Rockwell Automation 1503 User Manual

IntelliVAC™ Contactor
Control Module

USER MANUAL

(Series C and later)

Bulletin 1503VC

Important User Information

IMPORTANT

Read this document and the documents listed in the Additional Resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.

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

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.

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

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

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

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Product Description Chapter 1

Table of Contents

Scope ...................................................................................................... 1-1

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

IntelliVAC Features ..................................................................... 1-2

IntelliVAC Versions .................................................................... 1-3

Specifications ........................................................................................ 1-4

Mount ing a nd Connectio ns ....................................................... 1-4

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

Firmware ....................................................................................... 1-4

Electrical Ratings (Table 1.A) ..................................................... 1-5

Mechanical Ratings (Table 1.B) ................................................. 1-6

Altitude Derating (Table 1.C) ................................................... 1-6

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

Re ceiving and Stor age Chapter 2

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

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

Installation and Wiring Chapter 3

General Precautions ............................................................................. 3-1

Safety and Codes .................................................................................. 3-1

Arrangements ....................................................................................... 3-2

Integral to an Allen-Bradley MV Controller ............................ 3-2

OEM .............................................................................................. 3-3

Fuse Protection .................................................................................... 3-5

Gr ou ndi ng ............................................................................................ 3-5

Connections ......................................................................................... 3-6

Control Power .............................................................................. 3-6

Status R elays ................................................................................. 3-6

Interface Connections ................................................................. 3-7

Wiring Guidelines Electrically Held Contactors ............................. 3-8

Control with Solid-Stat e Devices ............................................... 3-9

Two-Wire Control ................................................................... 3-10

Three-Wire Control ................................................................. 3-11

Wiring Guidelines Mechanical Latch Contactors ........................ 3-13

Mechanical Latch Contactors ......................................................... 3-14

Capacitor Trip ........................................................................... 3-14

Motor Jogging Control .................................................................... 3-16

Undervoltage Protection ................................................................. 3-17

Time Delay Undervoltage ................................................................ 3-17

1503-U M052D-EN-P – Jun e 2013

ii Table of Conte nts

Setup and Commissioning Chapter 4

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

DIP Factory Default Settings (Table 4.A) ........................................ 4-2

IntelliVAC DIP Switch Explanation (Table 4.B) ............................ 4-2

Moni tori ng and Troubleshooting Chapter 5

Introduction ......................................................................................... 5-1

Module Status ...................................................................................... 5-1

Contactor Status .................................................................................. 5-2

IntelliVAC Status Indication, S eri es C (Table 5.A) ................ 5-3

IntelliVAC Status Indicati on, Seri es D (Ta ble 5.B) ................ 5-4

Module Troubleshooting (Table 5.C) ....................................... 5-5

Min. IntelliVAC Operatio nal Supp ly Vo lta ges ( Tab le 5.D )........ 5-6

Spare Parts Chapter 6

Spare Parts List ..................................................................................... 6-1

Optional Equipment ................................................................... 6-1

Appendix A Typical Contactor Drop-out Time Settings

Typical Contactor Drop-out Tim e Settings (Table A.1) .............. A-1

1503-UM 052D- EN-P – Jun e 2013

Chapter 1

Product Description

Introduction Thi s docu ment cont ains i nfor mat ion fo r the Allen-Bradley Bulletin

15 03VC I ntelli VAC™ co ntrol module. The Bullet in 1503 VC is used to
control t he Allen-Br adley Bullet in 15 02 va cuum cont actors t hat a re a
signifi cant component of the Bulletin 1500/1900 CE NTER LINE
Medium Voltage Motor Controllers offered by Rockwell Automation.

An IntelliVAC control modu le may a lso b e pr ovided as a loose

component, for application with a Bulletin 1502 contactor by a third
party (OEM).

Scope Thi s docu ment app lies t o Seri es C (or la ter ) ver sion o f Int elliVAC.

Refer to publication 1503-UM051_-EN-P for information related to
the Series A and B designs.

Description

Intelli VAC is an effici ent a nd flexible solut io n for cont rolli ng m edium

vo lta ge va cuum cont actors used in m otor sta rter and feeder
applications. IntelliVAC may be used to control both 400 and 800
Amp co nta ctors. E lectrica lly held and mecha nica lly la tched cont act or
types can be controlled with IntelliVAC.

1503-U M052D-EN- P – Ju ne 2013

1-2 Product Description

Micro Controller

Contactor Coil(s) Interface

Configuration

Inputs

(DIP

switches)

Command

Inputs

Current

Regulator

IGBT Coil
Switching

CC

Input

Power

Conditioning

Coil Current Transducer

Vacuum Contactor

Close Coil

Vacuum Contactor

Trip Coil

Supply

Voltage

110-240

VAC

or

110-250

VDC

Close

Signal

Open

Signal

Vacuum Contactor

Auxiliary

C
C

External
Capacitor
(Optional)

Module

Status

Contactor

Status

Aux.

Feedback

Status

Outputs

c

Altitude

Select

Drop-Out

Select

TDUV

Time

Select

Contactor

Select

c

c

c

c

cc

c

c

c

c

c

Flash EEPROM

Interface

Coil

Power

Supply

Control

Power

Supply

Power Up

Safety

c

c

c

Description (cont.)

Figure 1.1 – IntelliVAC Contactor Control Module

Figure 1.2 – IntelliVAC Block Diagram

IntelliVAC Features

 A wi de ra nge of supp ly vo lta ge (11 0 – 240 V AC 50/60 Hz, 110 -

250 V DC) a llows i mplementation i n multiple ap plications

 Co nsist ent vacuu m conta ctor p ick-up t ime (a t a g iven sup ply

voltage) ensures repea ta ble per for mance

 Selectable va cuum cont act or dr op-out time improves coordination

with upst rea m po wer fu ses

1503-U M052D- EN-P – Jun e 2013

 Elect roni c alt it ude compensation (40 0 A only) eli mi nat es

mechanical compensat ion r equi red for alt it udes a bov e 1,0 00
met ers (800 A contactors include a user -fri endly a lti tu de
adjustment)

Product D escri ption 1-3

 Power loss ri de-throug h (TD UV) a llows t he va cuum cont actor to

rem ai n closed du ring short po wer lo ss (may r equi re a n opt io nal
ext erna l capacitor, dependa nt on ride-thr ough time)

1503-U M052D-EN-P – Jun e 2013

1-4 Product Description

IntelliVAC Features (cont.)

 Anti-kiss and ant i-pu mpi ng pro tecti on ensure tha t t he vacuu m

contactor close – open sequence occurs as expected, avoiding rapid
re-closur e due t o fault y contro l devi ces

 Delayed r estart pr ot ects the va cuum cont actor b y ensuri ng t hat the

rated dut y cycle is not exceeded

 Tempo rary jog funct io n (electrically held conta ctors o nly) a llows

the motor to be po sit ioned f or p rocess set -up

IntelliVAC Versions

Series A

Series B

Series C

Up dat ed versi on o f the Seri es B module.

Ther e are t wo ver sio ns of Int elliVAC control. The
fi rst type i s used to cont ro l vacu um co nta cto rs that are
electrically held, with a single electrical coil t hat is
economized electronically. The second is used to
control m echanica lly latched vacu um contact ors.

There is a single version of IntelliVAC, to control
bo th elect ri cally held and mechanically lat ched
va cuum cont act ors.

Series D Minor funct ionali ty (f irmware) enha ncement s

(primarily related to definition and handling of Faults
and Wa rnings).

Refer to Cha pt er 6, for ca talog num bers fo r each ver sio n of Int elliVAC.

Note: A Series C or Series D IntelliVAC module can be used to

rep lace a Seri es A or Series B module. When rep laci ng an
old er series of Int elliVAC wit h a newer one, note that the
Mod ule and C ontact or S ta tus ou tpu ts may funct ion
di fferent ly. Refer t o publicat ion 150 3-UM051_-EN-P
and/ or Chapt er 5 of t his docum ent, and make a ny necessa ry
cha nges t o the cont rol ci rcuit.

