IPC-3 AND IPC-5 POWER SUPPLIES - Teknic

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USER MANUALIPC-3 AND IPC-5 POWER SUPPLIESVERSION 2.05 MAY 2, 2022TEKNIC, INCPHONE (585)784-7454

2THISPAGE INTENTIONALLY LEFT BLANK

3TABLE OF CONTENTSTABLEOFCONTENTS . 3INTRODUCTION . 4Features.4Symbols Used in This Document . 5SAFETY INFORMATION . 6Precautionary Statement .6General Disclaimer .6IPC-3 Special Safety Note . 7General Safety Instructions . 7PARTS OF AN IPC-3 / IPC-5 . 9Parts, Mating Connectors, and Pinouts.9IPC USE INSTRUCTIONS . 10Mounting Orientation. 10How To Connect IPC To A Load.11How To Disconnect IPC From A Load .11Additional Use Notes .11CABLES . 12IPC-3 & IPC-5 Accessory Cables. 12APPENDIX A: LED CODES . 13APPENDIX B: SPECIFICATIONS. 14APPENDIX C: MECHANICAL REFERENCE . 15Mounting Dimensions (IPC-3 and IPC-5). 15Mounting a Third-Party Fan (IPC-5 Only). 16Top Mount Fan (40mm x 40mm) . 16Side Mount Fan (80mm x 80mm) . 17DIN Rail Adapter (Optional, Third-Party) . 18APPENDIX D: MISCELLANEOUS TOPICS . 19How to Modify AC Line Cord For Use With 220VAC . 19Circuit Breaker For AC Input To The IPC-3/IPC-5.20Installing An AC Line Filter For CE Emissions Compliance . 21

4IPC-3, IPC-5 USER MANUAL REV. 2.05INTRODUCTIONAmazon IPC-3 and IPC-5 power supplies deliver stiff, responsive 75 VDCpower to Teknic's Eclipse, Meridian, and ClearPath servo systems. TheseDSP-based supplies feature tight power regulation and high peak outputto support high performance motion control. With a small footprint andattractive pricing, the IPC saves on space, weight, and machine cost aswell.IPC-3IPC-5Amazon IPC-3 and IPC-5 Power SuppliesFEATURESTEKNIC, INC.x75 VDC output with tight regulation, even with large peak loads.xDual AC input voltage ranges: 95-125VAC; 190-250VAC.xHigh peak output relative to continuous output rating (2.5x),optimized for servo drive peak demand requirements.xRapid output bus discharge upon AC power removal.xBuilt-in, automatic regenerated power management.xLarge output capacitance for reduced ripple and increasedefficiency.xFan mounting holes provided for increased continuous power(IPC-5 only).xIPC-5 is fully enclosed; IPC-3 is open frame.xThree year warranty.PHONE (585)784-7454

5IPC-3, IPC-5 USER MANUAL REV. 2.05SYMBOLS USEDINTHIS DOCUMENTWarningIdentifies information about practices or circumstances that can lead toequipment damage, personal injury, or loss of life.Hazardous voltageContact may cause electric shock, burn, or electrocution.Hot surfaceIdentifies presence of a burn hazard.Protective earth terminalIndicates points that must be connected to a reliable earth system forsafety compliance. Protective earth connections should never be omitted.Earth ground terminalFrame or chassis terminalDirect Current (DC)Alternating Current (AC)TEKNIC, INC.PHONE (585)784-7454

