Rockwell Automation 1503FC User Manual

IntelliVAC™ Contactor
Control Module

USER MANUAL

(Series E)

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 Connections ....................................................... 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 St orage 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 Dev ices ............................................... 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-UM053B -EN-P – Ju ne 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, Series C (Table 5.A) ................ 5-3

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

IntelliVAC Status Indication, Series E (Table 5.C) ................. 5-5

Module Troubleshooting (Table 5.D) ...................................... 5-6

Min. IntelliVAC Operatio nal Su pp ly Vo lta g es (Table 5. E)......... 5-7

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-U M053B -EN-P – Ju ne 2013

Chapter 1

Product Description

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

15 03VC I ntelli VAC™ co ntrol module. The Bullet in 15 03VC i s used to
control the Allen-Bra dley Bullet in 150 2 va cuum cont act ors t hat a re a
signifi cant component of the Bulletin 1500/1900 CENTERLINE
Medium Voltage Motor Controllers offered by Rockwell Automation.

An IntelliVAC control modu le may also be pr ovi ded a s a lo ose

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

Scope Thi s docu ment app lies t o the Seri es E v ersion of I ntelli VAC. Refer to

publication 1503-UM051C-EN-P for information related t o the S eries
A and B designs, and 1503-UM052C-EN-P for information related to
Seri es C a nd D desi gns.

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

vo lta ge va cuum cont actors used i n motor st ar ter and f eeder
applications. IntelliVAC may be used to control both 400 and 800
Amp co nta ctors. E lectri cally held a nd mecha nica lly la tched cont actor
types can be controlled with IntelliVAC.

1503-U M053B-EN-P – Ju ne 2013

1-2 Product Description

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 cont actor pi ck-up ti me (a t a g iven sup ply

voltage) ensures repea ta ble per for mance

 Selectable vacu um co nta ctor dr op-out time improves coordination

with upst rea m po wer fuses

 Elect roni c alt it ude compensati on (40 0 A only) elim ina tes

mechanical com pensa tion requi red for alti tud es abov e 1,0 00
met ers (800 A contactors include a user -fri endly alt itud e
adjustment)

 Power loss ride-t hro ugh ( TDU V) a llows t he va cuum cont actor to

rem ai n closed du ring short po wer lo ss (ma y req uir e an o ptional
ext erna l capacit or, dependant on ri de-through ti me)

1503-U M053B- EN-P – Ju ne 2013

Product D escri ption 1-3

IntelliVAC Features (cont.)

 Anti-kiss a nd anti -pumpi ng protection ensure tha t t he vacuu m

contactor close – open sequence occurs as expected, avoiding rapid
re-closure due to fau lty cont rol d evices

 Delayed r esta rt pr otects t he vacuu m conta ctor b y ensuri ng t hat the

rat ed dut y cycle is not exceeded

 Tempo rary jog function (elect rically held cont act ors o nly) allows

the motor to be posi ti oned for p rocess set -up

IntelliVAC Versions

Series A

Series B

Series C

Up dat ed versi on o f the Series B modu le.

Ther e are t wo versi ons o f I ntelli VAC co ntr ol. The
fi rst type i s used to control v acuu m cont actors that are
electrically held, with a single electrical coil that is
economized electronically. The second is used to
control mecha nica lly lat ched va cuum contact ors.

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

Series D Minor functionality (firmware) enhancements

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

Series E R evised ha rdware to allow co nnecti on t o t he

Int elliVAC Plus or I ntelli VAC MC> Remo val o f the
mi ni Din co nnecto r for fla shing fi rmwa re (firmwa re is
now flashed using the IntelliVAC Plus or IntelliVAC
MC boards) . N ew inpu t circui ts t o redu ce ther mal
ou tpu t, and d ecrease sensi ti vit y t o leakage cur rent .

Refer t o Cha pter 6, for cat alog num bers for each version of Int elliVAC.

Note: A Series C, D or E IntelliVAC m odule can be used t o rep lace

a Seri es A or Series B module. When rep laci ng an o lder ser ies
of Int elliVAC wi th a newer one, not e tha t t he Module and
Co nta ctor Status o utpu ts may functi on di fferent ly. R efer t o
publication 1503-UM051C-EN-P and/or Chapter 5 of this

1503-U M053B-EN-P – Ju ne 2013

1-4 Product Description

do cument , a nd make any necessa ry changes to the co ntrol
circuit.

