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g2 Display Manuel
g2 Display Manuel
G2 DISPLAY
BOARD
Operation
&
Maintenance
Manual
IP-POWERDSP-G2MAN
November 2011
Revision 1
IP-POWERDSP-G2
10 Technology Drive
Lowell, Massachusetts 01851
Tel: (866) 876-3340 Fax: 978-934-9499
www.ionpure.com
IONPURE ® G2 DISPLAY BOARD – IP-POWERDSP-G2
Table of Contents
1 INTRODUCTION ............................................................................................................................. 5
1.1 Caution and Warning Messages ................................................................................................ 5
1.2 General Description ................................................................................................................... 5
2 INSTALLATION............................................................................................................................... 7
2.1 Requirements............................................................................................................................. 7
2.2 Panel Mount ............................................................................................................................... 8
2.3 Connections ............................................................................................................................... 8
2.3.1 Connections to a Single G2 Power Controller....................................................................... 8
2.3.2 Connections to Multiple G2 Power Controllers ..................................................................... 9
2.4 Power Controller Setup ............................................................................................................ 10
2.4.1 DC Output Current Range Selection .................................................................................. 10
2.4.2 Unit ID Selection................................................................................................................. 11
3 OPERATION.................................................................................................................................. 12
3.1 Control/Navigation Keys........................................................................................................... 12
3.2 Menu Structure......................................................................................................................... 13
5 TROUBLESHOOTING................................................................................................................... 24
List of Figures
List of Tables
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. Should questions arise
which are not answered specifically in this manual, contact your equipment supplier.
Siemens reserves the right to make engineering refinements that may not be reflected in this manual.
The material in this manual is for informational purposes and is subject to change without notice.
In the event the content of this manual is altered or section/items are omitted during reproduction, in
whole or in part, and instructions or definitions within the reproduction result in personal injury to those
who follow the altered instructions, the burden of responsibility for personal injury falls solely on the
party who effects the reproduction.
1 Introduction
Notes are also used to draw attention to information. Notes may be located before or after the
related text.
NOTE: Notes are used to add information, state exceptions, and point out areas that may be of
greater interest or importance.
The display board employs a 20 X 4 LCD backlit display for a clear view of data under most lighting
conditions. Parameters can be adjusted and screens can be navigated using the four membrane
switches on the front panel. Once the parameters have been configured, the setup menu may be
locked out to require a four-digit password for further modifications.
One of the two RJ-45 ports available on the back of the unit is used for connection with the G2
power controller utilizing a Cat 6 cable, Ionpure part numbers IP-CABLE50CM-G2 or IP-
CABLE2M-G2. One display board can independently operate up to sixteen G2 power controllers
when they are linked together in a daisy chain. No external power supply is required with the
G2 display board.
2 Installation
2.1 Requirements
The G2 Display Board meets NEMA 4/IP65 requirements when properly installed. The unit is
intended to be mounted into an enclosed panel with the supplied gasket to provide a seal at the
panel cutout and it is secured from the back with the provided nuts.
Consider the display’s dimensions shown in Figure 2 to select the proper size for the panel.
a. Prepare a cutout and four mounting holes in the door of the panel as shown in Figure 3. All
cutouts should be clean and free of burrs.
b. Install the display board on the door of the enclosure using the supplied hardware and
gasket.
2.3 Connections
a. Connect one end of a standard Cat 6 cable to one of the two RJ45 ports on the back
of the display.
b. Connect the other end of the cable to one of the two RJ45 ports on the G2 power
controller.
c. Once the power controller is turned on, the display should power on.
a. Connect one end of a standard Cat 6 cable to one of the two RJ45 ports on the back
of the display.
b. Connect the other end of the cable to one of the two RJ45 ports on the first G2
power controller.
d. Once any of the power controllers is turned on, the display should power on.
The G2 display will detect the selected current range upon startup and will limit the DC output
current setpoint (A DC out) to this range.
0 1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 9
9 10
A 11
B 12
C 13
D 14
E 15
F 16
If two or more power controllers are mistakenly set to the same SW2 position, the G2 display
will show “ADDRESS CONFLICT” for that channel.
3 Operation
ESC: press to exit a submenu, deactivate the cursor or discard setpoint changes.