6IPC-3, IPC-5 USER MANUAL REV. 2.05SAFETY INFORMATIONIMPORTANT: Read this section before attempting to install, applypower to, or operate an IPC power supply. Failure to understand andfollow the information presented in this document could result inproperty damage, bodily injury, and/or death.PRECAUTIONARY STATEMENTAlways follow appropriate safety precautions when installing and usingany power supply. Equipment should be designed and utilized to preventpersonnel from coming into contact with moving parts and electricalcontacts that could potentially cause injury or death. Read all cautions,warnings and notes before attempting to operate or service power suppliesand motion control devices. Follow all applicable codes and standardswhen using this equipment. Failure to apply this equipment as describedmay impair or neutralize protections built into the product.GENERAL DISCLAIMERThe User is responsible for determining the suitability of this product fortheir application. The User must ensure that Teknic’s products areinstalled and utilized in accordance with all local, state, federal andprivate governing bodies and meet all applicable health and safetystandards.Teknic has made all reasonable efforts to accurately present theinformation in the published documentation and shall not be responsiblefor any incorrect information which may result from unintentionaloversights.Due to continuous product improvements, the product specifications asstated in the documentation are subject to change at any time and withoutnotice. The User is responsible for consulting a representative of Teknicfor detailed information and to determine any changes of information inthe published documentation.Should Teknic’s products be used in an application that is safety critical,the User must provide appropriate safety testing of the products, adequatesafety devices, guarding, warning notices and machine-specific training toprotect the operator from injury.TEKNIC, INC.PHONE (585)784-7454

7IPC-3, IPC-5 USER MANUAL REV. 2.05IPC-3 SPECIAL SAFETY NOTEUnlike the IPC-5, the IPC-3 is an open frame power supply. As such, thereare user-accessible, hazardous voltage points present on the device.Improper handling of this device while powered by AC mainsmay result in electrical shock, burns, or death.Users of this device, and any equipment or system that incorporates thisdevice, must be protected from exposure to electrical shock through theinstallation of appropriate shields, access guards, interlocks, warningsigns and user manuals that include safe handling practices for openframe power supplies.IPC-3 Power SupplyGENERAL SAFETY INSTRUCTIONSTEKNIC, INC.xRead these instructions.xKeep these instructions.xHeed all warnings.xDo not use this apparatus near water.xClean apparatus with a clean, dry cloth.xDo not block any ventilation openings. Install in accordance withmanufacturer’s instructions.xDo not install near a heat source.xIf sheet metal cover is damaged, immediately disconnectapparatus from the mains supply, remove from service, andreturn to Teknic for repair.xProtect the AC line cord and plug from being walked on orpinched, particularly at plugs, convenience receptacles, and at thepoint where the line cord exits the apparatus.xThe AC line cord shall be strain relieved at the power supply sideto prevent cable damage or breakage over time due to repeatedflexing.PHONE (585)784-7454

8IPC-3, IPC-5 USER MANUAL REV. 2.05TEKNIC, INC.xOnly use attachments and accessories specified by Teknic.xThere are no user serviceable parts on the IPC3 or IPC-5. Refer allservicing to qualified service personnel.xAny equipment or system that incorporates this device shall havea power disconnection switch or mechanism to ensure thatunplugging the AC line cord is not the sole means ofdisconnecting AC mains power to the device and downstreamequipment.xThis apparatus shall be connected to a mains socket outlet with aprotective earthing connection.xTo reduce the risk of fire or electric shock, do not expose thisapparatus to rain or moisture. Apparatus shall not be exposed todripping or splashing and no objects filled with liquids, shall beplaced on the apparatus.PHONE (585)784-7454

9IPC-3, IPC-5 USER MANUAL REV. 2.05PARTS OF AN IPC-3 / IPC-5PARTS, MATING CONNECTORS, AND PINOUTSRegen Indicator(Green LED)DC Output Mating ConnectorBlink patterns here indicatestatus of regenerativeenergy managementsystem. See LED codessection for details.DC OutputConnectors (2)Outputs 75VDC to yourservo drive, step drive,or ClearPath motor.Information LED(Yellow LED)Blink patterns here indicatevarious operational issues.See LED codes section fordetails.DC Bus (V-)1DC Bus (V )WIRE ENTRY VIEWHousing: Molex/44441-2002Terminals: Molex/43375-0001Crimp Tool: Molex/63811-7200Cable: 14-16AWG, 600V, strandedAC Input Mating ConnectorAC (Hot)51INSTALL JUMPERfor 95-125V AC PowerPE GND62(pins 6 or 7)73REMOVE JUMPERAC (Neutral)84for 190-250V AC PowerAC Input ConnectorConnect AC power here.Voltage ranges listed are:95-125VAC (single phase)190-250VAC (single phase)2WIRE ENTRY VIEWHousing: Molex/39-01-2080Terminals: Molex/39-00-0039Crimp Tool: Molex/638190900Cable: 18AWG, 300V, strandedIPC-5 shown (Note: IPC-3 has the same features but no cover).TEKNIC, INC.PHONE (585)784-7454