1503-U M052D- EN-P – Jun e 2013

Product D escri ption 1-5

Specifications Mounting and Connections

The IntelliVAC control m odules ar e mou nted usi ng t wo ( 2) scr ews ( see
Figur e 1.3 ). They ar e typi cally lo cat ed in the lo w v oltage control p anel
of t he m ediu m vo lta ge controller (Bullet in 1 500/ 1900 cont rollers, in
the case of Rockwell Automation).

IntelliVAC is int erfa ced t o the Bullet in 150 2 va cuum cont act ors u sing
a “qui ck” co nnecto r, located a t t he mo dule, a wir e ha rness and “qui ck”
connect or at the contact or. Co ntr ol po wer a nd other cont rol circu it
connect ions are similarly achi eved wi th “qui ck” co nnecto rs.

Configuration

IntelliVAC is easily confi gur ed for a wi de va riet y of medi um vo lta ge
mo to r and feeder cont rol app licat ions. It is confi gur ed usi ng D IP
swi tches, located wi thi n the enclosur e (fr ont si de). Plea se refer to
Chapter 4 for information.

Bulletin 1500/1900 controllers are shipped with IntelliVAC pre­confi gur ed for t he requ ired a ppli cat ion. Please refer to the docu ment s
pr ovi ded with t he or der.

Firmware

IntelliVAC ha s fir mwa re stored in flash EEP ROM; t herefore, thi s ma y
be upd ated i n the fi eld (if necessary). The IntelliVAC
is up dat ed usi ng t he mi ni-DIN connect or, which i s accessible i nside the
enclosure.

The firmware ver sion sup plied wi th the modu le is disp layed o n to p of
the DIP swi tches ( see Fig ure 4.1) .

Series C modules use only version 2. 003 appli cat io n fir mware. Thi s
fi rmwa re is also com pat ible wi th t he Ser ies A and B modules. Series D
mo dules use only versi on 3.0 01 or 3.0 02 a pplication fi rmwa re. Thi s
fi rmwa re is not compa ti ble wi th any other Series Let ter modules.

Refer t o Cha pt er 6 for p art numb ers of t he va riou s series of m odules.
The Series Letter of the mo dule i s pr int ed on t he lab el on t he cover of
the module, besi de t he part num ber.

board firmware

1503-U M052D-EN-P – Jun e 2013

1-6 Product Description

Table 1 .A – Electri cal Ratin gs

Main Inpu t Vo ltage

(L1 to L2/N)

AC – 110 to 240 V rms, +10/-15% , 47 to 6 3 Hz

DC – 1 10 to 250 V, +10/-15%

Main Input Current

(L1 to L2/N )

Command Inputs

⊇ ⊂

Desc ription

Con tac tor Ratin gs

(A mps)

Control Voltage

(AC o r DC)

Inr ush Current 400/800 120/240

Idle Curre nt
(Maximum without contactor coil

400/800 120/240 125 mA 35 mA

energized)
Hold Current ⊄ (maximum)

400/800 120/240 300 mA 100 mA

120 4.6 A 3.6 A

400

Close Current ⊄

(0.2 sec)

240 3.4 A 3.3 A
120 11.3 A 4.8 A

800

240 8.9 A 4.5 A
120 7.0 A 3.7 A

400

Trip Curr ent ( latch) ⊄

(0.2 sec)

240 3.6 A 2.0 A
120 7.0 A 3.3 A

800

240 4.3 A 1.9 A

AC – 100 to 240 V r ms
DC – 50 to 250 V
Max imum on state current f or open or close command:

@ 250 V A C, 60Hz, TA = 60°C

9mA

AC

9mA

@ 250 V DC, TA = 60°C

DC

Minimum on state curr ent f or open or close command:

@ 100 V A C, 60Hz, TA = 60°C

2mA

1.2 m A @ 50 V DC, T

AC

= 60°C

A

Max imum off state current for open or close command:

= 60°C

A

= 60°C

A

700 µA @ 20 V AC, 60 Hz, T
900 µA @ 30 V DC, T

AC Rating DC Rating

25 A peak (1/2

cycle )

25 A peak

1503-U M052D- EN-P – Jun e 2013

Status Output Contacts

Standards and Approvals

⊇ T

Ambient Temperature

A =

⊄ Includes idle current.
⊂ Ensure compatibility of IntelliVAC input ratings with those of circuit components activating these inputs.

Consider means of isolating/loading these signals, as required (using interposing relays or load resistors.)
Consult factory for assistance, if needed. The Series C and D IntelliVACs a re compatible with most PLC outputs,
and have been verified with Rockwell Automation OA type 120V triac outputs. See Chapter 3, Wiring Guidelines.

AC – 250 V rms, 5 A, R load; 2 A (reactive), PF = 0. 4

DC – 30 V, 5 A, R load; 2 A (reactive), L/R = 7 ms

CE, cULus, CSA, IE C pending

Product D escri ption 1-7

5.1 (0.20)

Dimensions in mm (inches)

29.7

(1.17)

174.8
(6.88)

185.3
(7.29)

59.4

(2.34)

165.9 (6.53)

5.8 (0.228)
2 places

5.1 (0.20)

Dimensions in mm (inches)

29.7

(1.17)

174.8
(6.88)

185.3
(7.29)

59.4

(2.34)

165.9 (6.53)

5.8 (0.228)
2 places

Specifications (cont.)

Table 1 .B – Mechanical Ratin gs

Ope rat ing: 0° to 60°C ambient at the control module 

Tempe rature

Non-Opera ting: -40° to 85°C

Altitud e
Po llution
Hu midity

Shock and Vibration

(Operational)

 Ambient temperature is derated at altitudes above 1,000 meters (3,300 feet).
Please refer to Table 1.C.

-1000 to 5000 meters
Pollution lev el II (as def ined by UL 840 and IEC 60664-1)
95% non-condensi ng
Shock – 15 g peak, 11 milliseconds

Vibration – 10 to 57 Hz, 0.015 inch displacement peak to peak

– 57 to 150 Hz, 2.5 g acceleration

Table 1 .C – Altitude Derating

Altitude

-1000 to 0 60
1 to 1000 60

1001 to 2000 58
2001 to 3000 56
3001 to 4000 54
4001 to 5000 52

Maximum Operating Ambient

at the control module (°C) 

 Derate by 2°C / 1000 m for high altitude operation

Figure 1.3 – Mechanical Dimensions

1503-U M052D-EN-P – Jun e 2013

Chapter 2

Receiving and Storage

Receiving Up on receivi ng t he controller, remov e the packing and check for da ma ge

tha t ma y have o ccurr ed during shi ppi ng. Rep ort any d amage i mmedi ately
to the cla ims offi ce of the carrier.

NOTE: If t he Int elliVAC m odu le i s an i nteg ral compo nent o f a

com plete MV co ntr oller (Bullet in 15 00/ 1900), speci al r eceiving and
ha ndling inst ruct io ns will apply. For deta ils, refer to the ser vice ma nua l
pr ovi ded with t he equipm ent.

Storage It is important to consider the following storage requi rement s if y ou a re

not inst alli ng your controller i mm ediately aft er receivi ng i t.

• St ore t he controller i n a clean, dr y, d ust-free environment.

• St ora ge t emper at ure sho uld b e maint ai ned bet ween -40°C and 85°C (­40°F and 185°F).

• Relati ve hum idity mu st no t exceed 95%, non-condensing.

1503-UM052D -EN-P – Jun e 2013

2-2 Receiving and Storage

(This page is intentionally left blank)

1503-U M052D- EN-P – Jun e 2013

Chapter 3

A T T E N T I O N

A T T E N T I O N

A T T E N T I O NA T T E N T I O N

A T T E N T I O NA T T E N T I O N

Safety and Codes

Installation and Wiring

General Precautions In add iti on to the precaut ions li sted thr ougho ut this manual, t he

followi ng st at ement s, whi ch ar e gener al to the syst em, m ust be rea d and
understood.

The cont roller cont ai ns ES D (electrost at ic
discharg e) sensi ti ve p arts and assemblies. St at ic
control p recaut io ns ar e required when
inst alli ng test ing, ser vicing, o r repa ir ing t he
assembly . Co mpo nent da mage may r esult if
ES D cont rol pr ocedures are not fo llowed. I f
you are not familiar with static control
pr ocedures, refer t o app lica ble ES D pro tect io n
handbooks.