UP: press to see the previous page of information or select between submenus or
configurable setpoints. When adjusting a setpoint, press to increase the value. Hold to
increase the value at a higher speed.
DOWN: press to see the previous page of information or select between submenus or
configurable setpoints. When adjusting a setpoint, press to decrease the value. Hold to
decrease the value at a higher speed.
ENTER: press to activate the cursor to select submenus or configurable setpoints. Press
again to enter the selected submenu or to accept setpoint changes.
OVERVIEW: this is the startup screen. It displays 3 channels at a time and shows the CEDI
module’s identification number (selected on the G2 Power Controller via switch SW2), DC
output volts, DC output current and module resistance in ohms. Unused channels are
represented with a line of asterisks (*). Resistance values above 999.9 are represented with
“***HI”. When the DC output current is zero, resistance will be represented with “----“ to
indicate that resistance can not be measured.
Channels 1, 2 and 3 are displayed upon startup of the unit. Pressing the UP or DOWN arrows
will scroll through all 16 channels.
A blinking module number indicates where the cursor is. Pressing the ENTER key will access
the RUN submenu of the CEDI module selected with the cursor.
A blinking row indicates and alarm condition for a specific power controller. The alarm type
can be identified under the ALARMS submenu.
RUN: this submenu provides operational data and access to adjust the DC output current of
the selected power controller, as well as access to submenus SETUP, ALARMS, LOGS and
DIAGNOSTICS.
PAGE 1:
V DC out: actual DC output voltage from the power controller to the selected
CEDI module.
A DC out: setpoint for the DC output current from the power controller to the
selected CEDI module. Press the ENTER key to adjust this value using the UP
or DOWN keys. Press ENTER again once the desired value has been set. This
setpoint can not be set to a value outside the current range selected in the power
controller via DIP switch SW1.
Ohms pres: actual resistance in ohms of the selected CEDI module. Resistance
values above 999.9 are represented with “***HI”. When the DC output current is
zero, resistance will be represented with “----“ to indicate that resistance can not
be measured.
Ohms init: initial resistance in ohms of the selected CEDI module. This value is
captured when the power controller has operated continuously for 2 hours after
PAGE 2:
V AC in: actual AC input voltage to the selected power controller. If this value is
higher than 726 VAC, a high AC input alarm will trigger.
PAGE 3:
Op.hours: hours in operation since the initial startup. Time is accrued only while
the Remote ON/OFF input of the power controller is closed.
PAGE 4:
Press ENTER to activate the cursor and use the UP or DOWN arrows to select
any of the following submenus: SETUP, ALARMS or LOGS. Press ENTER
again to access the selected option.
PAGE 5:
SETUP: this submenu provides access to adjust the following settings: Ohms limit, VDC limit,
Ext control, Change password? and Change module?
This submenu is protected by a 4-digit password. The factory default password is 0000 and it
can be changed by the user.
PAGE 1:
Ohms limit: the default and maximum setpoint is 996 ohms. When set correctly,
this value will alert the operator of a possible issue with the CEDI module due to
scaling, fouling or any other issue that could cause an abnormal increase in the
resistance of the module. This value should be adjusted to match a module’s
high resistance limit as follows: once the module has come to steady state
(typically after about 48 hours of actual operating time), set the Ohms limit to 1.5
times the steady-state electrical resistance. This is higher than the
recommendation in the EDI manual (25%) for resistance change to allow for
temperature fluctuations.
VDC limit: the default and maximum setpoint is 600 Volts. This voltage setting
will limit the actual DC output voltage of the power controller. It is recommended
that this number be set at the “Maximum Required DC Volts” value for the
specific CEDI module, as described in Table 3 of the G2 Power Controller
manual. If the actual DC voltage reaches the setpoint, a high DC voltage alarm
will trigger.
Ext control: the default setting is “No”. Changing this setting to “Yes” disables
the DC output current control capabilities of the display board so an analog
device can be used to control the DC output current of the power controller with
a 0-5 VDC signal at terminals Ic+/Ic-.
Change password?: press ENTER and use the UP/DOWN keys to change the
password of the SETUP submenu.
PAGE 2:
Change module?: it is recommended to use this option to reset all historic data
after a module replacement. Pressing ENTER will reset the following:
ALARMS: this submenu displays the status of alarms and provides the option to clear them.
