VNX SYSTEM TEST

& CHECKOUT
PROCEDURE

600VDC 50 - 300
GPM SYSTEMS

IP-VNX600-20-TEST
REV - C
March 2006

Procedure Covers:

TEST OF 600VDC/ 20 AMP

CONTROLLERS W/ 50 GPM SYSTEMS
TO 600VDC / 120 AMP CONTROLLERS
W/ 300 GMP SYSTEMS

IP-VNX600-20-TEST REV C
 Table of Contents

Section 1 Introduction Page

1.1 Caution and Warning Messages 1-1

1.2 General Warning Statements 1-1

Section 2 Pre-test Set-up 2-1

Section 3 Power on Tests 3-1

Section 4 Pre-Shipment Checks 4-1

IP-VNX600-20-TEST REV C i
 Section 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 will appear next to the messages associated with
them.

Warnings indicate condition, practices, or procedures that must be

observed to avoid personal injury or fatalities.

Cautions indicate a situation that may cause damage or destruction

of equipment or may pose a long-term health hazard.

1.2 General Warning Statements

UP TO 600 VOLTS AC/DC IS PRESENT WITHIN THE POWER SUPPLY

ASSEMBLY.
THE ENCLOSURES SHOULD ONLY BE OPENED BY QUALIFIED ELECTRICAL
PERSONNEL
DO NOT MAKE LOAD CONNECTIONS WHEN POWER IS APPLIED.
USE EXTREME CAUTION WHEN OPENING THE TRANSFORMER ENCLOSURE.
THE MAIN DISCONNECT SWITCH IN THE POWER SUPPLY ENCLOSURE MUST
BE OFF.

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 Section 2 Pre-test Setup

1. For systems with the multi-channel display (not

the 50 GPM): Set the switches on the back of
the display unit to the number of modules in the
system. See the switch setting legend
silkscreened on the back of the display unit.

2. Remove the power control covers and set JP1 to IFB for current feedback, or VFB for
voltage feedback per the system order. If not specified, set to IFB. See below:

JP1

3. Connect an appropriate resistive DC load to the system. One load per Module, maximum of
20 amps at 600 VDC per module, minimum of 4 amps DC per module.
4. Connect an oscilloscope to Module 1 load bank. Prepare the scope with the probe isolator to
read up to 600 VDC.

IP-VNX600-20-TEST REV C 2-1

5. Wire the transformer to TB2 and TB3 per the appropriate VNX wiring diagram.

6. Ohm out the transformer secondaries, do this on

the TB3 terminal strip: Check for an open
circuit between 1X1, 2X1, 3X1 etc. up to the
number of secondaries (and modules) for the
system. Check for continuity between 1X1 and
1X2, and again 1X2 and 1X3. In a similar
fashion check the other secondaries.

7. Wire 110T to 480 VAC, or 415 VAC connections based on order (transformer order).
Tighten all other terminals of 110T.
8. Connect an On/Off test switch to TB1 pins 1 & 2. In a similar fashion connect On/Off test
switches to TB1 pins 3 & 4, and TB1 pins 5 & 6. Set the switches in the OFF position at this
time.
9. Visually check for the following: A) All fuses installed and proper value. B) Connectors
inserted properly. C) All wiring completed. D) Grounding strap between cabinet door and
main cabinet. E) Any other items out of place.
10. Open the 107/108/113FU multi-fuse block
11. Set all Module On/Off switches to OFF. Pull out the E-Stop (no e-stop) button if in.
12. Connect 380, 415 or 480 VAC power to the system, based on order. Leave off at this time.

IP-VNX600-20-TEST REV C 2-2

 Section 3 Power on Tests

1. Verify proper line voltage at the top of the 103FDS disconnect switch.
2. Turn on the disconnect switch. The large transformer will start to hum.
3. Verify proper voltages from the transformer on TB3: TB3 pins 1, 2, and 3 have line voltage
applied. TB3 pins 4, 5, and 6 will have 468 VAC (445 for original orders) on each phase.
Verify all 3 phases for the correct voltage. Check the other transformer secondaries as
appropriate (TB3 pins 7, 8, and 9 etc.).

Check the voltage between TB3 pin 4 to pin 7, 5 to 8, 6 to 9, 7 to 10, 8 to 11, 9 to 12 in this
fashion for all transformer secondaries. The voltage here should be low, 30 volts or less. If
any voltage is higher near line voltage, then a phase is swapped. This test is possible due to
the high impedance of your meter vs. the somewhat lower impedance of the transformer.
4. Close the 107/108/113FU multi-fuse block. The Fans of the control and transformer
enclosures should start spinning. Measure the secondary voltage of 110T, X1 to X3 for 120
VAC. NOTE: Measure on terminals X1 to X4 for 380 VAC wired systems.
5. Temporarily remove the Thermostat wire on TB2 pin 3. Dont let the wire short to
anything. Press the Start pushbutton. Nothing should happen no relays pull in or button
illumination. Carefully reconnect this wire. Keep in mind that you have power on the
system (there should be no power on this wire).
6. Press the Start pushbutton: A) Verify the DC on lights of the 24 VDC power supplies
illuminate. B) Verify the 24 V LED of the DC power controllers illuminate. C) Verify the
front panel display unit illuminates. D) Measure the DC output of each 24 VDC power
supply. Verify 24 VDC +/- 0.05 VDC. Adjust as necessary.