10IPC-3, IPC-5 USER MANUAL REV. 2.05IPC USE INSTRUCTIONSMOUNTING ORIENTATIONxMount IPC in one of the orientations shown below. The verticalorientation shown below supports best convection cooling.xAllow a minimum 2” clearance above IPC. Allow at least 1”clearance at sides and bottom.xDo not mount IPC above a heat source such as a spindle drive orheating element.xDo not mount IPC in an unventilated enclosure or where theambient air temperature will exceed 40ºC.xSee Mechanical Appendix for complete mounting dimensions.DO NOT MOUNTIN THESE ”1”2”1”1”1”TEKNIC, INC.PHONE (585)784-7454

11IPC-3, IPC-5 USER MANUAL REV. 2.05HOW TO CONNECT IPC TO A LOADxRemove AC power from supply.xConnect DC power cable from supply to the load (typically a servodrive or ClearPath motor).xApply AC power to supply. Use minimum 18AWG for AC inputwiring to the power supply.HOW TO DISCONNECT IPC FROM A LOADxRemove AC power from supply.xDisconnect DC power cable from the load.ADDITIONAL USE NOTESTEKNIC, INC.xIPC-3/5 supplies are not designed to operate in series or parallelconfigurations. Do not wire these power supplies together in anyconfiguration.xAlways use the recommended wire gauge (or larger) for all cablesconnected to an IPC power supply.PHONE (585)784-7454

12IPC-3, IPC-5 USER MANUAL REV. 2.05CABLESIPC-3 & IPC-5 ACCESSORY CABLESThe accessory cables listed below are available at teknic.com. Links areprovided knic Part # IPC35-CABLE11078”Description: AC line cord (110V) for Amazon IPC-3and IPC-5 power supplies. Includes NEMA 5-15P toMinifit 8 pin connector, 78” in length (nominal).Teknic Part # PC-SBR-7272”Description: Power cable, Sabre to Sabre. FromIPC to Eclipse or Meridian 4xx/5xx series drives.72” in length (nominal).Teknic Part # CPM-CABLE-PWR-MS120120”Description: Power cable, Sabre to Molex Minifit Jr.4-position plug. From IPC to ClearPath Motor. 120”in length (nominal).TEKNIC, INC.PHONE (585)784-7454

13IPC-3, IPC-5 USER MANUAL REV. 2.05APPENDIX A: LED CODESRegenIndicatorIPC StateLED BlinkFrequency& Duty CycleDescriptionGREENRapid Blink(16 blinks/second)On (normal)No action required. The power supply is workingproperly. No significant regen detected.16 Hz.duty cycle 50%Intermittent - LEDturns on solid butreturns to rapidblink.Regeneratedenergy wasdetected.No action required. The power supply is workingproperly. LED turns on solid when DC bus voltagerises above nominal while staying below the RegenControl Threshold.Intermittentlyon solidRegen controlcircuit wasactivated.No action required. The power supply is workingproperly. This latching signal indicates that the busvoltage has gone over the Regen Control Thresholdand activated the internal regen control circuit.Note: This blink code will persist until AC poweris cycled.3 Hz.duty cycle 50%Regen capacitywas exceeded.Action required. This latching signal indicates thatthe power supply's ability to absorb regeneratedenergy was exceeded at least once since AC powerwas applied. When this occurs, the regen controlcircuit is automatically disabled as a protectivemeasure, but the DC output is still on. Solution:Upgrade to higher regen capacity supply. Note:This blink code will persist until AC power iscycled.0.5 Hz.duty cycle 2.5%IPC StateDescriptionLED BlinkFrequency& Duty CycleBlink - 3 blinksper secondStrobe - Oneshort blink everytwo secondsInformationLEDYELLOWMomentarily onMode transitionNo action required. The power supply is workingproperly. The LED will pulse on momentarily whenthe internal regulator changes operating modes.This may be accompanied by an audible "click" ofthe internal relay.LED blinksintermittentlyduring operationTemporaryoverloadoccurredA transient voltage event occurred (but was belowthe IPC's shutdown threshold). Action may berequired to prevent future shutdowns.N/AShutdownA critical voltage or temperature overload occurred,or a short was detected at DC output. IPC is inprotective shutdown state. Remove AC power untilLED turns off completely (2-5 minutes). Removeshort if applicable. Reapply AC power.On SolidLED on solidTEKNIC, INC.N/APHONE (585)784-7454