1503-U M053B- EN-P – Ju ne 2013

Product D escri ption 1-5

Specifications Mounting and Connections

The IntelliVAC control mod ules a re m ount ed usi ng t wo ( 2) scr ews ( see
Figur e 1.3 ). They are typi cally locat ed in the lo w volt age control pa nel
of the medi um vo lta ge cont roller (Bullet in 1500 /190 0 cont rollers, in
the case of Rockwell Automation).

Intelli VAC i s int erfa ced to the Bulleti n 1502 vacuum cont act ors u sing
a “qui ck” co nnector , locat ed at the mod ule, a wir e ha rness and “qui ck”
connector at the co nta cto r. Control po wer a nd ot her co ntr ol ci rcui t
connect ions are simila rly a chieved wi th “qui ck” co nnecto rs.

Configuration

IntelliVAC is easily confi gur ed for a wi de va riety of m ediu m vo lta ge
mo to r and feeder cont rol app lica ti ons. It is configu red using D IP
swi tches, locat ed withi n the enclosur e (fr ont side) . 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 io n. Please refer to the docu ment s
provided wit h the ord er.

Firmware

IntelliVAC ha s fir mwa re stored i n flash EEP ROM; t heref ore, thi s ma y
be updated in the field (if necessary). The IntelliVAC
is up dat ed usi ng ei ther the I ntelliVAC Plus, or Int elliVAC MC
supplem enta ry boa rds.

The firmware versi on suppli ed wi th t he mod ule is di splay ed on top o f
the DIP swi tches ( see Fig ure 4 .1) .

Seri es C modules use only ver sion 2.00 3 app lica ti on fi rmwa re. This
fi rmwa re is also compa ti ble wi th t he Seri es A a nd B modu les. Series D
modules use only version 3.001 or 3.002 application firmware. This
fi rmwa re is not com pat ib le wit h any ot her S eri es Letter mod ules.
Seri es E modules use o n 4 .00 4 or newer fi rmwa re. This fi rmwa re is not
com pati ble wi th a ny ot her S eries Let ter modules.

Refer t o Cha pter 6 f or p art number s of t he va rious ser ies of modu les.
The Series Letter of the mo dule i s print ed on t he label on t he cover of
the module, besi de the pa rt num ber.

board firmware

1503-U M053B-EN-P – Ju ne 2013

1-6 Product Description

Table 1 .A – El ectri cal Ratings

Main Inpu t Vo ltage

(L1 to L2/N)

AC – 110 to 240 V rms, +10/-15%, 4 7 to 63 Hz

DC – 1 10 to 250 V, +10/-15%

Main Input Current

(L1 to L2/N )

Command Inputs

⊇ ⊂

Des cription

Con tac tor Ratin gs

(A mps)

Control Voltage

(AC o r DC)

Inr ush Current 400/800 120/240

Idle Current
(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 Current (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 – 70 to 240 V rms
DC – 70 to 250 V
Max imum on state current f or open or close command:

@ 276 V AC, 60Hz, TA = 60°C

11mA

AC

2.4mA

@ 276 V DC, TA = 60°C

DC

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

@ 70 V AC, 60Hz, TA = 60°C

2.5mA

1.2 m A @ 68 V DC, T

AC

= 60°C

A

Max imum off state current for open or close command:

= 60°C

A

= 60°C

A

1.9 µA @ 60 V AC, 60 Hz, T
900 µA @ 60 V DC, T

AC Rating DC Rating

25 A peak (1/2

cycle )

25 A peak

1503-U M053B- EN-P – Ju ne 2013

Status Outp ut 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 resist ors.)
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 t ype 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, CS A, IEC 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 – Mechani cal Ratings

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

Vibra tion – 10 to 57 Hz, 0.015 inch displacement peak t o peak

– 57 to 150 Hz, 2.5 g acceler ation

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 M053B-EN-P – Ju ne 2013

Chapter 2

Receiving and Storage

Receiving Up on receiving the cont roller, r emove t he pa cki ng and check fo r da ma ge

tha t ma y ha ve occurred during shi ppi ng. Report a ny da mage immedi ately
to the cla im s office of the ca rrier.

