Rockwell Automation Allen-Bradley IntelliVAC User manual

IntelliVAC™
Contactor
Control Module
Bulletin 1503VC
User Manual

Important User Information
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.
Labels may also be on or inside the equipment to provide specific precautions.
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.
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.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
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).

Table of Contents
1503-UM051D-EN-P – June 2013
Product Description Chapter 1
Introduction ..............................................................................1-1
Description ...............................................................................1-1
IntelliVAC Features ......................................................... 1-2
IntelliVAC Versions ......................................................... 1-3
Specifications .......................................................................... 1-4
Mounting and 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
Receiving and Storage 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 ....................................................................... 3-6
Grounding ............................................................................... 3-6
Connections ............................................................................ 3-7
Control Power .................................................................. 3-7
Status Relays .................................................................... 3-7
Interface Connections ....................................................... 3-8
Wiring Guidelines Electrically Held Contactors .................. 3-10
Two-Wire Control .......................................................... 3-11
Three-Wire Control ........................................................ 3-12
Wiring Guidelines Mechanically Latched Contactors .......... 3-14
Mechanically Latched Contactors ........................................ 3-15
Capacitor Trip ................................................................ 3-14
Motor Jogging Control ......................................................... 3-17
Time Delay Undervoltage ..................................................... 3-18

ii Table of Contents
1503-UM051D-EN-P – June 2013
Setup and Commissioning Chapter 4
IntelliVAC Configuration ....................................................... 4-1
Monitoring & Troubleshooting Chapter 5
Introduction ............................................................................. 5-1
Module Status ......................................................................... 5-1
Contactor Status ...................................................................... 5-2
Series B Design ................................................................ 5-2
Spare Parts Chapter 6
Spare Parts List ....................................................................... 6-1
Optional Equipment ......................................................... 6-1
Appendix A Typical Contactor Drop-out Times
Table A.1 – Contactor Drop-out Times ................................. A-1

Chapter 1
1503-UM051D-EN-P – June 2013
Product Description
Introduction This document contains information for the Allen-Bradley Bulletin
1503VC IntelliVAC™ control module. The Bulletin 1503VC is
used to control the Allen-Bradley Bulletin 1502 vacuum contactors
that are a significant component of the Bulletin 1500/1900
Centerline Medium Voltage Motor Controllers offered by
Rockwell Automation.
An IntelliVAC control module may also be provided as a loose
component, for application with a Bulletin 1502 contactor by a
third party (OEM).
Description IntelliVAC is an efficient and flexible solution for controlling
medium voltage vacuum contactors used in motor starter and
feeder applications. IntelliVAC may be used to control both 400
and 800 Amp contactors. Electrically held and mechanically
latched contactor types can be controlled with IntelliVAC.
Figure 1.1 – IntelliVAC Contactor Control Module

1-2 Product Description
1503-UM051D-EN-P – June 2013
Description (cont.)
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
cc
c
Flash EEPROM
Interface
Coil
Power
Supply
Control
Power
Supply
Power Up
Safety
c c
c
Figure 1.2 – IntelliVAC Block Diagram
IntelliVAC Features
A wide range of supply voltage (110 – 240 V AC 50/60 Hz,
110 - 250 V DC) allows implementation in multiple applications
Consistent vacuum contactor pick-up time (at a given supply
voltage) ensures repeatable performance
Selectable vacuum contactor drop-out time improves
coordination with upstream power fuses
Electronic altitude compensation (400 A only) eliminates
mechanical compensation required for altitudes above 1,000
meters (800 A contactors include a user-friendly altitude
adjustment)
Power loss ride-through (TDUV) allows the vacuum contactor
to remain closed during short power loss (may require an
optional external capacitor, dependant on ride-through time)

Product Description 1-3
1503-UM051D-EN-P – June 2013
IntelliVAC Features (cont.)
Anti-kiss and anti-pumping protection ensure that the vacuum
contactor close – open sequence occurs as expected, avoiding
rapid re-closure due to faulty control devices
Delayed restart protects the vacuum contactor by ensuring that
the rated duty cycle is not exceeded
Temporary jog function (electrically held contactors only)
allows the motor to be positioned for process set-up
IntelliVAC Versions
Series A There are two versions of IntelliVAC control. The
first type is used to control vacuum contactors that
are electrically held, with a single electrical coil
that is economized electronically. The second is
used to control mechanically latched vacuum
contactors.
Series B There is a single version of IntelliVAC, to control
both electrically held and mechanically latched
vacuum contactors.
Refer to Chapter 6, for catalog numbers for each version of
IntelliVAC.
A Series B IntelliVAC module can be used to replace a Series A
module.

