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IONPURE DC3 Operation & Maintenance Manual

Power controller 600 vdc 15 amps with isolation
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Tewksbury, Massachusetts 01876, USA
Tel: (866) 876 – 3340
Fax: (978) 934 – 9499
IONPURE® and NEXED™ are trademarks of Evoqua and its subsidiaries or
affiliates in some countries. MODBUS® is a registered trademark of Schneider
Electric, USA, Inc. All other Trademarks are those of their respective owners.
558 Clark Road
www.ionpure.com
IONPURE
DC3
Power Controller
600 VDC
15 Amps
with isolation
Operation
&
Maintenance
Manual
IP-MAN-DC3-1019-EN
Revision 2
October 2019
Manual Covers Model #:
IP-DC3PH600V-M1
(W2T827150)
IP-PB600V45A-1
(W2T847507)
®

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Summary of Contents for IONPURE DC3

  • Page 1 Fax: (978) 934 – 9499 www.ionpure.com IONPURE® and NEXED™ are trademarks of Evoqua and its subsidiaries or affiliates in some countries. MODBUS® is a registered trademark of Schneider Electric, USA, Inc. All other Trademarks are those of their respective owners.

  • Page 2: Table Of Contents

    COMPLIANCE ..........................5 INTRODUCTION ........................7 1.1 Caution and Warning Messages ................... 7 1.2 General Description ......................7 1.3 DC3 Connection and Configuration Points ................9 INSTALLATION ........................10 2.1 Environment ........................10 2.2 Mounting Considerations ....................11 2.3 AC Supply .......................... 12 2.4 Over-Current Protection......................
  • Page 3 MODBUS TCP FIELDBUS INTERFACE AND PARAMETER LIST ..... 36 LIST OF TABLES Table A1: Maximum Required DC Volts, Amps for one Power Controller (IONPURE CEDI) ..26 Table A2: Maximum Required DC Volts, Amps for one Power Controller (NEXED EDR) ....27 LIST OF FIGURES Figure B1: Full-Scale Dimensional Drawing for IP-3PH600V-M1............

  • Page 4: Disclaimer Statement

    IONPURE. The client shall have the right to use and disclose to its employees the information contained herein for the purpose of operating and maintaining the IONPURE equipment, and for no other purpose.

  • Page 5: Compliance

    2014/30/EU – Electromagnetic compatibility 2014/35/EU – Electrical equipment designed for use within certain voltage limits IP 20 See EU Declaration of Conformity Part 15 Subpart B Class A Device See Certificate of Conformance IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 5 of 61...
  • Page 6 Rahoul Bhagat, Quality Assurance and Document Control Documentation for the above component can be found on www.ionpure.com. Should you need further assistance, please e-mail ionpure@evoqua.com. We value you as a customer and will accommodate you in whatever way to provide total satisfaction.

  • Page 7: Introduction

    (Ohm’s Law: I = V / R) The DC3 accepts a nominal input voltage of three-phase 380 VAC – 480 VAC (45 – 65 Hz), has a maximum output voltage of 600 Volts DC, and a maximum full frame current rating of 15 Amps DC.
  • Page 8 This feature allows the use of remote instrumentation, such as a flow switch, for turning off controller output. The DC3 Power Controller is a component of the DC power supply used with Ionpure’s CEDI modules. A complete DC power supply must include all of the following: ·...

  • Page 9: Dc3 Connection And Configuration Points

    1.3 DC3 Connection and Configuration Points Front ► ◄ Bottom Label Name Description Command Connections 24 VDC Input, Analog Input, Run/Stop signals, and (P1 connector) Analog Retransmits Relay Connections Two Form C relay connections, one for Run Status, (P2 Connector)

  • Page 10: Installation

    The DC3 Power Controller is intended for mounting on a sub-panel inside an enclosure. The overall dimensions of IP-DC3PH600V-M1 are (also see full-size drawing in Appendix B): ·...

  • Page 11: Mounting Considerations

    · Installing an air conditioning unit. · Using vortex cooling. The maximum heat generated by each DC3 is approximately 450 watts at full power output (9 kW). Additional heat generation may be contributed by other equipment in the enclosure. 2.2 Mounting Considerations Mount the power controllers vertically.

  • Page 12: Ac Supply

    2.3 AC Supply The DC3 accepts a nominal input voltage of three-phase 380 VAC – 480 VAC (45 – 65 Hz) and draws a current of 20 amps at full load. Electrical schematics for typical installations are shown in Figures B.2 and B.3 in Appendix B.