An incorrect ly a ppli ed or i nsta lled cont roller
can dam age compo nents o r reduce pr odu ct li fe.
Wi ri ng or a pplication erro rs, such a s incor rect
or ina dequ ate AC su pply, o r excessi ve ambi ent
temper at ures, may resu lt i n ma lfunct ion of t he

system.

Only personnel fam ili ar wi th t he controller a nd
associ at ed machi nery sho uld plan or i mplement
the installation, start-up, and su bsequ ent
ma intena nce of t he syst em. Fai lure t o do thi s
ma y r esult i n persona l injury and/or equipment

damage.

1503-U M052D-EN- P – Ju ne 2013

3-2 Installation and Wir ing

A T T E N T I O N

A T T E N T I O N

The Canadi an E lectri cal Co de (CEC ),
Na ti ona l Electrical Co de (N EC), or ot her local
cod es out line p rov isi ons fo r safely i nsta lling
electrical equi pment. Inst alla ti on MU ST
com ply wi th speci fica ti ons rega rding wi re type,
conduct or si zes, bra nch circui t prot ecti on,
int erlock ing and di sconnect devi ces. Fa ilure t o
do so may r esult in perso nal i njur y and/ or
equi pment da mage.

Arrangements

Integral to an Allen-Bradley M V Controller

The Int elliVAC i s ava ila ble a s a pri ma ry co mponent of a n Allen-Bradley

The Int elliVAC i s offer ed in two arrangements, Integr al ( par t of a

Bulletin 1500 /190 0 MV co ntr oller) or as an OEM co mponent .

Bulletin 1500/1900 MV controller as shown in Figure 3.1.

Figure 3.1 – Typical IntelliVAC Install atio n within a Bulletin 15 00/19 00 MV Con troller (Shown

with optional extern al capacit or)

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-3

OEM

The Int elliVAC may be o rder ed as an OEM com ponent. Thi s allows the
OEM t o mou nt t he com ponents in a confi gura ti on m ost sui tab le to t he
mo to r controller eq uipm ent la yout . Ca re must be exerci sed to ensur e t he
Intelli VAC ha s adeq uate ventila tion pro vided arou nd it. R efer t o Fi gur e

3.2 fo r mount ing t he Int elliVAC. It is recom mended that a mini mum o f

1. 5 inches ( 38. 1mm ) of free a ir space be p rov ided between the
Intelli VAC and any solid b arri er a bov e or belo w.

The OEM i s responsible for controller fusi ng, motor overload protection,
control d evices (eg . Start/Stop push buttons), and wiring between the
Intelli VAC and 1 502 v acuu m cont actor (using o ptional wi re ha rness).
Wi ri ng and mou nti ng fo r op tional i tems, su ch as TD UV C apa cit or, are
also the OEM’ s respo nsib ili ty. R efer t o Fi gure 3.3 for basi c connect ions.

1503-U M052D-EN-P – Jun e 2013

3-4 Installation and Wir ing

38.1

(1.50)

38.1

(1.50)

6.4 (0.25)

Additional Modules

(as required)

Minimum bottom clearance

Minimum top clearance

Dimensions in mm (inches)

38.1

(1.50)

38.1

(1.50)

6.4 (0.25)

Additional Modules

(as required)

Minimum bottom clearance

Minimum top clearance

Dimensions in mm (inches)

Arrangements (cont.)

Figure 3.2 – Typical Mounting Configurations

Note: Adja cent Int elliVAC modules ma y be mounted wit h a
minimum separation of 6.4 mm (0.25 i nches).

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-5

*

Refer to Table 3.A for recommended fuse sizing.

MOV

32

1

EC

-

+

4

TCO

12

11

AUX CCO

5

6

L1 L2/NG

+ -

STOP

START

OVERLOAD

CONTROL
POWER
FUSE

*

7 8

OPEN

16
15

CONTACTOR
STATUS

M

M-INTELLIVAC

M

CAPACITOR

(OPTIONAL)

+ -

9 10

CLOSE

14
13

MODULE

STATUS

INPUT POWER

CONFIGURATION

DIP SWITCHES

*

-

+

+ -

*

7 8

+ -

CONTROL POWER

Figu re 3.3 – IntelliVAC Typical Schematic (Electrically Held Vacuum Co ntactor)

1503-U M052D-EN-P – Jun e 2013

3-6 Installation and Wir ing

A T T E N T I O N

A T T E N T I O N

Fuse Protection The IntelliVAC module requires external fuse protection to coordinate

wi th t he power supply and co nta cto r. The fuse ratings sho wn in Table

3.A allow the passage of inrush currents expected when the contactor is
closed , or fro m reco mm ended external ca paci to rs fo r the TD UV o pti on.
They will also protect the cont act or coils in t he ev ent o f a modu le
malfunction.

The recommended fuses have been tested to ensure reliable protection of

the module. If t he supp ly vo lta ge is DC, the m odule m ust b e used wit h an
ext erna l fuse t hat is a ppr oved fo r and r at ed to interrupt the D C vo ltage
supply . The t ypes listed a re Ferraz-Sha wmut Mid get Fuses ( 1-1/2" X
13/32"). The TRM is a time-dela y t ype, rated 2 50 VAC. The ATM is a
fast-a cti ng type, rated 5 00 VDC.

Table 3 .A – IntelliVA C Fuse Protection

Rated Supply Voltage Contactor Type

400A EH TRM 2 T RM 3.2

110/120 VAC

220/240 VAC

125 VDC

250 VDC

EH = Electrically Held vacuum contactor
ML = Mechanical Latch vacuum contactor

800A EH

400/800A ML

400A EH TRM 2 TRM 6.25

800A EH

400/800A ML

400A EH/ML

800A EH/ML ATM 5 ATM 6

400A EH/ML

800A EH/ML

Recommended Fuse

(min imum) (ma ximum)

TRM 2

TRM 2

TRM 2
TRM 2

ATM 3

ATM 3

ATM 5

TRM 6.25

TRM 3.2

TRM 6.25
TRM 6.25

ATM 3

ATM 5

ATM 6

Note: If ext erna l ca pacit ors a re connect ed, o r more t han one

Intelli VAC mod ule is pr otect ed by a common cont rol fuse, the
ma xi mum recomm ended fuse should be used to pr event fu se
op ening due to increa sed i nrush current when control po wer i s
applied.

Grounding The Intelli VAC module must be connect ed to a common ground

term ina l (P E) o n the controller p anel. The ground termina l is locat ed on
the bot to m of m odu le enclosur e (refer to Fi gure 3.4 ).

It is important that IntelliVAC is properly
gr ounded usi ng the gr ound co nnecti on
provided. Fai lure to do so ma y r esult i n da mage

to equi pment or perso nal injury.

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-7

1503-U M052D-EN-P – Jun e 2013

3-8 Installation and Wir ing

L2/NL1

CONTACTOR STATUS OUTPUT (N.O.)

MODULE S TATUS OUTPUT (N.O.)

POWER INPUT

13 14 15 16

Ground Connecti on

Connections There are three green connectors on the IntelliVAC module for

connect ions to the co ntrol circui tr y. Connect or p lugs a re pr ovi ded wit h
the module. If a ddi ti onal plug s are req uir ed, r efer t o Chapt er 6, Spare

parts.

Control Power

Co ntrol po wer i s appli ed to the module wi th a two -pole co nnecto r

The IntelliVAC can accept either AC or DC cont rol power. R efer t o
Table 1.A for accept ab le i nput power and control signal ratings.

located at the bottom rear portion of the module. Refer to Figure 3.4 for
connections. The ‘L1’ connection is int ended t o be the ‘Hot’ o r ‘+ ’ side
of t he co ntrol po wer, and t he ‘L 2/N’ connect ion i s int ended to be the
‘Neutral’, ‘Return’, or ‘-’ si de of the co ntrol po wer.

St atus Relays

Status r elay connect ions a re accessed wi th a four-po le connect or loca ted

at the bottom front portion of the mo dule. Refer to Figur e 3.4 for
connect ions. Ther e a re two stat us rela ys, ea ch wi th o ne nor ma lly-open
contact:

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

Refer to Cha pt er 5 Monitoring and Troubleshooting for a descr ipt io n of

op eration fo r the r elays.

Refer to Table 1.A for electr ical ratings of t he sta tu s relays.