1-4 Product Description
1503-UM051D-EN-P – June 2013
Specifications Mounting & Connections
The IntelliVAC control modules are mounted using two (2) screws
(see Figure 1.3). They are typically located in the low voltage
control panel of the medium voltage controller (Bulletin 1500/1900
controllers, in the case of Rockwell Automation).
IntelliVAC is interfaced to the Bulletin 1502 vacuum contactors
using a “quick” connector, located at the module, a wire harness
and “quick” connector at the contactor. Control power and other
control circuit connections are similarly achieved with “quick”
connectors.
Configuration
IntelliVAC is easily configured for a wide variety of medium
voltage motor and feeder control applications. It is configured
using DIP switches, located within the enclosure (front side).
Please refer to Chapter 4 for information.
Bulletin 1500/1900 controllers are shipped with IntelliVAC pre-
configured for the required application. Please refer to the
documents provided with the order.
Firmware
IntelliVAC has firmware stored in flash EEPROM; therefore, this
may be updated in the field (if necessary). The IntelliVAC board
firmware is updated using the mini-DIN connector, which is
accessible inside the enclosure.

Product Description 1-5
1503-UM051D-EN-P – June 2013
Table 1.A – Electrical Ratings
Main Input Voltage
(L1 to L2/N) AC – 110 to 240 V rms, +10/-15%, 47 to 63 Hz
DC – 110 to 250 V, +10/-15%
Description Contactor Ratings
(Amps) Control Voltage (AC or DC) AC Rating DC Rating
Inrush Current 400/800 120/240 25 A peak
(1/2 cycle) 25 A peak
Idle Current
(Maximum without contactor
coil energized)
400/800 120/240 125 mA 35 mA
Hold Current  (maximum) 400/800 120/240 300 mA 100 mA
120 4.6 A 3.6 A
400
240 3.4 A 3.3 A
120 11.3 A 4.8 A
Close Current 
(0.2 sec)
800 240 8.9 A 4.5 A
120 7.0 A 3.7 A
400
240 3.6 A 2.0 A
120 7.0 A 3.3 A
Main Input Current
(L1 to L2/N) 
Trip Current (latch) 
(0.2 sec)
800
240 4.3 A 1.9 A
Command Inputs
 \
AC – 100 to 240 V rms
DC – 24 to 250 V
Maximum on state current for open or close command:
9mAAC @ 250 V AC, 60Hz, TA=60°C
9mADC @ 250 V DC, TA=60°C
Minimum on state current for open or close command:
2mAAC @ 100 V AC, 60Hz, TA=60°C
600µADC @ 24 V DC, TA=60°C
Maximum off state current for open or close command:
400µAAC @ 11 V AC, 60Hz, TA=60°C
400µADC @ 15 V DC, TA=60°C
Status Output
Contacts 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
Standards and
Approvals CE , cULus, CSA, IEC pending
 T
A = Ambient Temperature
 Refer to Chapter 6 for suitable EMC filter needed to meet CE requirements.
Also refer to Chapter 3 for EMC filter installation guidelines.
 Please consult Factory for DC input current ratings.
 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.