  • Page 13: Wiring

    The AC voltage supplied to the power controller should be three-phase, can range from 380 VAC to 480 VAC, and must provide 20 amps at full load. The DC3 can accept wye or delta. The DC3 tolerates input voltage variations of 15% +10% of the nominal values of 380 –...

  • Page 14: Low Voltage Connections

    · Keep cable length as short as possible. · Keep signal wires as far away as possible from AC wires and rapidly switched DC wires. Place them in separate wire trays or ducts. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 14 of 61...
  • Page 15 3.2.3 24 VDC Input (P1-1, P1-2) A separate 24 VDC power source with a minimum of 44 watts (1.84 amps) per DC3 is required to supply the fans and control electronics and to maintain critical communications to your control system when the mains are absent.
  • Page 16 The output alarm relay provides a relay signal that indicates an alarm. This signal can be used for remote status indication (e.g. alarm light). Connections are P2-6 (N.O), P2-7 (Common) and P2-8 (N.C). IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 16 of 61...
  • Page 17 Maximum switching current 3.2.11 Torque Specifications for Low Voltage Connections Recommended Tightening Torque for P1/P2 Connectors Number of wires Wire Size (AWG) Torque 16 – 26 0.34 Nm (3.0 IN-LBS) 0.34 Nm (3.0 IN-LBS) IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 17 of 61...

  • Page 18: Selector Switches

    Constant power mode The default current setting is Constant Current mode at 13.2 Amps (OFF-OFF-ON-OFF-OFF). Refer to Table A1 in Appendix A for correct current range settings (from column “Maximum Required DC Amps”). IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 18 of 61...
  • Page 19 192.168.0.114 192.168.0.115 To connect more than 16 DC3 units in a single daisy chain, it is necessary to use the Ionpure Power Panel software (Communications page) to reconfigure the base IP address of some of the units. For example, if DC3 units 17 to 32 are given the base IP address of 192.168.0.116, then setting the rotary switch would assign IP addresses from 192.168.0.116 to 192.168.0.131.

  • Page 20: Usb

    4 USB 4.1 USB Interface and Power Panel Software A micro-USB interface is standard on all power controllers for connecting the controller to the Ionpure Power Panel software application (available for registered users on Ionpure.com). This PC-based utility software assists with the installation, parameter setup, operation and troubleshooting of Ionpure DC3 and DCR power controllers.

  • Page 21: Operation

    Adjust the flow rates through the module of the dilute and concentrate streams. · Slowly increase the DC output current to the value calculated by the Ionpure/Nexed Projection Program. In constant current mode, the power controller will maintain the current at that setting if the required voltage to drive the current is lower than the maximum DC voltage available.

  • Page 22: Indicator Leds

    6 INDICATOR LEDS Troubleshooting should be performed by qualified personnel only. Safety procedures should be reviewed prior to working with the DC3 Power Controller. The power controller status can be determined by looking at the LEDs on the front of the power controller.

  • Page 23: Troubleshooting

    7.3 Warning Alarms (Displayed in Power Panel Software) – do not latch The alarm code is represented by two numbers, separated by a dash. Warning alarms are in the second position. They do not prevent DC output. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 23 of 61...

  • Page 24: Alarm Reset Methods

    7.3.7 DC Output Short-Circuit / Shorted Load (warning code 64) 7.4 Alarm Reset Methods 7.4.1 Cycle 24 VDC control power off / on. 7.4.2 Reset button (switch) on bottom of DC3 next to micro USB port (see 1.3). 7.4.3 From Power Panel Software, drop-down box.

  • Page 25: Appendix Adesign Considerations

    DC output. · Power to the CEDI module must be enabled / disabled using the remote on / off input of the power controller, as described in Section 3.2.6. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 25 of 61...

  • Page 26: Table A1: Maximum Required Dc Volts, Amps For One Power Controller (Ionpure Cedi)

    VNX55HH VNX-Max VNX-Mini MX30 MX60 MX125 MX250 MX500 * For feed hardness of 1.0-2.0 ppm as CaCO Table A1 has been updated according to Ionpure Technical Bulletin IPTB-2018-02 Changes in DC Voltage Requirements. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 26 of 61...