Figure 3.4 – Bottom side connections

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-9

1503-U M052D-EN-P – Jun e 2013

3-10 Installation and Wiring

CONTACTOR INTERFACE

11 128 9 105 6 72 3 41

EX. CAP.

Interface Connections

All other cont rol int erfa ce connect ions are made a t a twelve-pole
connect or loca ted on the to p of the module. Refer t o Figu re 3. 5 and
Table 3.B for connect ions ( and Table 1.A for elect ri cal ra tings).

Refer to the Wiring Guidelines secti on i n this cha pter for gui dance in
ma ki ng connect io ns to the co ntrol circui t.

Figu re 3.5 – Top side co nnections

Table 3 .B – Terminal Assignments for IntelliVAC Interface Connections 

Terminal No . Te rmina l De s igna tion Desc ription

1 External capacitor (negat ive) 
2 External capacitor (positive) 
3 Lat ch tr ip coil (com mon) 
4 Lat ch tr ip coil 
5 Close coil (common)
6 Close coil
7 Open / Jog comm and 
8 Open / Jog command (common) 
9 Close command 

10 Close command (common) 
11 Contactor auxiliary contact 
12 Cont actor auxiliary contact 

 Refe r to T able 1.A for ele ctri cal ratings .
 No connection required if option is not used.
 Ensure compatibilit y of IntelliVAC input ratings with those of circuit components activating these inputs. Consider means of

isolati ng/loading these signals, as required (using interposing relays or load resistors). Consult factory for assistance, if needed. The
Series C and D IntelliVACs are compatib le wi th most P LC outp uts , and ha ve been verified with Rockwell Automation OA type 120V
triac outputs. See Wiring Guidelines.

 For electrically held contactor, this command will energize the close coil output (CCO).

For mechanically held contact or, this command will energize the trip coil output (TCO).

Power connection for TDUV or capacitor trip options
only

Out put for mechanical latch contactor trip coil

Output to close coil of electrically held &
mechanical latch contactors

Input to open a mecha nical latch cont actor or j og
an electrically held contactor (mutually exclusive)

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

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

contact )

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-11

A T T E N T I O NA T T E N T I O N

Wiring Guidelines Electrically

The IntelliVAC can be applied with two- or three-wir e cont rol ci rcuits.

Held Contactors

The cont rol syst em utili zed will deter mi ne the co nfigu ration of t he inpu t
wiring. Consider the following input and output for the type of control
used:

• Term i nals 9 and 10 – Close Contactor

• Ter mi na ls 15 and 16 – Contactor Status

In eit her ca se, the CLOSE i nput must recei ve a ma intained vo ltage hi gh

to keep t he cont act or closed .

Note:

1. When used with electrically held contactors, the IntelliVAC allows

close co mm ands ever y six seconds. This is to ensure the rated
contactor duty cycle is not exceeded.

2. If IntelliVAC powers up configured for an electrically held contactor,

and t he va cuum cont act or i s det ected a s bei ng closed, the mod ule will
not respond t o a close com ma nd unt il the va cuum contactor auxiliary
contact inp ut i s in t he corr ect ( closed) st ate a nd mo dule power is
rem oved a nd re-applied. (See Chapt er 5)

3. In general, a Clo se comma nd sho uld o nly be appli ed 4 seconds aft er

energi zing Int elliVAC .

For E mergency S top a pplications requiring
rem oval of power, a cont act should be placed in
the “L1” co ntrol po wer r ung t o t he I ntelli VAC.
If t he TD UV feat ure i s used, the cont act or wi ll
not open unt il t he progr ammed TDUV t ime

has expired.

1503-U M052D-EN-P – Jun e 2013

3-12 Installation and Wiring

-+

3

2

12

11

AUX

MOV

M

TCO

5

6

-+1

EC

CCO

4

9 10

M

CLOSE

N

G

OVERLOAD

*

CONTROL
POWER
FUSE

CONTROLPOWER

M

M-IV

M-IV

L

CR

CR

SOLID STATE

OUTPUT

INPUT POWER

*

Refer to Table 3.A for recom m ended f use sizing.

Cont rol with Solid-State Devices

If contro l devi ces tha t em ploy electroni c or su ppressed o utput circui ts a re

used i n t he rung(s) tha t co ntr ol the i nput s to the I ntelli VAC, alt ernate
arr ang ement s may be r equi red. D evices em ployi ng t ra nsist or or triac
ou tpu t ci rcui ts ha ve fi nit e im peda nce and allow a leak age cu rrent t o flow
in t he b locki ng o r off st at e. Some P LC a nd I/O m odu les wit h rela y
ou tpu ts a lso ha ve R-C snub ber cir cuits across the cont acts t o suppr ess
noise generated d uri ng cont act openi ng. The im peda nce of these circui ts
also allows leakage cur rent to flo w when t he cont act s ar e open. The hi gh
impedance i nput cir cuit s of the Int elliVAC ma y be t ri gger ed by thi s
leakage cu rrent or r esidua l t ermina l voltage, causing uni ntended
op eration of t he cont act or, or ma intena nce of t he closed st at e when the
control si gna l is removed .

This situation can be p revent ed by co nsideration of t he cont ro l devi ces

when desi gni ng t he co ntrol system. If PL C or si milar control devi ces are
to be int erfaced t o t he Int elliVAC, consider using relay o utpu ts wi th no
suppr ession devi ces a cross the cont act s (the I ntelli VAC input s ar e a hi gh
impedance, resistive loa d). If t his canno t be do ne, consi der the leak age
cur rent of the d evice to see if it is comp at ible wi th I ntelli VAC i nput s (see
Table 1.A) . If not compa ti ble, co nsid er usi ng a n int erpo sing relay
connect ed as shows in Figur e 3.6 .

1503-U M052D- EN-P – Jun e 2013

Figure 3.6 – Co ntr ol wi th So lid -State Devi ces

Installati on a nd Wiri ng 3-13

A T T E N T I O N

A T T E N T I O N

A T T E N T I O NA T T E N T I O N

CONTROL
POWER
FUSE

CAPACITOR
(OPTIONAL)

M-IV

EC

TCO

AUX

CCO

L2/N

L1

G

MOV

M

OVERLOAD

RUN

M-IV

CLOSE

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

EMERGENCY STOP

(when required)

M

1
2

4
3

11

6

12 5

CONTROL POWER

Two-Wire Control

Wiring Guidelines Electrically
Held Contactors (cont.)

Som e two-wire control schemes may be configur ed such tha t a close

If usi ng two-wire control, the C LOS E cont act or i nput is m aint ained hi gh
using a single contact. Mom enta rily openi ng t his i nput wi ll cause t he
Intelli VAC to open t he conta ctor. Ma int aini ng t he cont act will pr ovide a
CLOS E command t o I ntelli VAC (gi ven t hat all p ermi ssiv es are sati sfied).
If a fa ult occur s, in a ddit ion t o cycli ng co ntr ol po wer t o the I ntelliVAC
module, the CLOSE command must be removed for a minimum of 4
seconds, before b eing re-app lied. Refer t o Figu re 3. 7.

command is present when IntelliVAC is energized. In this case, the
Power-Up Safet y fea ture may b e disabled by set ti ng D IP swi tch 1 2
accordingly. Refer to Table 4.B.

Only disable the Power-U p saf ety fea tur e when
abso lutely necessa ry. Doing so ca n crea te

unsa fe oper at ing condi ti ons.

For E mergency S top a pplications requ iring
rem oval of power, a cont act should be placed in
the “L1” co ntrol po wer r ung t o t he I ntelli VAC.
If t he TD UV feat ure i s used, the cont act or wi ll
not open unt il t he progr ammed TDUV t ime

ha s exp ired.

1503-U M052D-EN-P – Jun e 2013

3-14 Installation and Wiring

A T T E N T I O N

A T T E N T I O N

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

MOV

32

1

EC

-

+

4

TCO

12

11

AUX CCO

5

6

L1 L2/NG

+ -

STOP

START

OVERLOAD

CONTROL
POWER
FUSE

*

M-IV

9 10

CLOSE

M-IV

15 16

CONTACTOR

STATUS

M

M-IV

M

CAPACITOR
(OPTIONAL)

CONTROL POWER

EMERGENCY STOP

(when required)

Figu re 3.7 – Two-Wi re Contro l

Three-Wire Control

If using three-wi re cont rol, t he CLOS E cont actor i nput i s maint ained

hi gh usi ng t wo co nta cts. Momentarily op ening thi s inp ut wi ll cause t he
Intelli VAC to open t he conta ctor. Moment arily closi ng t he START
contact will prov ide a CLO SE co mma nd to I ntelli VAC ( given t hat all
per missives ar e sat isfi ed).