1-6 Product Description
1503-UM051D-EN-P – June 2013
Table 1.B – Mechanical Ratings
Operating: 0° to 60°C ambient at the control module X
Temperature Non-Operating: -40° to 85°C
Altitude -1000 to 5000 meters
Pollution Pollution level II (as defined by UL 840 and IEC 60664-1)
Humidity Class II
Shock – 15 g peak, 11 milliseconds
Shock and
Vibration
(Operational) Vibration – 10 to 57 Hz, 0.015 inch displacement peak to peak
- 57 to 150 Hz, 2.5 g acceleration
X Ambient temperature is derated at altitudes above 1,000 meters (3,300 feet).
Please refer to Table 1.C.
Table 1.C – Altitude Derating
Altitude DIP Switch Setting 1, 2, 3 X Maximum Operating Ambient
at the control module (°C) Y
-1000 to 0 000 60
1 to 1000 001 60
1001 to 2000 010 58
2001 to 3000 011 56
3001 to 4000 100 54
4001 to 5000 101 52
X Refer to Chapter 4.
Y Derate by 2°C / 1000 m for high altitude operation
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
Figure 1.3 – Mechanical Dimensions
Specifications (cont.)

Chapter 2
1503-UM051D-EN-P – June 2013
Receiving and Storage
Receiving Upon receiving the controller, remove the packing and check for
damage that may have occurred during shipping. Report any
damage immediately to the claims office of the carrier.
NOTE: If the IntelliVAC module is an integral component of a
complete MV controller (Bulletin 1500/1900), special receiving
and handling instructions will apply. For details, refer to the
service manual provided with the equipment.
Storage It is important to consider the following storage requirements if you
are not installing your controller immediately after receiving it.
• Store the controller in a clean, dry, dust-free environment.
• Storage temperature should be maintained between -40°C and
85°C (-40°F and 185°F).
• Relative humidity must not exceed 95%, non-condensing.

2-2 Receiving and Storage
1503-UM051D-EN-P – June 2013
(This page is intentionally left blank.)

Chapter 3
1503-UM051D-EN-P – June 2013
Installation and Wiring
General Precautions In addition to the precautions listed throughout this manual, the
following statements, which are general to the system, must be read
and understood.
ATTENTIONATTENTION
The controller contains ESD (electrostatic
discharge) sensitive parts and assemblies.
Static control precautions are required when
installing testing, servicing, or repairing the
assembly. Component damage may result if
ESD control procedures are not followed. If
you are not familiar with static control
procedures, refer to applicable ESD
protection handbooks.
ATTENTIONATTENTION
An incorrectly applied or installed controller
can damage components or reduce product
life. Wiring or application errors, such as
incorrect or inadequate AC supply, or
excessive ambient temperatures, may result
in malfunction of the system.
ATTENTIONATTENTION
Only personnel familiar with the controller
and associated machinery should plan or
implement the installation, start-up, and
subsequent maintenance of the system.
Failure to do this may result in personal
injury and/or equipment damage.
ATTENTIONATTENTION
The Canadian Electrical Code (CEC),
National Electrical Code (NEC), or other
local codes outline provisions for safely
installing electrical equipment. Installation
MUST comply with specifications regarding
wire type, conductor sizes, branch circuit
protection, interlocking and disconnect
devices. Failure to do so may result in
personal injury and/or equipment damage.
Safety and Codes

3-2 Installation and Wiring
1503-UM051D-EN-P – June 2013
Arrangements The IntelliVAC is offered in two arrangements, Integral (part of a
Bulletin 1500/1900 MV controller) or as an OEM component.
Integral to an Allen-Bradley MV Controller
The IntelliVAC is available as a primary component of an Allen-
Bradley Bulletin 1500/1900 MV controller as shown in Figure 3.1.
Figure 3.1 - Typical IntelliVAC Installation within a Bulletin 1500/1900 MV Controller
(Shown with optional external capacitor)

