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Summary of Contents for Evoqua IONPURE IP-POWER600-G2
- Page 1 ® IONPURE G2 DC POWER CONTROLLER 600 VDC 13.2 Amps Operation & Maintenance Manual IP-POWER600-G2 MAN REV. 11 June 2014 Manual Covers Model #: 10 Technology Drive Lowell, Massachusetts 01851 IP-POWER600-G2 Tel: (866) 876-3340 Fax: 978-934-9499 www.ionpure.com...
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Page 2: Table Of Contents
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Table of Contents DISCLAIMER STATEMENT ........................4 PROPRIETARY RIGHTS STATEMENT ....................4 MANUAL REVISION HISTORY ......................4 INTRODUCTION ..........................5 1.1 Caution and Warning Messages ....................5 1.2 General Description ........................5 INSTALLATION ..........................7 2.1 Mounting ............................ - Page 3 ® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 A.1 Isolation Transformer ....................... 18 A.2 Other Power Supply Assembly Components ................20 APPENDIX B UL AND CE COMPLIANCE ..................22 B.1 UL (US/CANADA) ........................22 B.2 EUROPEAN UNION DIRECTIVE ..................... 22 APPENDIX C ENGINEERING DOCUMENTS AND DRAWINGS .............
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Page 4: Disclaimer Statement
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Disclaimer Statement The operation and maintenance manual should provide complete and accurate information to meet your operating and/or service requirements based on the information available at the time of publication. The information in this manual may not cover all operating details or variations or provide for all conditions in connection with installation, operation and maintenance. -
Page 5: Introduction
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 1 Introduction 1.1 Caution and Warning Messages WARNING and CAUTION labels are used to attract attention to essential or critical information in this manual. The labels are located to the left of the associated messages. Caution and Warning messages will be located immediately before related text. - Page 6 ® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 provide a high power factor at most outputs other than at the lowest power levels, which is a result of the unit’s design as a low bandwidth current source looking into a primarily resistive load. The power controller has input over-voltage protection as well as heat sink over-temperature protection.
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Page 7: Installation
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 2 Installation 2.1 Mounting Electrostatic discharge can damage electronic components. Make contact with a grounded conductive pad and/or wear a grounded wrist strap when you handle the power controller. The DC power controller is intended for mounting on a sub-panel inside an enclosure using four to six screws, either M4 or UNC 8-32. -
Page 8: Over-Current Protection
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 The secondary of the transformer MUST NOT be connected to earth ground. Grounding both the secondary and the GND terminal will damage the power controller. 2.2.2 Over-current Protection The power controller does not have built-in fuses for the AC input. Over- current protection devices, such as circuit breakers or fuses, must be installed between the isolation transformer and the AC input terminals, for example as shown in Figure 3. -
Page 9: High Voltage Connections
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 transformer, while the single phase version can be installed on the transformer secondary. Refer to the Voltage Snubber instruction manual (available at www.ionpure.com) for details. 2.3 High Voltage Connections 2.3.1 Initial Selection of AC Input Voltage The AC voltage supplied to the power controller should be at least 1.1 times higher than the maximum DC voltage required by the CEDI module(s). - Page 10 ® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 The GND terminal of the power controller must be connected to earth ground (PE) inside the power supply enclosure. Do NOT install fuses, circuit breakers or any type of switching device between the DC output of the power controller and the CEDI module. Doing so might eventually cause damage to the power controller.
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Page 11: Selector Switches
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 2.4 Selector Switches 2.4.1 DIP Switch for Current Range Selection DC output current range is selected via a current range DIP switch, as described in Figure 1. Figure 1: Current Range Selection DIP Switch The default current setting is 0-2.5 amps. -
Page 12: Low Voltage Connections
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 2.5 Low Voltage Connections 2.5.1 Analog Signal Wiring Guidelines Proper grounding and wiring of all electrical equipment is important to help ensure optimum operation of your system and to provide additional electrical noise protection for your application. -
Page 13: Remote On/Off
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Signal positive Signal negative The 0-5 VDC corresponds to 0-100% of the selected DC output current range. 2.5.3 Remote ON/OFF The DC output is switched on/off by a remote isolated non-powered (dry) contact connected to the plug-in terminals labeled “ON/OFF”... -
Page 14: Operation
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 3 Operation 3.1 Initial Startup The startup sequence depends on the design of the CEDI system. Please consult the Operation Manual for the CEDI system. 3.1.1 Example of Initial Startup Procedure The following startup procedure is only an example for a typical single module CEDI system with an electrical schematic as shown in Figure 3. -
Page 15: Troubleshooting
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 4 Troubleshooting Troubleshooting should be performed by qualified personnel only. Safety procedures should be reviewed prior to working with the DC Power Controller. The controller status can be determined by looking at the LEDs on the circuit board. - Page 16 ® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Input Over-voltage (after three incidents) Possible Cause Action Source AC too high for power controller Check AC voltage at isolation transformer primary; ensure that transformer primary is wired to match voltage available at site. Check voltage at transformer secondary with multi-meter, confirm that it is less than 660 VAC +10%.