  • Page 27: Table A2: Maximum Required Dc Volts, Amps For One Power Controller (Nexed Edr)

    Table A2: DC Volts and Amps Required for One NEXED EDR Module Module Type (ED) Maximum Required DC Maximum Required DC Volts Amps NEXED3 NEXED6 NEXED12 IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 27 of 61...

  • Page 28: Appendix Bengineering Documents And Drawings

    · Figure B1: Full-scale dimensional drawing for IP-DC3PH600V-M1 · Figure B2: Electrical schematic of a typical single-module installation · Figure B3: Electrical schematic of a typical multi-module installation · Figure B4: DC3 Electrical connections IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 28 of 61...

  • Page 29: Figure B1: Full-Scale Dimensional Drawing For Ip-3Ph600V-M1

    Figure B1: Full-Scale Dimensional Drawing for IP-3PH600V-M1 IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 29 of 61...
  • Page 30 Figure B2: Electrical Schematic of a Typical Single-Module Installation IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 30 of 61...
  • Page 31 Figure B3: Electrical Schematic of a Typical Multi-Module Installation IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 31 of 61...

  • Page 32: Figure B4: Electrical Connections

    Figure B4: DC3 Electrical Connections IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 32 of 61...

  • Page 33: Appendix Cparalleling Accessory

    (3) DC3 Power Controllers to one module. The Parallel Board allows for a power throughput of up to 15 amps per DC3 Power Controller for a combined load of 45 Amps at 600 VDC.

  • Page 34: Mounting Dimensions And Considerations

    76.2 mm (3.00 in.) free from obstructions as measured from the edge of the base. Dimensions above are measured from the edge of the base. Figure 1: Mounting Dimensions for IP-PB600V45A-1 Figure 2: Mounting Considerations for IP-PB600V45A-1 IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 34 of 61...

  • Page 35: Wiring

    2.70 Nm (24 IN-LBS) C.5 Connections Connect the DC+ output of each DC3 Power Controller to A1, B1, and/or C1 input of the Parallel Board. The DC+ output (labelled +) connects to the positive terminal of the load (module). The DC- output of each DC3 is connected to the DC- of the load.