In thi s confi gura tion, t he STATU S outp ut a cts as a seal-in co nta ct. If a

fa ult occu rs, in a ddition t o cycling control power over t o the IntelliVAC
mo dule, the CLO SE co mmand must be removed for a minimum of 4
seconds b efore being r e-ap plied. Refer to Figur e 3.8 .

For E mergency S top a pplications requ iring
rem oval of power, a cont act should be placed in
the “L1” co ntrol po wer r ung t o t he I ntelli VAC.
If t he TD UV feat ure i s used, the contact or will
not open unt il t he progr ammed TDUV t ime

has expired.

Fig ure 3 .8 – T hree-W ir e Con tro l

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-15

CLOSE COMMAND

TO MICRO

MICRO OUTPUT
TO CLOSE COIL

CONTACTOR STATUS

RELAY OU T P U T

CONTACTOR

AUXLIARY

INPUT TO MICRO

CLOSE LEVEL OF

CURRENT TO CLOSE

COIL

MODULE STATUS

RELAY OUTPUT





Contact status relay closes on request to close. It will open if the contactor auxiliary contact does not close within 200 milliseconds and
module will fault (opening module status relay).

15mS

200mS

90mS

(@120VAC)

80mS

60mS

5mS

SELECTABLE DROP

OUT TIME

(0 TO 190mS)

CLAMP DELAY

DEBOUNCE

NATURAL

CONTACTOR

DROP OUT

CONTACTOR PICK UP

ACKNOWLEDGE

WINDOW

DEBOUNCE

30mS



For this example, the 130 milli s econd drop-out time has been selected. The base drop-out time is 50 milliseconds. The microcontroll er del ay i s
130-50=80 milliseconds.

15mS



Wiring Guidelines Electrically
Held Contactors (cont.)

Figu re 3.9 – Tim ing Diagr am 400A (Electr ically Held ) Contacto r

for IntelliVAC Control with three-wire Control

1503-U M052D-EN-P – Jun e 2013

3-16 Installation and Wiring

MOV

32

1

EC

-

+

4

TCO

12

11

AUX CCO

5

6

L1 L2/NG

+ -

CLOSE

OVERLOAD

CONTROL
POWER
FUSE

*

CONTROL POWER

M-IV

9 10

CLOSE

CC

M-IV

M

MOV

TC

M

+ -

M-IV

7 8

OPEN

OPEN

OVERLOAD

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

IntelliVAC control may be u sed for m echanica l la tch co nta ctors.

Wiring Guidelines Mechanical
Latch Contactors

A mom enta ry control signal is needed to close the co nta ctor, a nd a second
mo ment ar y contro l sig nal i s needed to open t he cont actor. The
mo ment ar y op en/close comma nds m ust b e at least 50 m illi seconds in
duration.

Refer to Figur e 3.10 for a ty pical mecha nica l lat ch cont rol schem e.

Note:

1. A mecha nica l lat ch contactor ma y a lready be closed when power is
appli ed to the I ntelliVAC cont ro l module.

2. I t i s permissible to apply an open command to the IntelliVAC
mo dule a s power is re-applied.

Figu re 3.10 – Mechanical Latch Contactor Control

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-17

Mechanical Latch Contactors

Capacitor Trip

The Int elliVAC can be confi gured to pr ovi de capa cit or trip functionality

wi th m echanical lat ch cont act ors. A capa citor mu st be connect ed t o the
Intelli VAC (term ina ls #1 a nd #2 ) in ord er to pr ovi de thi s capabi lity . The
capa cit or pr ovi des control po wer fo r t he Int elliVAC a s well as sto red
energy t o trip t he contactor. Maxi mum recom mended ca pacitor size i s
1650 µF for 120V control or 330 µF for 240V control. Use o f lar ger
capa cit ors wi ll requi re a cur rent lim iti ng circui t t o pr event openi ng t he
control fuse on energization.

The Int elliVAC must recei ve an ‘OP EN’ comma nd wi thin a few seconds

of losing AC co ntr ol po wer. This t im e lim it dep ends on voltage and
capa cit or size as sho wn in the t able below. If t he elapsed time exceeds thi s
limit, the cont act or ca nnot be t ri pped by I ntelli VAC. In thi s case, t he
contact or ca n be t ripp ed by pressi ng the r elease but to n on t he door i n
front of the contactor.

A sepa ra te vo ltag e sour ce is needed t o pr ovi de the ‘OP EN’ command. This

may be taken from the external capacit or as shown in Figure 3.11.

Table 3 .C – Mechani cal Latch Contactor – Capacit or Trip Times

Con tac tor

Ra ting

400 Amp

No minal Vo lta ge

(Vac)

120

240

Ac tual

V

(Vac )

input

120
110 2.7
100 1.7
240
200 4.7

Note: Minimum capacitor voltage ratings:

Ext. Capa c itor

(µF)

1650

330

Ma x. time

for trip

(sec)

3.5

7.5

• 120V applications – 200V DC (250V DC preferred)

• 240V applications – 400V DC (450V DC preferred)

1503-U M052D-EN-P – Jun e 2013

3-18 Installation and Wiring

MOV

32

1

EC

-

+

4

TCO

12

11

AUX CCO

5

6

L1 L2/NG

+ -

CLOSE

OVERLOAD

CONTROL
POWER
FUSE

*

CONTROL POWER

M-IV

9 10

CLOSE

CC

M-IV

M

MOV

TC

M

+ -

M-IV

7 8

OPEN

OPEN

CAPACITOR

OVERLOAD

*

Refer to Table 3.A for recommended fuse sizing.

Figure 3.11 – Mechan ical Latch Contactor with Capacitor Trip Option

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-19

A T T E N T I O N

A T T E N T I O N

MOV

32

1

EC

-

+

4

TCO

12

11

AUX CCO

5

6

L1 L2/NG

+ -

STOP

START

OVERLOAD

CONTROL
POWER
FUSE

*

CONTROL POWER

M-IV

9 10

CLOSE

M-IV

15 16

CONTACTOR

STATUS

M

M-IV

M

+ -

JOG

M-IV

7 8

OPEN

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

EMERGENCY STOP

(when required)

Motor Jogging Control Note: Jog functiona lit y can work wi th elect ri cally held cont act or o nly.

When used with electrically held contactors, t he IntelliVAC a llows close

com ma nds ever y six seconds. Thi s i s t o ensur e t he r at ed cont act or du ty
cycle o f 60 0 op erations per hour is not exceed ed.

For motor jogg ing oper at ions, t he second co ntr ol input , or O PEN

com ma nd, will close t he cont act or f or a s long a s the inp ut i s present , a nd
op en t he cont act or when t he inp ut i s rem oved. (Refer to Figure 3.12.)
Thi s m etho d will byp ass the st and ard six second mot or r e-sta rt dela y fo r
jogg ing purpo ses only. Opera ti ons will be li mited t o t wo st art s every
twelve seconds.

If t he TD UV feat ure i s used, the cont act or wi ll
not open unt il t he progr ammed TDUV t ime
ha s exp ired. Ther efor e, ap plications requ iring
an i mmedi at e remov al of power du ring
emer gency stop co nditi ons are not compa ti ble

wit h the TDUV feature.

Figu re 3.12 – Motor Jog ging Con tro l

1503-U M052D-EN-P – Jun e 2013

3-20 Installation and Wiring

A T T E N T I O NA T T E N T I O N

Undervoltage Protection The Intelli VAC cont roller prot ects t he contact or from cont rol vo lta ge

di ps and loss of p ower. It pro vides underv olta ge relea se a nd pr event s
attempt s to close t he co nta ctor when ther e is no t suffi cient power
ava ila ble t o gu arant ee reliable closi ng o f the cont act s. The under volt ag e
pr otection wi ll be i nit ia ted und er the fo llowi ng co nditions, reg ardless o f
nominal control voltage:

1. I f the supply vo lta ge dr ops b elow 90 V (AC or DC) during the first

20 0 milliseconds aft er a Clo se co mmand i s recei ved. Thi s a ppli es to
bo th elect ri cally held and m echanica l la tch co nta ctors.