50 GPM SYSTEM NOTE: 127PS is a 12 VDC power supply

on the 50 GPM, 20 Amp single channel system. This is an
exception to the paragraph above.
7. Press the E-Stop button. The power supplies should turn off,
the display unit goes blank etc. Pull back out the E-Stop and
press the Start pushbutton again.
8. Turn on the Module 1 switch. Nothing should happen yet.
Turn on the RO switch - the switch connected to TB1 pins 1 &
2. The following should happen: A) The light on the Module
1 switch should illuminate. B) 202 contactor should pull in. C)
Verify phase A, B, & C LEDs on the 250 SCR power controller
illuminate. D) The phase rotation LED on this power controller
should illuminate.

50 GPM SYSTEM NOTE: The 50 GPM 20 amp single channel system requires you to turn
on the Flow switches (mentioned in step below) at this time for the 202 contactor to pull in.

IP-VNX600-20-TEST REV C 3-1

 Also verify when done so the Standby indicator on the single channel display unit goes
from Standby to On when the contactor pulls in.
9. Turn on the Flow switches the switches connected to TB1 pins 3 & 4, and TB1 pins 5 &
6. Verify the Disabled indicator on the multi-channel display unit goes from Disabled to
Enabled. Verify if either flow switch is turned off, the display unit indicates Disabled.
Leave the flow switches on.
10. Select channel 1 on the multi-channel display unit. Slowly increase the power level from
minimum to maximum. Observe proper SCR firing on the oscilloscope. Verify 0 to
approximately 600 VDC operation.
11. Move the scope probe to the Module 2 load bank. Turn on Module 2 switch. The switch
should illuminate and the following happen: A) 206 contactor pulls in. B) Verify phase A,
B, & C LEDs on the 315 SCR power controller illuminate. C) The phase rotation LED
should illuminate.

Select channel 2 on the multi-channel display unit. Slowly increase the power level from
minimum to maximum. Observe proper SCR firing on the oscilloscope. Verify 0 to
approximately 600 VDC operation.
12. Repeat the step above for each Module and SCR power controller in the system.
13. Set all modules at 480 VDC as indicated by the display unit. Let run for approximately 10
minutes.
14. CALIBRATION CHECK WHEN CURRENT FEEDBACK IS SELECTED:
The MON. CAL potentiometer will calibrate the DC output current to match the control
signal as follows:

JP1

SPAN

MON CAL

IP-VNX600-20-TEST REV C 3-2

 O-5 VDC input Meter output value DC Current output measured
0.00 0.00 +/- 0.15 0.00 Adc
1.00 1.00 +/- 0.15 4.00 Adc +/- 0.50 Adc
2.00 2.00 +/- 0.15 8.00 Adc +/- 0.50 Adc
3.00 3.00 +/- 0.15 12.00 Adc +/- 0.50 Adc
4.00 4.00 +/- 0.15 16.00 Adc +/- 0.10 Adc
5.00 5.00 +/- 0.15 20.00 Adc +/- 0.50 Adc

It should not be required to calibrate the DC output current with a new system. If calibration
is desired, it is suggested to calibrate at the 16 Amp DC output level and a 4.00 VDC
command signal. To calibrate:
a. Attach a suitable DC current meter in series with the output, or use a clamp on type
DC ammeter. Set the control signal so the output current is at a desired level.
b. Measure the control signal on pins 8 and 9. Divide this value by 5, then multiply by
20, e.g., 4.03 measured / 5 = 0.806 * 20 = 16.12 Amps.

The following step requires removal of the

cover of the DC power controller. Use caution
when removing to prevent accidental contact
of the cover with live components.
c. Carefully remove the cover of the DC power controller. Dont electrocute yourself.
If the cover wants to hang on anything, then its better to power down. If you power
down more than a minute, you should wait for 10 minutes after re-applying power for
output stabilization to be optimized.
d. While monitoring the DC output current with a meter, adjust the MON. CAL pot in
the SCR power controller for the value calculated in step b above.

VOLTMETER OUTPUT CHECK:

a. Monitor the DC output voltage of the power controller. Adjust the control signal for
approximately 480 VDC on the output terminals. Divide this value by 600, then
multiply by 5, e.g., 485 measured / 600 = 0.8083 * 5 = 4.041 Volts DC.
b. With a second voltmeter, monitor voltage on the E Meter output pins 10(+), and
11(-).