PAGE 1:
Clear alarms?: if any alarms are active, pressing ENTER on this page will
activate the cursor to change the “N” to “Y” using the UP or DOWN arrows.
Pressing ENTER once “Y” is selected will clear all alarms that are active (not
“ok”).
Input VAC: reports the level status of the actual AC input voltage to the power
controller. The alarm will be “ok” if the input voltage is lower than 726 VAC; it will
be “hi” if it exceeds this value.
Output VDC: reports the level status of the actual DC output voltage from the
power controller. The alarm will be “ok” if the output voltage is lower than the
value set for VDC limit in the SETUP submenu; it will be “hi” if it exceeds this
value.
Resistance: reports the level status of the actual resistance of the CEDI module.
The alarm will be “ok” if the resistance is lower than the value set for Ohms limit
in the SETUP submenu; it will be “hi” if it exceeds this value.
PAGE 2:
Board temp: reports the level status of the actual temperature of the power
controller’s heatsink. The alarm will be “ok” if the temperature is lower than
64±4oC, and it will be “hi” if it exceeds this value.
Unit status: reports the status of the power controller’s power stage and
temperature sensor. The alarm will be “ok” if no issues are found, and it will be
“fail” otherwise.
LOGS: this submenu provides access to historical data recorded in the power controller. Data
is grouped in three logs: MAX VALUES, MIN VALUES and MODULE OHMS&S.
Press ENTER to activate the cursor and use the UP or DOWN arrows to select any of the
data logs. Press ENTER again to access the selected log.
VDC: maximum registered DC output volts from the selected power controller to
the CEDI module.
ADC: maximum registered DC amps from the selected power controller to the
CEDI module.
VDC: minimum registered DC output volts from the selected power controller to
the CEDI module.
ADC: minimum registered DC amps from the selected power controller to the
CEDI module.
DIAGNOSTICS: this submenu provides the firmware revisions of the selected power
controller, the display and the results of the power controller’s self test routine.
Self test: a G2 power controller monitors continuously the status of its power stage and
temperature sensor. The G2 display board reports in this screen the status of these
components using the following codes:
If the self test routine outputs error codes ERR1 or ERR2, the “Unit status” alarm will
trigger. In this case, contact your Ionpure products supplier for assistance.
4 Getting Started
The following startup procedure is only an example for a typical single module CEDI system:
1. Close the main disconnect switch (or circuit breaker) for the CEDI system.
2. Open the appropriate valves and start the pretreatment equipment, such as the reverse
osmosis (RO) system, upstream of the CEDI system.
3. Adjust the flow rates of the dilute and concentrate streams through the module.
4. For each operating channel on the G2 display, enter the RUN submenu and adjust “A
DC out” to set the DC output current to the value calculated by the Ionpure Performance
Projection Program (Current Startup Calculator). 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.
5. Verify that the DC output is removed when the CEDI module flow is interrupted.
5 Troubleshooting
Table 2: Troubleshooting
UL (US/CANADA)
The G2 display board was evaluated as an accessory of the G2 power controller. Both are recognized
by UL through compliance with the following standards:
• UL 61010-1 (Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use; Part 1: General Requirements)
• CAN/CSA-C22.2 No. 61010-1 (Safety Requirements for Electrical Equipment for Measurement,
Control, and Laboratory Use; Part 1: General Requirements)
The G2 display board was evaluated as an accessory of the G2 power controller. Both meet the
Electromagnetic Compatibility (EMC) Directive 2004/108/EC and the Low Voltage Directive (LVD)
2006/95/EC through compliance with the following standards:
Used with:
10A (1Ø) DC
Power
Controllers
Operation
&
Maintenance
Manual
IP-MAN-SNUB Rev 1
October 2008
IP-SNUBCIRC-1PH
IP-SNUBCIRC-3PH
10 Technology Drive
Lowell, Massachusetts 01851
Tel: (866) 876-3340 Fax: 978-934-9499
www.ionpure.com
IONPURE® SNUBBER CIRCUIT BOARD
TABLE OF CONTENTS
INSTALLATION .......................................................................................................................................... 7
IONPURE reserves the right to make engineering refinements that may not be reflected in these
manuals. The material in these manuals is for informational purposes and is subject to change without
notice.