14IPC-3, IPC-5 USER MANUAL REV. 2.05APPENDIX B: SPECIFICATIONSIPC-3PowerInput Voltage (230 VAC nominal range)Input Voltage (115 VAC nominal range)IPC-5190-250VAC, single phase108 -125VAC (start under load at ambient temps 0-15 C)95-125VAC (load independent at ambient temps 15-40 C)Input Frequency Range50-60HzNominal Output Voltage75VDC 0.5VContinuous RMS Power Output at 115VAC or 230VACin; convection cooled.225W RMS 0-40 C ambient350W RMS 0-40 C ambientContinuous RMS Power Output at 115VAC or 230VACin; fan cooled.N/A500W RMS 0-40 C ambientPeak Power Capability at 115VAC or 230VAC in900W for 3 sec. (single pulse load at 40 C)Peak In-rush Current 65ARegenerated Energy / Power Absorption12.7 joules / 13.3 watts RMS at 40 CCapacitive Energy Storage53 joules at 75VDCAllowable (user added) output capacitance10,000 uF maximumInput Leakage Current 500uA @ 250VAC/60HzRipple 500mV P-P, zero to full loadMin. equivalent startup load16 ohms @ AC input 105/210V min.Output Resistance 300 milliohms19.1 joules / 20 watts RMS at 40 CPhysicalWeight2.11 lbs.2.25 lbs.Dimensions181mm x 132mm x 57.3mm183mm x 132mm x 57.3mmFinger SafeNo. User must be protected from shock hazard.YesEnclosureNonePerforated, epoxy coated aluminumOperating EnvironmentTemperature Range0-40 CHumidity10% - 90% (non-condensing)Pollution Level2Acoustic Noise @ 1 distance meter 50 dBA (variable, dependent on load and AC line)Certifications/ComplianceSafetyUL-508C, EN61010RF EmissionsMeets EN55011/22 Class A requirements when used with AC line filter part number: EPCOSB84112G0000B110.RoHSCompliantProtective FeaturesOver-Voltage ProtectionHalts power delivery until voltage returns to specified output voltageOver-Current ProtectionHiccup mode with auto-recoveryOutput Short-Circuit ProtectionHiccup mode with auto-recoveryThermal OverloadHalts power delivery until power removal/reapplicationOutput bus dump load controlDuring Regeneration: Initiated at 92VDC, off at 88VDC;At power-off: Initiated within 200mS of AC power removal, off when output is below 12VDC.TEKNIC, INC.PHONE (585)784-7454

