical Support For stand alone products and integrated systems Repair & Renewal Parts Remanufacturing, exchange services and renewal parts

Reduce Costs

For More Information For more information about Rockwell Automation Services and Support go to www.rockwellautomation.com/services. To learn which other Rockwell Automation Services and Support will be most beneficial to your maintenance strategy, contact your local authorized Allen-Bradley distributor or Rockwell Automation sales office.

Allen-Bradley, ArmorStart, Compact I/O, DeviceLogix, DriveLogix, FORCE Technology, IntelliCENTER, PowerFlex, Rockwell Automation, SMC-Flex, SynchLink and XM are trademarks of Rockwell Automation. Trademarks not belonging to Rockwell Automation are proerty of their respective companies.

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 1500-SG001A-EN-P - September 2006
Copyright 2006 Rockwell Automation, Inc. All rights reserved. Printed in Canada