Advanced Energy Pinnacle 20 kW User manual

U S ER
MANUAL
Fort Collins, CO 80525 USA
970.221.4670
[email protected]
1625 Sharp Point Drive
Advanced Energy Industries,Inc.
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ii 5702199-A
Advanced Energy®
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User Manual
Pinnacle™ 20 kW
5702199-A
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iv 5702199-A
Advanced Energy®
Copyright
This manual and the information contained herein is the property of Advanced Energy Industries, Inc.
No part of this manual may be reproduced or copied without the express written permission of
Advanced Energy Industries, Inc. Any unauthorized use of this manual or its contents is strictly
prohibited. Copyright ©4/13/01 by Advanced Energy Industries, Inc. All Rights Reserved.
Disclaimer and Limitation of Liability
The information contained in this manual is subject to change by Advanced Energy Industries,
Inc. without prior notice. Advanced Energy Industries, Inc. makes not warranty of any kind
whatsoever, either expressed or implied, with respect to the information contained herein.
Advanced Energy Industries, Inc. shall not be liable in damages, of whatever kind, as a result
of the reliance on or use of the information contained herein.
Product Usage Statement
Trademark Information
is a registered trademark of Advanced Energy Industries, Inc.
Advanced Energy is a registered trademark of Advanced Energy Industries, Inc.
AE is a registered trademark of Advanced Energy Industries, Inc.
DeviceNet is a trademark of Open DeviceNet Vendor Association, Inc., Boca Raton, FL.
Pinnacle is a trademark of Advanced Energy Industries, Inc.
Read this entire manual and all other publications pertaining to the work to be
performed before you install, operate, or maintain this equipment. Practice all plant and
product safety instructions and precautions. Failure to follow instructions can cause
personal injury and/or property damage. All personnel who work with or who are
exposed to this equipment must take precautions to protect themselves against serious
or possibly fatal bodily injury.
Advanced Energy Industries, Inc., (AE) provides information on its products and
associated hazards, but it assumes no responsibility for the after-sale operation of the
equipment or the safety practices of the owner or user. This equipment produces or uses
potentially lethal high-voltage, high-current, radio frequency (RF) energy. NEVER
DEFEAT INTERLOCKS OR GROUNDS.
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5702199-A Table of Contents v
Pinnacle™ 20 kW
Chapter 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Read This Section! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Interpreting the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Type Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Icons (Symbols) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Product Safety/Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chapter 2. Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Output Impedance Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Output Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Microprocessor Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Arc-Suppression Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Housekeeping Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Output Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Logic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Remote Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Functional Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
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Chapter 4. I/O Communication and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
User Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Pin-description Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
DeviceNet™Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Rotary Switches: Baud Rate and Addressing . . . . . . . . . . . . . . . . . . . . . . 4-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Poll Command Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Response Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Explicit Messaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Rear Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Module Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Network Status LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Passive Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Active Front Panel/ Pinnacle Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Connecting to the Remote Active Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Understanding the Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Control Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Output Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Modify Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Regulation Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
On/Off switches & LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Arc LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Control Panel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Output Power Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Regulation Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Two-Line Output Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Modify Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Control Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Understanding the Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Using the Service Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Checking Service-type Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Checking Service-type Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Checking the Total Energy Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Checking the Amount of Idle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Checking the Number of Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Checking the Number of Cycles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Debugging Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
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Checking Your Master/Slave System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Checking Your Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking Your Communications Card . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking Your Software Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking Your ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking Your Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Using the Supply Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Setting the AE Bus Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Setting the Supply Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Setting the Panel Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Selecting Remote or Local Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Selecting a Lock Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Selecting the Number of Clicks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Setting the Program Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Using Process Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Monitoring Your Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Establishing a Minimum Process Voltage. . . . . . . . . . . . . . . . . . . . . . . 4-29
Setting an Out-of-Setpoint Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Changing the Target Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Setting Process Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Setting a Strike Voltage Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Setting a Maximum Limit for Output Voltage . . . . . . . . . . . . . . . . . . . 4-32
Setting the Maximum Limit for Output Current . . . . . . . . . . . . . . . . . . 4-32
Setting the Maximum Limit for Output Power . . . . . . . . . . . . . . . . . . . 4-32
Setting Arc Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Setting the Voltage Arc Trip Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Setting the Arc Count Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Viewing the Arc Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Setting the Length of the Arc Average Window . . . . . . . . . . . . . . . . . . 4-34
Setting the ARC Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Predefined Arc Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Enabling Arc Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Setting Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Setting Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Setting Ripple Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Using the Target Conditioning Cycle (TCC) . . . . . . . . . . . . . . . . . . . . . . 4-38
Enabling Target Conditioning Cycle (TCC) . . . . . . . . . . . . . . . . . . . . . 4-38
Setting the Target Conditioning Cycle (TCC) TIMER . . . . . . . . . . . . . 4-39
Setting Joule Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Setting the Joule Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Setting the Joule Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Setting the Ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Standard Serial (Flash) Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Standard Serial Port Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Transmission Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
AE Bus Serial Communications (Host) Port . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
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Transmission Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Using DIPs to Set the Pinnacle Unit’s Network Address . . . . . . . . . . . . . 4-44
Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
External DIPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Internal DIPs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Min-switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Setting the Pinnacle Unit’s Network Address . . . . . . . . . . . . . . . . . . . . 4-48
Setting Baud Rates and Communication Mode . . . . . . . . . . . . . . . . . . . 4-49