15IPC-3, IPC-5 USER MANUAL REV. 2.05APPENDIX C: MECHANICAL REFERENCEMOUNTING DIMENSIONS (IPC-3 AND IPC-5)Units: mm [inches]Tol. 2Tol. 136.0[1.417]9.23[.363]Tol. 2BA14.15 [.557]A60.5[2.382]Tol. 180.0[3.15]Tol. 1AUPABTol. 1Mounting holes for optionalDIN rail adapter (see note*)Dia. 2.50mm [.098”]Qty. 3, M3 x 0.5 - 6HMax. penetration intocase 5.5mm [0.22”]160.0[6.3]Size “A” holes are provided* Note:for use with optional DIN railadapter bracket, Phoenix UTA-89(not sold by Teknic.)BDia. 3.45mm [.136”]Qty.3, 8-32 UNC-2BMax. penetration intocase 6.35mm [0.25”]BTol. 211.0 [.433]Tol. 2TEKNIC, INC.39.7[1.563]36.7[1.445]Holes for direct mountTol.Tol.11Mechanical TolerancesTol. 1 /- .203 mm /- .008 in.Tol. 2 /- .381 mm /- .015 in.PHONE (585)784-7454

16IPC-3, IPC-5 USER MANUAL REV. 2.05MOUNTINGATHIRD-PARTY FAN (IPC-5 ONLY)The IPC-5 can be equipped with a standard 40 mm or 80 mm case fan, toachieve up to 40% more continuous output power.xCase fans (also called muffin fans) can be found at onlineelectronics suppliers such as Digikey and Mouser.xUse non-conductive hardware to secure fan to case, such as plasticor rubber screws, rubber fan “push pins” or similar bymanufacturers such as Nexus and Lamptron.xSelect an “open corner” (open frame) fan for easier mounting.xSelect a fan with a CFM rating of 15 or greater.xInstall fan such that air is drawn air out of the case. Do not installfan to blow air into the case.xFans require an external power source, typically 12-24VDC.TOP MOUNT FAN (40MM X 40MM)UNITS mm13.463240 mm case fan16324x Ø 4mmMounting hole patternfor 40 mm top-mount fanTop mounted IPC-5 case fanTEKNIC, INC.PHONE (585)784-7454

17IPC-3, IPC-5 USER MANUAL REV. 2.05SIDE MOUNT FAN (80MM X 80MM)UNITS mm11.9471.512.63x Ø 4mm71.5NOTE: DO NOT DRILL INTO CASE.Use only the (3) mounting holesindicated to attach fan to case.Mounting hole patternfor 80mm side-mount fan80mm fanNo screw hereIPC-5 shown with optional80 mm (side-mount) fanSide mounted 80mm IPC-5 case fanTEKNIC, INC.PHONE (585)784-7454

18IPC-3, IPC-5 USER MANUAL REV. 2.05DIN RAIL ADAPTER (OPTIONAL, THIRD-PARTY)The IPC-3 and IPC-5 casting comes with tapped holes specifically for usewith the DIN rail adapter shown below: Phoenix Contact PN: UTA-89,(also listed as PN: 2853970). Note: This adapter is not sold byTeknic.Mounting ScrewsM3 x 0.5 - 6HMax. penetrationinto case 5.5mmTappedholes(3 places)Description: Universal DIN railmount. Material: Die-cast zinc.Dimensions: 89mm x 52mm.Complete Information availableat www.phoenixcontact.com.ANNiiwAs HeRePhoenix PN UTA-89(also PN 2853970)DIN Rail AdapterPull down torelease latch.Tip: Connect a pull straphere to make “blind”removal from DIN rail easier. (SJFC)Strap sold separately.Clearance Note: If your DIN rail is screwed directly to a solid wall or cabinet, youmay need to install standoffs to provide clearance for mounting and removing theunit. See illustration below.Use only threemounting screwsand standoffs.No screw here!Standoffs, unthreaded (qty. 3)Metric: Length: 10mm. Inner diameter 3mmEnglish: Length: 3/8”. Inner diameter 3mmScrews for use with standoffs (qty. 3)Metric: M3 x 0.5, Class 6H, length: 16-18mmTEKNIC, INC.PHONE (585)784-7454