In the event the content of this manual is altered or section/items are omitted during a reproduction, in
whole or in part, and instructions or definitions within the reproduction result in personal injury to those
who follow the altered instructions, the burden of responsibility for personal injury falls solely on the party
who effects the reproduction.
Notes, Warnings, Cautions are used to attract attention to essential or critical information in a manual.
Warnings and Cautions will appear before the text associated with them, and notes can appear either
before or after associated text.
NOTE: Notes are used to add information, state exceptions, and point out areas that may be of
greater interest or importance.
IONPURE continually strives to provide safe, efficient, trouble-free equipment using the optimum
technology for your application. If problems should develop, IONPURE's worldwide network of technical
support will be available to provide assistance. For service, sales, parts, or additional manual copies,
please visit the website: www.ionpure.com.
The recommended design of a CEDI power supply includes an AC contactor to switch the AC input to
Power Controller. The contactor coil is energized when there is water flow through the CEDI module(s).
Possible locations for the contactor are on the primary or the secondary side of the isolation transformer.
When a contactor installed on the primary side closes, there is an inrush current through the primary
windings of the transformer as its core is energized. Mechanical chattering or bouncing of the contacts in
the contactor interrupts the inrush current and results in arcs and voltage spikes across the contacts. The
voltage spikes are transmitted to the secondary windings through magnetic coupling, which could cause
damage to the Power Controller. Ionpure Service Bulletin 2003-02 discusses this issue and recommends
two possible solutions:
FIGURE 2. TYPICAL POWER SUPPLY WITH CONTACTOR AT THE SECONDARY OF THE ISOLATION TRANSFORMER
The SCR’s used on the single-phase power controller boards are rated for a maximum peak voltage of
1,200 volts. Figure 4 shows that moving the contactor to the secondary alone may not be sufficient if the
transformer secondary voltage is set to 660 VAC. In such cases, the addition of a voltage snubber is
recommended.
1800
1600
Peak Spike Voltage at Secondary (V)
1400
1200
Contactor Location:
1000 Primary (No Snubber)
Primary (With Snubber)
800 Secondary (No Snubber)
600
400
200
0
330 440 660
Transformer Secondary RMS Voltage (VAC)
A voltage snubber consists of a resistor in series with a capacitor. This combination is used to suppress
voltage spikes that can damage the Power Controller. The snubber should be installed downstream of
the contactor that will switch AC power to the Power Controller(s). The location of the contactor (see
Figures 2 and 3) will determine the type of snubber to use (single-phase or three-phase) as shown in
Figures 5 and 6.
CONTACTOR
AC LINE FROM
TO POWER
ISOLATION
CONTROLLER
TRANSFORMER
C1
C1 is a 1.0 µF, 600 VAC capacitor.
R1 is a 20 ohm, 25 watt, 550 VAC resistor.
R1
CONTACTOR
L1
TO
L2 ISOLATION
TRANSFORMER
L3
C1
R1
C3
C1, C2 and C3 are 1.0 µF, 600 VAC capacitors.
R1, R2 and R3 are 20 ohm, 25 watt, 550 VAC resistors.
C2
R3
R2
INSTALLATION
IP-SNUBCIRC-1PH
Connect the 2 wires coming from the transformer secondary (T1 and T2) through the contactor, to the
voltage snubber as shown in Figure 4 and Picture 1.
T1
T2
Connect the 3 wires coming from the transformer primary (L1, L2 and L3) through the contactor, to the
voltage snubber as shown in Figure 5 and Picture 2.
L1
L2
L3
Capacitor: GE snubber capacitor, catalog # A28F5604, 1 µF, 2000 volts peak, 12 amps, ±10%
tolerance, height 4.50", case style A.
Resistor: Vishay-Dale wirewound resistor, aluminum housed, chassis mount, Model RH-25, 25 watt,
20 ohm. Meets MIL-PRF-18546.
IONPURE® For more information IONPURE is a registered trademark of Siemens. Siemens reserves the right to change the
about IONPURE Products, call the specifications referred to in this literature at any time, without prior notice.
local Ionpure center:
North America: 866-876-3340
Europe: (+44) 190-851-1307
Pacific (ex. China): +886-930-432-111
China: (+86) 21-58824988-2561
http://www.ionpure.com