2. If t he supply voltage dr ops b elow 72 V (AC or DC) aft er t he 200

millisecond close sequence (electrically held cont act ors only) .

Time Delay Undervoltage

The Int elliVAC can be confi gur ed to p rovide time dela y under voltag e
(TDUV) pr otect ion. The feat ure i s available to keep elect ri cally held
contact ors clo sed during a vo lta ge di p or b rief power loss. This opt io n
ma y r equi re the a ddi ti on of a capa cit or (see belo w). Refer t o Cha pt er 6
for typi cal ca pacitor si zing. The ca paci tor i s connected t o t ermina ls 1(-)
and 2(+) of the IntelliVAC. (Refer to Fi gure 3.1 3.)

If t he TD UV feat ure i s used, the cont act or wi ll
not open until t he prog rammed TD UV t ime
ha s exp ired. Ther efor e, ap plications requ iring
an i mmedi at e remov al of power du ring
emer gency stop co nditi ons are not compa ti ble

wi th t he TDUV fea ture.

Table 4.B of the “S etup a nd Com mi ssioni ng” cha pt er ha s the dip switch

settings t o pr ovi de TDUV fro m 0.2 to 2 seconds. Int elliVAC can
pr ovi de TDUV prot ecti on witho ut t he use of a n ext ernal capa cit or, as
shown in Table 3.D.

Table 3 .D – Maximum TDUV Time (without Capacitor)

Control Voltage

110/120 V
220/240 V

Max. TDUV Time (secs)

400 A 800 A

0.2

1.0

0.2

1.0

If t he underv oltage condi ti on persi sts b eyond t he set dela y t ime, the

contact or will be o pened a nd an undervoltage fault o r warning condition will
occu r (see Cha pter 5) .

1503-U M052D- EN-P – Jun e 2013

Installati on a nd Wiri ng 3-21

1503-U M052D-EN-P – Jun e 2013

3-22 Installation and Wiring

*

Refer to Table 3.A for recommended fuse sizing.

MOV

32

1

EC

-

+

4

TCO

12

11

AUX CCO

5

6

L1 L2/NG

+ -

STOP

START

OVERLOAD

CONTROL
POWER
FUSE

*

CONTROL POWER

M-IV

9 10

CLOSE

M-IV

15 16

CONTACTOR

STATUS

M

M-IV

M

CAPACITOR

(cont.)

Time Delay Undervoltage

Figure 3.13 – TDUV Control Circuit

1503-U M052D- EN-P – Jun e 2013

Chapter 4

S H O C K H A Z A R DS H O C K H A Z A R D

I M P O R T A N TI M P O R T A N T

Rem ove p ower fr om the module befo re

LEDs

Ground Stud

Supply Power Input

Interfac e C onnections

EEPROM Programming Port

(Mini DIN Connector)

DIP Switches

Status Relay Outputs

Internal Cont rol Fuse

Setup and Commissioning

IntelliVAC Configuration The Int elliVAC module i s confi gur ed for a speci fic app lica ti on by set ti ng

DIP switches. They are accessed by loo sening the two screws on the front
of t he uni t, and r emovi ng t he cov er by slidi ng i t for war d. The swi tches
are found on t he front edg e of the I ntelli VAC cir cuit boa rd (see Fi gur e

4.1) . Ther e are 12 swit ches, with nu mber 1 being at the top next to the

mi ni DIN connect or. ( Refer to Table 4. B).

Hazardo us volt age is pr esent insi de the module
whi ch may ca use per sona l i njury o r dea th.
Rem ove a ll sou rces of po wer fro m t he mo dule
and d ischa rge any connect ed cap acit ors b efor e
rem oving the co ver.

rem oving the co ver a nd before cha ngi ng the
DIP switch set ti ngs. The new DIP switch
settings a re reco gni zed o nly on power-up.

Figure 4.1 – DIP Switch and Connector Locations

1503-U M052D-EN-P – Jun e 2013

4-2 Setup and Comm issioning

An Intelli VAC unit shi pped sepa ra tely fr om the fa cto ry wi ll hav e a

default configu ration per Table 4 .A.

1503-UM 052D- EN-P – Jun e 2013

Setup and Commissio ning 4-3

Table 4 .A – DIP Switch Factory Default Settings

1

Table 4 .B – IntelliVAC DIP Switch Explanation

| | |

|

12

0

0 1 1

1 1

0 0

0 1

1 0

1 1

9

0 1

1 0

1 1

DIP switc h

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

Altitude: 0 – 1000m 0 0 1

Drop-out time: 130 msec 0 1 1

Contactor config.: 400A EH

TDUV config.: No TDUV

Ext. cap TDUV time: 0.2 sec 0 0

Power -Up Safety: Enable 0

0

0

IntelliVAC u nit s shipped in a complet e MV controller (Bullet in

15 00/ 1900 ) wi ll be confi gured to sui t t he installed appli cat ion (i.e.
contact or t ype). The user should veri fy t he settings before energi zing the
equi pment . Table 4.B defines t he sett ing s for each swit ch.

UP = 1

DOWN = 0

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

Altitud e 

-1000 to 0
1 to 1000 0

1001 to 2000
2001 to 3000 0
3001 to 4000

4001 to 5000

Not defined
Not defined

 The altitude compensation by DIP switch settings applies to Series E 400 amp vacuum contactors only. All 800 amp contactors are adapted

for altitude by altering the return springs. 800 amp contactors are to be set for 1 to 1000m (001 DIP setting).

1 2 3

0 0 0

0 1 0

1 0 0
1 0 1
1 1 0
1 1 1

Drop out time 

50 msec

75 msec 0
100 msec
130 msec
150 msec
175 msec
200 msec 1
240 msec 1

4 5 6

0 0 0

0 1 0 0 0
0 1 1 0 1
1 0 0 1 0
1 0 1 1 1

DIP switch SW1

7 8

Powe r-Up Sa fety

10 11

TDUV c onfig.

0
1

No TDU V

TDUV Enabled

Ena ble
Disable

Ext. cap. TDUV time

0.2 sec

0.5 sec

1.0 sec

2.0 sec

Contactor Config.

400A Mech. Latch

400A Elec. Held

800A Mech. Latch

800A Elec. Held

1503-U M051C-EN-P – Jun e 2005

4-4 Setup and Comm issioning

 By-pass contactors in MV SMC applications must be set for 50 millisecond drop-ou t time .

Refer to Appendix A for typical drop-out time settings used when power fuses are provided by Rockwell Automation.

1503-UM 052D- EN-P – Jun e 2013

Monitoring and Troubleshooting

Introduction

The I ntelli VAC module ha s t wo li ght emi tt ing di odes (L EDs) a nd rela y

ou tpu ts t o indi cat e the stat us of t he conta ctor a nd t he mo dule. The LEDs
are v isi ble on the fro nt o f the mod ule and t he relay outputs are accessed
on the bottom front of the module.

Chapter 5

Figure 5.1 – Int elli VAC L EDs

Note: Thi s u ser manua l cont ai ns information fo r bo th Ser ies C a nd

Seri es D Int elliVAC versions. R efer to the co rrect information
belo w f or t he Intelli VAC seri es in use.

Module Status The Module Sta tus i s ind icat ed with a Green L ED if t he m odule i s

funct ioning pr oper ly a nd has a vali d confi gur at ion. If t he mo dule powers
up with an invalid configur at ion t he LED will be Red (fla shing o nce),
indicating a Fault condition whi ch will no t allow t he cont act or t o clo se. If
the m odule po wers up p rop erly a nd exper iences an undervolt age condit ion
when att empt ing to close the co nta ctor or while t he co nta cto r is closed:

• Series C – the LED will be Red (Fa ult) . If t he cont act or does not
close p rop erly, a Fault is generated, the LED tu rns Red , and inp uts
are i nhi bit ed unti l the m odule power is remov ed and r eapp lied.

• Series D – the LED will be yellow (flashing once). If the
und ervo lta ge condi ti on i s corr ected during the selected TDUV
int erva l (a s set via DIP switch), then no rmal oper at ion resum es.

