Rockwell Automation Allen-Bradley IntelliVAC 1503VC-BMC5 User manual

IntelliVAC Contactor Control Module
Catalog Number Bulletin 1503VC (Series E)
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).

Rockwell Automation Publication 1503-UM053C-EN-P - March 2015 3
Table of Contents
Chapter 1
Product Description
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IntelliVAC Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
IntelliVAC Versions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2
Receiving and Storage
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 3
Installation and Wiring
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Arrangements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Integral to an Allen-Bradley MV Controller . . . . . . . . . . . . . . . . . . . . 15
OEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Control Power Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Status Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrically Held Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control with Solid-State Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Two-Wire Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Three-Wire Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wiring Guidelines Mechanical Latch Contactors . . . . . . . . . . . . . . . . . . . 26
Mechanical Latch Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Capacitor Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor Jogging Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Undervoltage Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Time Delay Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 4
Setup and Commissioning
IntelliVAC Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4Rockwell Automation Publication 1503-UM053C-EN-P - March 2015
Table of Contents
Chapter 5
Monitoring and Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Module Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Contactor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chapter 6
Spare Parts
Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Appendix A
Contactor Drop-out Time Settings
Typical Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Rockwell Automation Publication 1503-UM053C-EN-P - March 2015 5
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Attention Table added for TDUV feature limitations 30
Added notations to table for DIP Switch explanation Table 32

6Rockwell Automation Publication 1503-UM053C-EN-P - March 2015
Summary of Changes
Notes:

Rockwell Automation Publication 1503-UM053C-EN-P - March 2015 7
Chapter 1
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. IntelliVAC is an efficient and flexible solution
for controlling medium voltage vacuum contactors used in motor starter and
feeder applications.
An IntelliVAC control module may also be provided as a loose OEM component,
for use with a Bulletin 1502 contactor by a third party (OEM).
Scope This document applies to the Series E version of IntelliVAC. See publication
1503-UM051C-EN-P for information related to the Series A and B designs, and
1503-UM052C-EN-P for information related to Series C and D designs.
Description An IntelliVAC module may be used to control Bulletin 1502 400 and 800 Amp
vacuum contactors. Both electrically held and mechanically latched contactor
types can be controlled with IntelliVAC.
Figure 1 - IntelliVAC Contactor Control Module

8Rockwell Automation Publication 1503-UM053C-EN-P - March 2015
Chapter 1 Product Description
Figure 2 - IntelliVAC Block Diagram
IntelliVAC Features
•A range of supply voltage (110 – 240V AC 50/60 Hz, 110 - 250V 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 (Bulletin 1502 400 A only) eliminates
mechanical compensation required for altitudes above 1000 meters
(Bulletin 1502 800 A contactors include a user-friendly mechanical
altitude adjustment).
External
Capacitor
(optional)
Supply
voltage
Close
Signal
Open
Signal
Altitude
Select
Dropout Time
Select
Contactor Type
Select
TDUV Select
Power Up
Safety Enable
Unused
Input
Power
Conditioning
Command
Inputs
Call
Power
Supply
Control
Power
Supply
Micro Controller
Flash EEPROM
Interface
Status
Outputs
Aux
Feedback
Current
Regulator
IGBT Coil
Switching
Vacuum
Contactor
Trip Coil
Vacuum
Contactor
Close Coil
Vacuum
Contactor
Auxiliary
Module
Status
Contactor
Status
110 - 240V AC
or
110 - 250V DC
DIP Sw.1
DIP Sw.2

Rockwell Automation Publication 1503-UM053C-EN-P - March 2015 9
Product Description Chapter 1
•Power loss ride-through (TDUV) allows the vacuum contactor to remain
closed during short power loss (may require an optional external capacitor,
dependent on ride-through time).
•Anti-kiss and anti-pumping protection ensure that the vacuum contactor
close – open sequence occurs as expected, avoiding rapid reclosure 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
See Chapter 6 for part numbers of the various series of modules. The Series Letter
is printed on the large label on the right-hand side of the enclosure, beside the
part number.
Series A There are two versions of IntelliVAC control. The first type is used to
control vacuum contactors that are electrically held, with one electrical coil that is
economized electronically. The second is used to control mechanically latched
vacuum contactors (no longer available).
Series B There is one version of IntelliVAC, to control electrically held and
mechanically latched vacuum contactors (no longer available).
Series C Updated version of the Series B module (no longer available).
Series D Minor functionality (firmware) enhancements, primarily related to
definition and handling of Faults and Warnings (no longer available).
Series E Revised hardware to allow connection to the IntelliVAC Plus or
IntelliVAC MC. The removal of the mini Din connector for updating firmware
(firmware is now updated using the IntelliVAC Plus or IntelliVAC MC boards).
New input circuits to reduce thermal output, and decrease sensitivity to leakage
current.
See Chapter 6 for catalog numbers for each version of IntelliVAC.
IMPORTANT
A Series C, D or E IntelliVAC module can be used to replace a Series A or Series B
module. When replacing an older series of IntelliVAC with a newer one, note
that the Module and Contactor Status outputs may function differently. See
publication 1503-UM051C-EN-P and/or Chapter 5 of this document, and make
any necessary changes to the control circuit.

10 Rockwell Automation Publication 1503-UM053C-EN-P - March 2015
Chapter 1 Product Description
Specifications Mounting and Connections
The IntelliVACcontrol modules are mounted using two screws, see Figure 3 on
page 12. 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
IntelliVACis 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). See Chapter 3 for information.
Bulletin 1500/1900 controllers are shipped with IntelliVAC preconfigured for
the required application. Please see the documents provided with the order.
Firmware
IntelliVAChas firmware stored in flash EEPROM. This may be updated in the
field (if necessary). The IntelliVACboard firmware is updated using either the
IntelliVAC Plus, or IntelliVAC MC supplementary boards.
The firmware version supplied with the module is displayed on top of the DIP
switches, see Figure 17 on page 31
Series C modules use only version 2.003 application firmware. This firmware is
also compatible with the Series A and B modules. Series D modules use only
version 3.001 or 3.002 application firmware.This firmware is not compatible
with any other Series Letter modules. Series E modules use on 4.004 or newer
firmware. This firmware is not compatible with any other Series Letter modules.