- Page 17 ® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Open On/Off Input Possible Cause Action Low flow switch activated (open) Check operation of flow switch. Check availability of feed water. Check upstream and downstream valves. No jumper at on/off interlock input on G2 board Install jumper.
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Page 18: Appendix Adesign Considerations
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Appendix A Design Considerations Isolation Transformer Basic Transformer Design Considerations: Primary: single or three-phase, selected to match the power available at the site. Secondary: single-phase, at any voltage from 220 to 660 VAC. The AC voltage required should be at least 1.1 times higher than the maximum DC voltage required by the CEDI module. -
Page 19: Table 3: Isolation Transformer Size And Secondary Voltages For A Single Power Controller
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Table 3: Isolation Transformer Size and Secondary Voltages for a Single Power Controller Fuse Size Maximum Maximum Recommended Minimum Module Type Required Required Input Voltage to G2 Transformer KVA Secondary DC Volts DC Amps (VAC) rating (Amps) -
Page 20: Other Power Supply Assembly Components
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Other Transformer Design Considerations: Temperature Rise and Insulation Class: Transformers with 130 or 150 °C temperature rise with an insulation class of 220 °C are commonly available. Transformers with lower temperature rise are more efficient and have longer service life, but are priced higher. - Page 21 ® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Use Table 3 to select fuse size (in Amps). The voltage rating should match or exceed the nominal AC input voltage to the power controller. Over-current protection devices must also be installed on the primary of the isolation transformer and sized according to applicable local electrical codes.
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Page 22: Appendix Bul And Ce Compliance
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Appendix B UL and CE Compliance UL (US/CANADA) The G2 power controller is recognized by UL through compliance with the following standards: UL 61010-1 (Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use;... -
Page 23: Appendix Cengineering Documents And Drawings
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Appendix C Engineering Documents and Drawings Engineering Drawings included in this section Figure 2: Full-scale Dimensional Drawing for IP-POWER600-G2 Figure 3: Electrical Schematic of a Typical Single-module installation - Single-phase Transformer ... - Page 24 ® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Figure 2: Full-Scale Dimensional Drawing for IP-POWER600-G2 IP-POWER600-G2 MAN REV. 11 Page 24 of 28...
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Page 25: Figure 3: Electrical Drawing Of A Typical Single-Module Installation - Single-Phase Transformer
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Figure 3: Electrical Drawing of a Typical Single-Module Installation - Single-Phase Transformer IP-POWER600-G2 MAN REV. 11 Page 25 of 28... -
Page 26: Figure 4: Electrical Drawing Of A Typical Multi-Module Installation - Single-Phase Transformer With Shared Secondary Winding
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Figure 4: Electrical Drawing of a Typical Multi-Module Installation - Single-Phase Transformer with Shared Secondary Winding IP-POWER600-G2 MAN REV. 11 Page 26 of 28... -
Page 27: Figure 5: Electrical Schematic Of A Typical Multi-Module Installation - Three-Phase Primary With
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Figure 5: Electrical Schematic of a Typical Multi-Module Installation - Three-Phase Primary with Independent Secondary Windings IP-POWER600-G2 MAN REV. 11 Page 27 of 28... -
Page 28: Figure 6: Electrical Connections And Switches
® IONPURE DC POWER CONTROLLER – IP-POWER600-G2 Figure 6: Electrical Connections and Switches IP-POWER600-G2 MAN REV. 11 Page 28 of 28...
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