Installation and Wiring 3-3
1503-UM051D-EN-P – June 2013
OEM
The IntelliVAC may be ordered as an OEM component. This allows
the OEM to mount the components in a configuration most suitable
to the motor controller equipment layout. Care must be exercised to
ensure the IntelliVAC has adequate ventilation provided around it.
Refer to Figure 3.2 for mounting the IntelliVAC. It is recommended
that a minimum of 1.5 inches (38.1mm) of free air space be provided
between the IntelliVAC and any solid barrier above or below.
The OEM is responsible for controller fusing, motor overload
protection, control devices (eg. Start/Stop push buttons), and wiring
between the IntelliVAC and 1502 vacuum contactor (using optional
wire harness). Wiring and mounting for optional items, such as
TDUV Capacitor are also the OEM’s responsibility. Refer to Figure
3.3 or 3.4 for basic connections.
An optional EMI filter is required to meet CE EMC requirements
(refer to Chapter 6 for recommended type).
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)
Figure 3.2 – Typical Mounting Configurations
Note: Adjacent IntelliVAC modules may be mounted with a
minimum separation of 6.4 mm (0.25 inches).

3-4 Installation and Wiring
1503-UM051D-EN-P – June 2013
Arrangements (cont.)
∗Refer to Table 3.A for recommended fuse sizing.
MOV
32
1EC
-
+
4
TCO
12
11 AUX CCO 5 6
L1 L2/NG
+-
STOP START
OVERLOAD
CONTROL
POWER
FUSE
*
78
OPEN
16
15
CONTACTOR
STATUS
M
M-INTELLIVAC
M
CAPACITOR
(OPTIONAL)
+-
910
CLOSE
14
13
MODULE
STATUS
CONTROL POWER
INPUT POWER
CONFIGURATION
DIP SWITCHES
∗Refer to Table 3.A for recommended fuse sizing.
MOV
32
1EC
-
+
4
TCO
12
11 AUX CCO 5 6
L1 L2/NG
+-
STOP START
OVERLOAD
CONTROL
POWER
FUSE
*
78
OPEN
16
15
CONTACTOR
STATUS
M
M-INTELLIVAC
M
CAPACITOR
(OPTIONAL)
+-
910
CLOSE
14
13
MODULE
STATUS
CONTROL POWER
INPUT POWER
CONFIGURATION
DIP SWITCHES
Figure 3.3 – IntelliVAC Typical Schematic (Electrically Held Vacuum Contactor)
Without Optional EMC Filter

Installation and Wiring 3-5
1503-UM051D-EN-P – June 2013
∗Refer to Table 3.A for recommended fuse sizing.
MOV
32
1EC
-
+
4
TCO
12
11 AUX CCO 5 6
L1 L2/NG
+-
STOP START
OVERLOAD
CONTROL
POWER
FUSE
*
78
OPEN
16
15
CONTACTOR
STATUS
M
M-INTELLIVAC
M
CAPACITOR
(OPTIONAL)
+-
910
CLOSE
14
13
MODULE
STATUS
CONTROL POWER
INPUT POWER
CONFIGURATION
DIP SWITCHES
N'
N
EMC FILTER
G
P'
P
∗Refer to Table 3.A for recommended fuse sizing.
MOV
32
1EC
-
+
4
TCO
12
11 AUX CCO 5 6
L1 L2/NG
+-
STOP START
OVERLOAD
CONTROL
POWER
FUSE
*
78
OPEN
16
15
CONTACTOR
STATUS
M
M-INTELLIVAC
M
CAPACITOR
(OPTIONAL)
+-
910
CLOSE
14
13
MODULE
STATUS
CONTROL POWER
INPUT POWER
CONFIGURATION
DIP SWITCHES
N'
N
EMC FILTER
G
P'
P
Figure 3.4 – IntelliVAC Typical Schematic (Electrically Held Vacuum Contactor)
With Optional EMC Filter