NOTE: If t he Int elliVAC m odule is a n integra l com ponent of a

com plete MV co ntr oller (Bullet in 150 0/19 00), special receivi ng a nd
ha ndling inst ruct io ns will app ly. For deta ils, refer to the ser vice ma nual
pr ovi ded with t he equipm ent.

Storage It is important to consider the following storage requi rem ents i f yo u ar e

not inst alli ng your cont roller i mm edia tely aft er r eceivi ng i t.

• St ore t he controller i n a clean, dry , dust -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 must not exceed 9 5%, non-condensing.

1503-UM053B -EN-P – Ju ne 2013

2-2 Receiving and Storage

(This page is intentionally left blank)

1503-U M053B -EN-P – Ju ne 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 it ion t o the preca ut ions list ed throu ghout t his manual, t he

followi ng st at ement s, whi ch ar e g eneral t o the system, m ust be read a nd
understood.

The cont roller cont ains ESD (electrostat ic
discharge) sensit ive part s and a ssemblies. St ati c
control pr ecaut io ns ar e requi red when
inst alli ng test ing, ser vici ng, o r repa iri ng the
assembly . Co mpo nent da ma ge ma y result if
ES D cont rol pr ocedu res are not followed. I f
you are not familiar with static control
pr ocedures, refer t o app lica ble ES D prot ecti on
handbooks.

An incorrectly app lied o r inst alled controller
can dam age compo nents o r reduce pro duct life.
Wi ri ng or a pplicati on err ors, su ch as i ncorrect
or ina dequ ate AC su pply, or excessive am bient
temper at ures, ma y result in m alfu ncti on of t he

system.

Only personnel fam ili ar wit h the cont roller a nd
associ at ed machi nery sho uld plan or implem ent
the installation, start-up, a nd subseq uent
ma intena nce of t he syst em. Fa ilur e to do t his
ma y r esult i n persona l injury a nd/or equi pment

damage.

1503-U M053B-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 lectr ical Co de (CEC) ,
Na ti ona l Electrica l Code (N EC) , or other local
cod es out line pr ovi sio ns for safely i nsta lling
electrical equi pment. Inst alla tion MU ST
com ply wi th speci fica ti ons regardi ng wi re t ype,
conduct or si zes, bra nch ci rcui t pro tect io n,
int erlock ing and di sconnect devi ces. Fa ilure t o
do so may resu lt i n personal i njury 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 com ponent of a n Allen-Bradley

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

Bulletin 1500/ 1900 MV cont ro ller) o r a s an OEM co mpo nent.

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

Figure 3.1 – Typical IntelliVAC Install atio n within a Bul letin 15 00/19 00 MV Controller (Shown

with o ptional external cap acitor)

1503-U M053B -EN-P – Ju ne 2013

Installati on a nd Wir ing 3-3

OEM

The Int elliVAC may be o rder ed as an OEM compo nent. This a llows the
OEM t o mou nt t he com ponents i n a confi gur at ion m ost sui tab le to the
mo to r controller equi pment lay out . Ca re m ust b e exerci sed t o ensur e t he
Intelli VAC ha s adequ ate venti lat ion pr ovided arou nd it. Refer to Figur e

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

1. 5 inches ( 38. 1mm ) of free air spa ce be pr ovi ded b etween t he
Intelli VAC and any solid b arrier abov e or b elow.

The OEM i s responsible for controller fusing, mot or overload pro tection,
control devi ces (eg. Start/Stop push buttons), and wiring between the
Intelli VAC and 15 02 v acuu m contactor (using optio nal wir e harness) .
Wi ri ng and mou nti ng fo r opt ional i tem s, such a s TDU V Capacitor, are
also the OEM’s responsibilit y. R efer t o Figur e 3.3 for basic connect io ns.

1503-U M053B-EN- P – Ju ne 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 modu les may be mo unted wit h a
minimum separation of 6.4 mm (0.25 inches).

1503-U M053B -EN-P – Ju ne 2013