  • Page 36: Appendix Dmodbus Tcp Fieldbus Interface And Parameter List

    APPENDIX D MODBUS TCP FIELDBUS INTERFACE AND PARAMETER LIST The DC3 is the Modbus TCP server. The client would be the PLC or computer. The destination port used for Modbus TCP is 502, the source port is random assigned/used by the client.
  • Page 37 DIP switch during initialization following power-up or reset. This value is also used to scale the Meter analog output signal for the Meter output used to represent Load Current (Default for Meter output 1). IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 37 of 61...
  • Page 38 The value set for current limit is 110% of the Full Scale current value. Power Limit Units: Watts Minimum: Maximum: 10500 Default: 9000 Power Limit sets the absolute maximum output power allowed by the controller. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 38 of 61...
  • Page 39 BIT 0 = Relay 1 Alarm mask determines the alarm events that will energize the on-board relay. When a bit is set to 1 and the corresponding event occurs the relay will energize. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 39 of 61...
  • Page 40 This parameter sets the number of times the controller will retry after an over-current trip event. The controller will latch into fault state after attempting the number of retries set by this parameter. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 40 of 61...
  • Page 41 This is the Input Voltage low threshold. If the input voltage drops to this threshold the controller output immediately shuts down. When the input voltage rises above this threshold the output will turn back ON after ½ second. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 41 of 61...
  • Page 42 Relay 1 System Alarm mask determines the system events that will energize the on-board relay. When a bit is set to 1 and the corresponding event occurs the relay will energize. (Relay 1 is by default the “Output ON” relay) IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 42 of 61...
  • Page 43 Set to voltage if the signal is 0 to 10 volts. Set to current if the signal is 0 to 20 ma. NOTE: This PCB supports only a current input signal, therefore this value should remain set for Current. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 43 of 61...
  • Page 44 Maximum: 125.00 Default: 100.00 This sets the commanded percent, of the Full Scale feedback value for the Feedback Type selected, that corresponds to the signal level set by SP-93 Analog Input Hi Command. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 44 of 61...
  • Page 45 Default: 2 Selections: Analog Input Digital Setpoint 1 Digital Setpoint 2 This determines the setpoint that the control loop will use when SP-104 Control Setpoint Select is set to 2 = Setpoint 2 source. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 45 of 61...
  • Page 46 Communications Heartbeat Time sets the interval, in seconds, that the controller will wait for a Modbus TCP message packet before indicating communication timeout, and executing the selected Timeout Action set by SP-128. NOTE: A value of 0 seconds disables the Heartbeat timer, therefore no timeout will occur. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 46 of 61...
  • Page 47 When this parameter is set to 2 the controller will use the Network Timeout Setpoint (SP-108) immediately after a timeout occurs, until the timeout is cleared by the reception of another Modbus TCP packet. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 47 of 61...
  • Page 48 Meter 1 Output Type sets the type of signal generated by the controller for the Meter 1 Output (P2-1 P2-2). The signal is scaled with SP-142 through SP-145. NOTE: Only Current (0 to 20 ma) is available on this PCB IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 48 of 61...
  • Page 49 This sets the value, in percent of the Full Scale, corresponding to the selection for SP-141 Meter 1 Signal Select that generates the output signal set by SP-145 Meter 1 Signal Hi Output. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 49 of 61...
  • Page 50 NOTE: Only Current (0 to 20 ma) is available on this PCB Meter 2 Signal Select Units: N/A Minimum: Maximum: Default: 1 Selections: Load Voltage Load Current Load Power Load Resistance Direct Out (SP-153) This determines what the Meter 2 Output signal represents. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 50 of 61...
  • Page 51 Meter 2 Out Direct Units: V, ma Minimum: 0.00 Maximum: 20.00 Default: 0.00 Use this parameter to set the Meter output signal level when SP-148 Meter 2 Signal Select is set to 5 = Direct out. IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 51 of 61...
  • Page 52 Analog Input Units: %, Based on Full Scale Values Representation: SXXX.XX Analog Input Command Value Units: Amps or Volts (corresponding to Feedback type selected) Representation: SXXX.X Analog Input Signal Units: V, ma Representation: SXX.XX IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 52 of 61...
  • Page 53 Transformer Over Temperature Input Voltage Low Input Voltage High Output Voltage High Heatsink Over Temperature Over Current Trip (PWM Fault output over current) Over Current Trip (PWM Fault input over current) not used IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 53 of 61...
  • Page 54 000000000 = 0 Maximum: 111111111 = 511 Representation: 0 = open/not-active, 1 = closed/active Inductor Fan is ON not used not used Relay 2 Relay 1 not used not used GP I/O Run/Stop-Reset IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 54 of 61...
  • Page 55 Load Current DIP Switch Selection (live) Units: Amps Representation: XX.X Input Voltage Units: Volts Representation: SXXX.X Load Voltage Units: Volts Representation: SXXX.X Load Current Units: Amps Representation: SXX.X Load Resistance Units: Ohms Representation: XXX.XX IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 55 of 61...
  • Page 56 FAULT RESET Output Command Units: % Representation: XX.X Command Reference (HI word) Command Reference (LO word) Units: Volts, Amps, Watts Representation: XXXXX.X Feedback (HI word) Feedback (LO word) Units: Volts, Amps, Watts Representation: SXXXXX.X IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 56 of 61...
  • Page 57 Representation: XX The value set by the rotary switch on the PCB IP Address (HI word) IP Address (LO word) Units: N/A Representation: XXXXXXXXXX (4 bytes = XXX.XXX.XXX.XXX) Example: 3232235620 = C0A80064 = 192.168.0.100 IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 57 of 61...
  • Page 58 Live Calibration bits in (LO word) Units: ADC Bits Representation: XXXXXXXXXX Firmware ID Units: N/A Minimum: Maximum: 32767 Firmware Version Units: N/A Representation: XX.XX ** Full with MP-333 Minor Revision appended ** Minimum: 0.00.01 Maximum: 99.99.99 IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 58 of 61...
  • Page 59 Trace is ON, Collecting data not used Trace is Enabled, waiting for trigger Waiting for the Enter Key during Initialization USER Unlock, Access Code successfully entered not used MFG Unlock, Access Code successfully entered IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 59 of 61...
  • Page 60 MFG SP V-Table checksum Failure User SP V-Table checksum Failure Blank, Initialization Required Read/Write Failure Firmware Update Code Units: N/A Representation: XXXXX Network Heartbeat timer Units: Seconds Representation: XXXXX Bootloader Version Units: N/A Representation: XX.XX IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 60 of 61...
  • Page 61 IP-MAN-DC3-1019-EN.pdf (REV. 2) Page 61 of 61...

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