3-6 Installation and Wiring
1503-UM051D-EN-P – June 2013
Fuse Protection The IntelliVAC module requires external fuse protection to
coordinate with the power supply and contactor. The fuse ratings
shown in Table 3.A allow the passage of inrush currents expected
when the contactor is closed, or from recommended external
capacitors for the TDUV option. They will also protect the contactor
coils in the event of a module malfunction.
The recommended fuses have been tested to ensure reliable
protection of the module. If the supply voltage is DC, the module
must be used with an external fuse that is approved for and rated to
interrupt the DC voltage supply. The types listed are Ferraz-Shawmut
Midget Fuses (1-1/2" X 13/32"). The TRM is a time-delay type,
rated 250 VAC. The ATM is a fast-acting type, rated 500 VDC.
Table 3.A – IntelliVAC Fuse Protection
Recommended Fuse
Rated Supply Voltage Contactor Type (minimum) (maximum)
400A EH TRM 2 TRM 3.2
800A EH TRM 2 TRM 6.25
110/120 VAC
400/800A ML TRM 2 TRM 3.2
400A EH TRM 2 TRM 6.25
800A EH TRM 2 TRM 6.25
220/240 VAC
400/800A ML TRM 2 TRM 6.25
400A EH/ML ATM 3 ATM 3
125 VDC 800A EH/ML ATM 5 ATM 6
400A EH/ML ATM 3 ATM 5
250 VDC 800A EH/ML ATM 5 ATM 6
EH = Electrically Held vacuum contactor
ML = Mechanically Latched vacuum contactor
Grounding The IntelliVAC module must be connected to a common ground
terminal (PE) on the controller panel. The ground terminal is located
on top of the module enclosure for Series A design (refer to Figure
3.7), and on the bottom of module enclosure for Series B design,
(refer to Figure 3.6)
ATTENTIONATTENTION
It is important that IntelliVAC is properly
grounded using the ground connection
provided. Failure to do so may result in
damage to equipment or personal injury.

Installation and Wiring 3-7
1503-UM051D-EN-P – June 2013
Connections There are three green connectors on the IntelliVAC module for
connections to the control circuitry. Connector plugs are provided
with the module. If additional plugs are required, refer to Chapter 6,
Spare parts.
Control Power
The IntelliVAC can accept either AC or DC control power. Refer to
Table 1.A for acceptable input power and control signal ratings.
Control power is applied to the module with a two-pole connector
located at the bottom rear portion of the module. Refer to Figures
3.5 and 3.6 for connections. The ‘L1’ connection is intended to be
the ‘Hot’ or ‘+’ side of the control power, and the ‘L2/N’ connection
is intended to be the ‘Neutral’, ‘Return’, or ‘-’ side of the control
power.
In order to meet CE electromagnetic interference requirements, an
external EMC filter must be installed. Refer to Chapter 6 for suitable
EMC filter part number and install per Figure 3.4.
Status Relays
Status relay connections are accessed with a four-pole connector
located at the bottom front portion of the module. Refer to Figure
3.5 or 3.6 for connections. There are two status relays, each with one
normally-open contact:
Module Status: Terminals 13 and 14
Contactor Status: Terminals 15 and 16
Refer to Chapter 5 Monitoring and Troubleshooting for a description
of operation for the relays.
Refer to Table 1.A for electrical ratings of the status relays.
L2/NL1
CONTACTOR STATUS OUTPUT (N.O.) MODULE STATUS OUTPUT (N.O.) POWER INPUT
13 161514
Figure 3.5 – Bottom side connections (Series A)

3-8 Installation and Wiring
1503-UM051D-EN-P – June 2013
Connections (cont.) Interface Connections
Ground Connection
L2/NL1
CONTACTOR STATUS OUTPUT (N.O.) MODULE STATUS OUTPUT (N.O.) POWER INPUT
13 161514
Ground Connection
L2/NL1
CONTACTOR STATUS OUTPUT (N.O.) MODULE STATUS OUTPUT (N.O.) POWER INPUT
13 161514
Figure 3.6 – Bottom side connections (Series B)
Interface Connections
All other control interface connections are made at a twelve-pole
connector located on the top of the module. Refer to Figure 3.7 or
3.8 and Table 3.B for connections. Refer to the Wiring Guidelines
section in this chapter for guidance in making connections to the
control circuit.
CONTACTOR INTERFACE
11 1289105672341
EX. CAP.
Ground Connection
CONTACTOR INTERFACE
11 1289105672341
EX. CAP.
Ground Connection
Figure 3.7 – Top side connections (Series A)
CONTACTOR INTERFACE
11 1289105672341
EX. CAP.
Figure 3.8 – Top side connections (Series B)