The following step requires removal of the cover

of the DC power controller. Use caution when
removing to prevent accidental contact of the
cover with live components.
c. To calibrate: Carefully remove the cover of the DC power controller. Dont
electrocute yourself. If the cover wants to hang on anything, then its better to power

IP-VNX600-20-TEST REV C 3-3

 down. If you power down more than a minute, you should wait for 10 minutes after
re-applying power for output stabilization to be optimized.
d. While monitoring the E Meter voltmeter output, adjust the SPAN pot in the SCR
power controller for the value calculated in step a above.

15. CALIBRATION CHECK WHEN VOLTAGE FEEDBACK IS SELECTED:

The SPAN potentiometer will calibrate the DC output voltage to match the control signal.
a. Verify a 4.0 +/- 0.1 VDC signal at all SCR power controllers on pins 8(+) and 9(-) of
the 12 pin connector. Divide this value by 5, then multiply by 600, e.g., 4.03
measured / 5 = 0.806 * 600 = 483.6 (484)
b. Measure the DC output of the SCR power controller. If the DC output is within 3.0
VDC of the value calculated above, no calibration is required.

The following step requires removal of the cover

of the DC power controller. Use caution when
removing to prevent accidental contact of the
cover with live components.
c. To calibrate: Carefully remove the cover of the DC power controller. Dont
electrocute yourself. If the cover wants to hang on anything, then its better to power
down. If you power down more than a minute, you should wait for 10 minutes after
re-applying power for output stabilization to be optimized.
d. While monitoring the DC output with a meter, adjust the SPAN pot in the SCR power
controller for the DC output voltage to match the calculated in step a above.

CURRENT METER OUTPUT CHECK:

It should not be required to calibrate the DC current meter output with a new system. If
calibration is desired, it is suggested to calibrate at the 16 Amp DC output level:
a. Attach a suitable DC current meter in series with the output, or use a clamp on type
DC ammeter. Set the control signal so the output current is at a desired level.
b. Measure the DC output current. Divide this value by 20, then multiply by 5, e.g.,
15.6 Amps measured / 20 = 0.780 * 5 = 3.90 VDC.

The following step requires removal of the cover

of the DC power controller. Use caution when
removing to prevent accidental contact of the
cover with live components.
c. To calibrate: Carefully remove the cover of the DC power controller. Dont
electrocute yourself. If the cover wants to hang on anything, then its better to power
down. If you power down more than a minute, you should wait for 10 minutes after
re-applying power for output stabilization to be optimized.

IP-VNX600-20-TEST REV C 3-4

 d. While monitoring the I Meter current meter output, adjust the MON.CAL pot in
the SCR power controller for the value calculated in step b above.

16. Multi-Module systems: Verify the all zones return to zero level when the Flow switches
the switches connected to TB1 pins 3 & 4 and TB1 pins 5 & 6 are turned off. Turning the
switches back on returns all power controllers to their previous operating level.
17. Let the system run at a minimum of 4 hours at a 300-480 VAC operation level.
18. Run each Module zone to maximum (for a final operation check), then back down to 0 output
using the display unit. NOTE: The display unit remembers its operation level after power
down - very similar to a mechanical potentiometer. We want be sure the setpoint is down to
0 for delivery to the customer.
19. Turn off all module switches.
20. Turn off power tests are complete.

IP-VNX600-20-TEST REV C 3-5

 Section 4 Pre-shipment Checks

CONTROL SYSTEM ENCLOSURE:

1. Remove all test switches, load banks etc. Clean enclosure as required.
2. JUMPER TB1 pins 3 & 4, and TB1 pins 5 & 6 (dont jumper TB1 pins 1 & 2).
3. REMOVE wires 1070 and 1132 from 110T control transformer. Tape off and attach a
yellow laminated connection tag.
4. If not done so already, serialize the power controllers using the Approach Database and
attach serial number label to top (end panel, not cover) of the SCR power controller(s).
5. Attach the following labels to the control enclosure:
a. System identification /serial number labels to the inside of door.
b. UL required Fuse Replacement Label to the inside of door.
c. Large triangular voltage warning to the outside of door near the disconnect.
6. The test technician to date and sign a shipping tag that reads This unit was tested to the
IP-VNX600-20 procedure.
7. Place one copy of the wiring diagram at the back of the IONPURE manual and put the
manual in the print pocket. Also provide another copy of the wiring diagram in the print
pocket.
8. Verify all module on/off switches are set to off.

TRANSFORMER ENCLOSURE:
1. Attach a yellow laminated connection tag to the large isolation transformer voltage
configuration connections.
2. Verify the cooling fan connections are labeled and the capacitor connection is plugged, so the
installer does not connect fan wiring to wrong location.
3. Attach the following labels to the control enclosure:
a. System identification /serial number labels to the inside of door.
b. Transformer connection diagram provided by transformer manufacturer to the inside
of door.
c. Large triangular voltage warning to the outside of door.
d. Graphical hazard warning label to the outside of door (previous systems have a text
type hazard warning label).

IP-VNX600-20-TEST REV C 4-1