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

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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

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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.

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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

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 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)

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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.

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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

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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

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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

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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.

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2-2 Receiving and Storage

(This page is intentionally left blank)

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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.

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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)

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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.

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