1503-U M052D-EN-P – Jun e 2013

5-2 Monit oring a nd Troubleshoot ing

I M P O R T A N T

I M P O R T A N T

Module Status (cont.) If the pro cessor ha s an int erna l fault , the L ED will be Red, t he out put s

will be cleared, and the processor must be reset (input power must be
cycled). If the reset is successful, the L ED will be Gr een a nd the m odule
wi ll respo nd to t he cont rol input s. The inp ut com ma nd mu st be togg led
before the module wi ll r espond t o a new com mand ( risi ng edg e trigger ed).

For S eri es D, the Mo dule Sta tus L ED i s also used to indicate vari ous

“Warning” co nditions relat ed to the co nta cto r per formance (see Table

5.B).

Mod ule Status o utput relay ha s a normally op en cont act . The co nta ct i s

op en dur ing a Fault condi ti on (LED red) , and closed during a hea lthy
condi tion (LED green). The relay i s o pen for some wa rning condi ti ons,
but closed for less severe issues.

The module stat es ar e summ arized i n Tables 5. A and 5.B.

Contactor Status

Co nta ctor Status o utput relay ha s a normally op en cont act . The co nta ct

The cont act or st at es ar e summ ari zed in Tables 5.A a nd 5.B.

The Contactor Status is indicated with a yellow LED that is off until a

CLOS E command i s recei ved. The yellow L ED will sta y on if t he
contact or clo ses prop erly, until t he cont act or is opened . If the pro cessor
ha s a n int erna l fau lt, the LED will be red.

is open when t he contact or i s open (LE D of f), and closed when t he
contact or has received a close comm and (for 20 0 milli seconds) or if i t i s
closed (LE D on).

The LED s ar e red/ green types with both
sections ON t o pr odu ce yellow. If viewed fr om
a sha rp a ngle, you m ay see only green or r ed.
Please vi ew fr om di rectly in fr ont of t he mo dule
to ensur e a ccura te co lor reco gniti on.

1503-UM 052D- EN-P – Jun e 2013

Monitorin g and Troubles hooti ng 5-3

Table 5 .A – IntelliVAC Status Indication (Series C only)

Con dition s



Desc ription

Module Status

LED Color Re lay LED Color Re lay

Norm al Healthy Module and Contactor OPEN Green Closed Off Open
Norm al Healthy Module and Contactor CLOSED Green Closed Yellow Closed
War ning Invalid Com mand Present  Yellow Closed Off Open
War ning Mechanical Latch Fail to Trip Yellow Open Yellow Closed
Fa ult Power Up with Contactor CLOSED  Red – Flash 2  Open Yellow Closed
Fa ult Contactor Fails to Pick Up Gr een O pen Red – Flash 1  Open
Fa ult Contactor Drop Out During Hold Green Open Red – Flash 2  O pen
Fa ult Long Contactor Drop Out Time Green Open Red – F lash 3  Open
Fa ult Microcontroller Malfunction Red O pen Re d Ope n
Fa ult Power Up with Invalid Dip Switch Configuration

Red – Flash 1 ⊂

Open Off Open

Fa ult Unde rvoltage wit h a CLOSE Comma nd Present  Red O pen Of f Ope n

 W arning = Recoverable Condit ion – Remove and retry offending signal
 Fa ult = No n-recoverable condition – Module power must be removed and re-applied.
 Flash 1 = 1 Flash Red LED followed by a pause.
 Fl ash 2 = 2 Consecutive Red LED flashes followed by a pause.
 Flash 3 = 3 Consecutive Red LED flashes followed by a pause.
 Only for Electrically Held Contactor
 Invalid Command Types:

1. Close, Jog or Trip commands present during power up sequence.

2. Close or Jog command re-applied to o quickly (be fore contactor o pening sequence is verified).
Allow at least 60 msec, plus drop out delay time, before re-applying thes e signals.

NOTE: Contactor will only respond to a close command re-applications after the re-start delay timer has expired.

3. Close a nd Trip commands present simultaneously (valid with Mechanical Latch contactors only).
 U ndervoltage conditions are defined on page 3-17.

Contactor Status

1503-U M052D-EN- P – Ju n e 2013

5-4 Monit oring a nd Troubleshoot ing

11

11

12

12

Contactor Status (cont.)

Table 5 .B – IntelliVAC Status Indication (Series D only)

Con dition s



Desc ription

Norm al Healthy Module and Contactor OPEN Green Closed Off Open
Norm al Healthy Module and Contactor CLOSED Green Closed Yellow Closed
War ning Invalid Command Pr esent  Yellow Closed Of f Open
War ning Mechanical Latch Fail to Trip Yellow Closed Yellow Closed
Fa ult Power Up with Contactor CLOSED Red – Flash 2  Open Yellow Closed
War ning Contactor Fails to Pick Up Yellow – R1  Closed Off / Yellow  O pen/Clos ed 
War ning Contactor Drop Out During Hold Yellow – R2  Closed Off / Yellow  O pen/Closed 
War ning Long Contactor Drop Out Time Yellow – R3  Closed Off / Yellow  Open/Cl osed 
Fa ult Microcontroller M alfunction Re d O pen Red Open
Fault Power Up with Invalid Dip Switch Configuration

Red – Flash 1 ⊂

War ning Undervoltage with a CL OSE Command Present Yellow – F lashi ng Open/Closed  Off / Yellow  Open/Close d 

 W arnings will be cleared when a change of input state occurs, and the condition has been resolved.
 Faults require control power to be removed until the unit resets
 Flash 1 = 1 Flash Red LED followed by a pause
 Flash 2 = 2 Consecutive Red LED flashes followed by a pause
 Ye llow – R1 = Yellow with 1 Red flash followed by a pause
 Yellow – R2 = Yellow with 2 consecutive Red flashes followed by a pause
 Ye llow – R3 = Yellow with 3 consecutive Red flashes followed by a pause
 Invalid Command Types:

1. Close, Jog or Trip commands present during power up sequence

2. Close or Jog command re-applied too quickly (be fore contactor o pening sequence is verified).
Allow at least 60 msec, plus drop out delay time, before re-applying thes e signals.
NOTE: Contactor will only respond to a close command re-applications after the re-start delay timer has expired.

3. Close a nd Trip commands present simultaneously (valid with Mechanical Latch contactors only).

 Open during undervoltage, Closed if voltage restored
 W ill reflect actual status of the contactor

Only for Electrically Held Contactor
Undervoltage conditions are defined on page 3-17.

Module Status Contac to r Status

LED Color

Re lay

LED Color

Open Off Open

Re lay

1503-UM 052D- EN-P – Jun e 2013

Monitorin g and Troubles hooti ng 5-5

Module status LED ‘Green’ and Contactor Status LED

Table 5 .C – Module Troubleshooting

Problem or Trip Indicated Indication of the following conditions Possible Solutions

Contactor does not energize • Motor Protection activated

• Both Status LEDs ‘Off’

• Module Stat us LED ‘Red’ upon power up

• Module Status ‘Red Flash 1’ upon power up • Improper set ting of dip switches. Check settings and

• Loose connection in control circuit. • Verify contactor auxiliary set up. Reference Publication

Contactor closes momentarily and will not

reclose.

Contactor fails to close.

• Module status LED ‘Red’ (Series C) and Contactor
Status LED ‘Off’

or

• Module status LED ‘Yellow – Flashing’ and Contactor

Status LED ‘Off’ (Series D)

•
‘Red Flash 1’ (Series C)

or

• Module status LED ‘Yellow-R1’ (Series D) and

Contactor Status LED ‘Off’

• Both status LEDs ‘Of f’ • Check internal control fuse. Verif y IntelliVAC oper ation

• Investigate and reset

• Check Control Power

• Loose connections in control circuit

• V erify Int elliV AC power input plug is in place and

properly seated

• Verify internal control fuse has not opened (Refer to

Figure 4.1 for locat ion)

• IntelliV AC faulted. Cycle control power to reset.

Replace IntelliVAC if unsuccessful.

cycle control power.

1502-UM052_ -EN-P (400A) or 1502-UM051_ -EN-P
(800A ) – Auxiliary Contact Set-up Procedure.

• Verify circuit continuity (is contactor plug connected

proper ly?)