19IPC-3, IPC-5 USER MANUAL REV. 2.05APPENDIX D: MISCELLANEOUS TOPICSHOWTOMODIFY AC LINE CORD FOR USE WITH 220VACRead this section if you plan to power your IPC-3 or IPC-5 using 220VACnominal power and you have a Teknic AC cable, part number IPC35CABLE110. This cable ships configured for use with single-phase 110 VAC.MODIFY THIS CABLE ONLY IF YOU NEED TO USE 220 VACPOWER.DO NOT MODIFY THIS CABLE If you intend to use it with 110VAC power.off standard 110VAC2 Cutplug and replace with athis jumper1 Removeif supply is to beAC Line(brown)PE Ground(green/yellow)AC Line(blue)51627384properly rated, 190250VAC grounded plug.powered by 190-250VAC mains power.How to remove or cut jumper wire (for use with 190-250 VAC only)NOTE: Disconnect cable from AC before attempting to modify.Preferred MethodAlternative MethodRemove terminals with Molex extraction tool.Cut wire and insulate with heatshrink or tape.Note: Exposed leads are a shock hazard.PULL WIRE ANDTERMINALORTERMINAL51627384HOUSINGSLOTS FOREXTRACTORTOOLTEKNIC, INC.EXTRACTOR TOOLMOLEX PN: 11-03-004451627384PHONE (585)784-7454

20IPC-3, IPC-5 USER MANUAL REV. 2.05CIRCUIT BREAKER FOR AC INPUT TO THE IPC-3/IPC-5An AC circuit breaker is not required to protect your IPC-3/IPC-5 powersupply from AC input overload. The AC input of every IPC-3/IPC-5 isprotected by an internal fuse.Please consult the regulations governing your machinery to determine ifan upstream circuit breaker is required to protect the AC wiring you haveinstalled to supply power to the IPC-3/IPC-5. If an upstream AC circuitbreaker is required, the size of such a breaker would be dictated by thewire gauge used to carry AC power to the supply. Note: Use minimum18AWG wiring for AC input to your IPC-3/IPC-5.TEKNIC, INC.PHONE (585)784-7454

21IPC-3, IPC-5 USER MANUAL REV. 2.05INSTALLING AN AC LINE FILTER FOR CE EMISSIONS COMPLIANCEThis is an optional installation step. ClearPath conducted and radiatedemissions–even with no additional filtering–are unlikely to disturb otherequipment, therefore a line filter is not required for most installations.However, for users seeking CE certification for their machine, Teknicrecommends the line filter shown below: EPCOS (TDK) part#B84112G0000B110.Recommended AC Line FilterMfg: EPCOS (TDK)Part#: B84112G0000B110AC Line Filter InstallationDirectly connect the body of the EPCOS filter to a large, continuous metal RF groundplane such as the machine chassis.The filter (and all other system components) should be mounted to an area of exposedbare metal to provide the best conductivity. Powder coated surfaces do not provide goodelectrical connection.Use electrically conductive mounting hardware.EPCOS (TDK)B84112G0000B110PEL1L2IPC 3/5Power SupplyMinimize the distance between the filter andthe IPC-3/5. Keep the connections as short aspossible for best performance. If connectionsmust be greater than 12" long, consider usingshielded cable.TEKNIC, INC.75 VDCClearPathMotorPEEquipment Chassis (Metal)AC Line FilterDC OutL1L2AC InIncoming AC Power andProtective Earth (PE)conductorPEA representative system was proven to comply withEN55011 class A conducted emissions standards.PHONE (585)784-7454

IPC-3, IPC-5 USER MANUAL REV. 2.0522Teknic, Incorporated115 Victor Heights PkwyVictor, NY 14564 2022 TEKNIC INCORPORATED, ALL RIGHTS RESERVEDTEKNIC, INC.PHONE (585)784-7454

IPC-3, IPC-5 USER MANUAL REV. 2.04 7 TEKNIC, INC.PHONE (585)784-7454 IPC-3 SPECIAL SAFETY NOTE Unlike the IPC-5, the IPC-3 is an open frame power supply. As such, there are user-accessible, hazardous voltage points present on the device.

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