• Under volta ge fault (no TDUV), contr ol volta ge dipped
below trip point. Verify voltage levels ar e 110 to 240

VAC, 110 to 250VDC

• Coil damaged or connections ar e loose. Repair and
cycle control power (Series C).

• Auxiliary Contact Assembly improperly adjusted.
Reference Publication 1502-UM052_ -EN-P (400A) or
1502-UM051_ -EN-P (800A) – Auxiliary Contact Set-up
Procedure. Cycle control power to reset (Series C).

• A rmature Plate obstructed from closing to coil face.
Verify no foreign material behind the armature plate.

Cycle contr ol power to reset.

in test mode bef ore a pplying Medium Voltage. (Refer to
Fig. 4.1 for location.)

Refer t o Table 5. A (Series C) or Table 5. B ( Series D) for definition of Module

LE D sta tes.

1503-U M052D-EN- P – Ju n e 2013

5-6 Monit oring a nd Troubleshoot ing

Module Status LED ‘Green’ and Contactor Status LED

R2’ and Contactor Status

Module Status LED ‘Yellow’ and Contactor Status LED

Table 5 .D – Minimum IntelliVAC Operational Supply Voltages

Contactor Status (cont.)

Table 5 .C – Module Troubleshooting (cont.)

Problem or Trip Indicated Indication of the following conditions Possible Solutions

Contactor opens during operation

Contactor does not open (mechanical latch) •

• Motor Protection activated

• Stop command initiated

• M odule Status LED ‘Red’ (Series C)

or ‘Yellow – Flashing’ (Seri es D)

•
‘Red Flash 2’ (Series C)

or

• Module Status LED ‘Yellow –

LED ‘Off’

• Both status LEDs ‘Of f’

‘Yellow’

• Investigate and reset.

• Verify circuit

• Under voltage f ault (no T DUV) , control volt age dipped

below trip point. Verify voltage levels ar e 110 to 240
VAC, 110 to 250 VDC.

• With external capacitor and TDUV feature activated,
undervoltage condition for longer than progr ammed

TDUV time. Undervoltage fault activated.

• Contactor Status feedback between Terminals 11 and
12 on the IntelliVAC has closed. The IntelliVAC will de­energize the coil, t hinking the contactor has opened

for other reasons.

• Check control voltage and inter nal control fuse. ( Refer

to Figure 4.1 for location.)

• T rip me chanism is dam aged. Inspect and replace if
needed.

• Check f or loose connecti ons i n the cont rol circuit .

Cont actor does not open

(electrically held)

• Series C – Module Status LED ‘Green’ and Contactor
Status ‘Red Flash 3’

• Series D – Module Status LED ‘Yellow – R3’ and

Contactor Status LED ‘Yellow’

• Contact or welded or mechanisms binding. Inspect and
repair if needed.

Refer t o Table 5.A (Seri es C) or Tab le 5.B (Seri es D) for definition of Module

LE D sta tes.

Voltage Level

Pick -Up 400/800 95

Drop-O ut 400/800 75

Tr ip (M echanical Latch)

Contactor Rating

(A mps)

400 70
800 80

Minimum Voltage

(VAC, 47 to 63 Hz)

1503-UM 052D- EN-P – Jun e 2013

Chapter 6

Spare Parts

Spare Parts List IntelliVAC (elect rically held) Series A 1503VC-BMC1

Intelli VAC (mechani cal la tch) Series A 1503VC-BMC2

IntelliVAC (electrically held and

mecha nica l lat ch) S eries B 1503VC-BMC3

IntelliVAC (electrically held and

mechanical la tch) Seri es C and D

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

Multi-pole connect ors:
2 pole (m odu le power) 80174-014-01-R
4 p ole (status outputs) 80174-014-03-R
12 pole (co il and I/O co nnecti ons) 80174-014-11-R

 1503VC-BMC4

Optional Equipment

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

 The Series Letter i s print ed on t he lar ge label on the right-hand s ide of th e enclos ure,

 Includes mounting bracket and terminal guards

besi de th e part number.



1503-U M052D-EN- P – Ju ne 2013

6-2 Spar e Parts

(This page is intentionally left blank)

1503-U M052D- EN-P – Jun e 2013

Appendix A

Table A .1 – Typi cal Contactor Dr op-Out Time Settings

4R 6R 9R

18R

19R

2 x 24R ⊇ 100

2 x 32R

⊇

240 *

2 x 38R

⊇

2 x 48X

⊇

⊇

Typical Contactor Drop-out Time Settings

The cont act or d rop -out time settings shown i n the fo llowi ng t able are

typical minimum v alues u sed when the po wer fuses a re pr ovi ded a s part of
a com plet e MV cont roller from Ro ckwell Aut oma ti on. The
recommenda tions a re ba sed on Ferraz-Shawm ut p ower fuses. Ot her fuse
types may req uire a lter nat e dro p-out ti me sett ing s.

The Int elliVAC module D IP swi tches are set up t o pr ovi de the m ini mum

drop-out ti mes shown (refer t o Cha pt er 4) .

Fus e Ra ting Contactor Drop-out Time Setting ( mse c)

Vo ltag e De sign ation 400A 800A

2R
3R

50

12R

< 5000

⊇ Fus e not suitable for use with contactor.

24R
32R

38R ⊇

48X

57X ⊇ 200

2 x 57X

100
240

⊇

⊇

⊇
⊇

50

75

Note: The drop-ou t t ime is cho sen t o be equa l t o or grea ter tha n

the int ersect ion of t he ra ted contact or i nter rup ting cur rent and
the fuse melt time curve (except where noted * ).

1503-U M052D-EN-P – Jun e 2013

A-2 Typical Contactor Drop-out Times

Table A .1 – Typi cal Contactor Drop-o ut T im e Settings ( co nt. )

50E

65E

150E

175E

75

450E

130

75

2 x 250E ⊇ 50

2 x 350E

75

2 x 400E

100

⊇

⊇

⊇

Fus e Ra ting Contactor Drop-out Time Setting (ms ec )

Vo ltag e De sign ation 400A 800A

20E
30E
40E

80E

50

100

< 5000

100E
125E

200E
250E
300E
350E
400E

50

500E
600E
750E
900E

2 x 300E

2 x 450E
2 x 500E
2 x 600E
2 x 750E

2 x 900E ⊇ ⊇

⊇ Fuse not suitable for use with contactor.

240

240 *

⊇

⊇

⊇

⊇

⊇

⊇

⊇

200

240 *

75

130
240

240 *

Note: The drop-out ti me i s chosen to be equ al to or greater tha n the

int ersection of t he r at ed cont act or i nterrup ting cur rent and t he
fuse melt time curve (except where noted * ).

1503-U M052D- EN-P – Jun e 2013

Typical Contactor Drop-out T imes A-3

Table A .1 – Typi cal Contactor Drop-o ut T im e Settings ( co nt. )

4R

6R

9R

75

32R

240 *

⊇ 75

48X

150

⊇

⊇

⊇

⊇

10E

15E

65E

150E

175E

Fus e Ra ting Contactor Drop-out Time Se tting (ms ec )

Vo ltag e De sign ation 400A 800A

2R
3R

50

50

12R
18R
24R

150

7200

8250

⊇ Fuse not suitable for use with cont actor.

38R

57X
2 x 18R
2 x 24R
2 x 32R
2 x 38R
2 x 48X
2 x 57X

20E

25E

30E

40E

50E

80E

100E
125E

200E

⊇

200

⊇

⊇

⊇
⊇

⊇ ⊇

50 50

240 *

50

130

Note: The drop-out ti me i s chosen to be equ al to or greater tha n the

intersection of t he rated contactor i nterr upti ng curr ent a nd t he
fuse melt time curve (except where noted *)

1503-U M052D-EN-P – Jun e 2013

A-4 Typical Contactor Drop-out Times

1503-U M052D- EN-P – Jun e 2013

Me dium Volt age Products,

Pu blication 1503-UM052D-EN-P – Ju ne 2013 Copy righ t © 2013 Rockw el l Aut oma ti on, I nc. Al l r i gh ts r es erve d. Pri nt ed in Cana da.

Supers edes P ubli cat ion 1503-UM052C -EN-P – June 2007

135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: [phone], Fax: [phone], www.ab.com/mvb