Host/Pinnacle Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Header. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Optional Length Byte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Data (Data Bytes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Creating an Ideal Communications Transaction . . . . . . . . . . . . . . . . . . . . 4-52
Understanding Command Status Response (CSR) Codes. . . . . . . . . . . . . 4-53
Host/Pinnacle Software Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Host Port Command Sequence Examples . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Example 1: Setting the Timeout Value. . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Example 2: Setting Target Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Unit Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Chapter 5. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Meeting Spacing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cooling Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cabinet Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Making Rear Panel Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Connecting a Pinnacle Remote Active Panel. . . . . . . . . . . . . . . . . . . . . . . . 5-6
Connecting a Remote Passive Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Connecting for User Port Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Connecting to the Standard Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Connecting for Serial (Host) Port Control . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Contactor Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Connecting for DeviceNet™Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Connecting Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Terminal Block Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Connecting for Master/Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Configuring Your Master Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Configuring Your Slave Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Monitoring Your Master / Slave System . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Clearing Faults in a Master/Slave System . . . . . . . . . . . . . . . . . . . . . . . 5-15
Understanding Master/Slave Input On/Off Combinations . . . . . . . . . . . 5-16
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Back Panel Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Chapter 6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operating Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Understanding Pinnacle™Arc Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Voltage Arc Trip Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
TCC Algorithm Enable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Target Type: Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Target Type: Non-Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Target Type: Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Arc Detect Delay Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Arc Shutdown Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Arc Recovery Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Arc Recovery Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Chapter 7. Troubleshooting and Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Before Calling AE Global Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
First Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Checks with the Power Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Checks with the Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Checks if the Output Does Not Turn On . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Help Code Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Passive Display Panel Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
LED Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Clearing the Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Error Code Troubleshooting Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Error E081 Fault Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Slave Status Low Byte. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Slave Status High Byte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Personality Card Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
AE Global Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Returning Units for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Authorized Returns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
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5702199-A List of Figures xi
Pinnacle™ 20 kW
Figure 2-1. Pinnacle functional block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Figure 3-1. Operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Figure 3-2. Impedance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Figure 4-1. 15-pin User port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Figure 4-2. DeviceNet™port with pin designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Figure 4-3. DeviceNet rotary switches and LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Figure 4-4. Remote active panel connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Figure 4-5. Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Figure 4-6. Control panel main menu functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
Figure 4-7. Service menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
Figure 4-8. Supply menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
Figure 4-9. Process menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Figure 4-10. Standard Serial port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41
Figure 4-11. Host port connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
Figure 4-12. Rocker DIP switch (internally located on a master/slave interface card) . . . .4-45
Figure 4-13. Slide DIP switch (externally located on units without a master/slave card) . .4-45
Figure 4-14. Orientation of the Host port and DIP switch on the back panel (units without a
master/slave interface card installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
Figure 4-15. Location of the internal DIP switch on the master/slave interface card . . . . .4-47
Figure 4-16. Graphic representation of a message packet . . . . . . . . . . . . . . . . . . . . . . . . . .4-50
Figure 4-17. AE Bus communications transaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52
Figure 4-18. Communications transaction example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55
Figure 4-19. Passive front panel (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-90
Figure 4-20. Active front panel (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-91
Figure 4-21. Remote panel (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-92
Figure 4-22. Remote panel (rear view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-93
Figure 4-23. Remote panel (dimensions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-94
Figure 5-1. Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Figure 5-2. Top, side, and inter-unit clearance for Pinnacle units stacked in a cabinet . . . . .5-5
Figure 5-3. Contactor interlock connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Figure 5-4. Rear view of terminal block housing without strain relief attached. . . . . . . . .5-11
Figure 5-5. Pinnacle master/slave interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Figure 5-6. Configuration for Pinnacle master/slave system . . . . . . . . . . . . . . . . . . . . . . . .5-14
Figure 5-7. Passive and active front panel (rear view) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
List of Figures
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5702199-A List of Tables xiii
Pinnacle™ 20 kW
Table 1-1. Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Table 1-2. Safety Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Table 3-1. Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Table 3-2. Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Table 3-3. Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Table 3-4. Climatic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Table 3-5. Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Table 4-1. User Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Table 4-2. DeviceNet™Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Table 4-3. Structure of the poll command message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Table 4-4. Structure of the poll command message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Table 4-5. MOD Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Table 4-6. Network Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Table 4-7. Passive Display Panel Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Table 4-8. Display Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Table 4-9. Remote Panel Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Table 4-10. Strike Voltage Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
Table 4-11. Arc detect, arc shutdown, and TCC times for pre-defined targets . . . . . . . . . .4-35
Table 4-12. Serial Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42
Table 4-13. AE Bus (Host) Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
Table 4-14. Address Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Table 4-15. Setting Switch 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
Table 4-16. Baud Rate Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
Table 4-17. Command Status Response (CSR) Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53
Table 4-18. Host Port Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55
Table 5-1. Minimum CFM Required for a Pinnacle Supply . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Table 5-2. Approximate Cooling Requirements for Three Supplies Mounted in a Cabinet .5-4
Table 5-3. Input Sequences for Master and Slave Units . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Table 7-1. Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Table 7-2. Passive Display Panel Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Table 7-3. Troubleshooting LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Table 7-4. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Table 7-5. AE Global Support Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
List of Tables
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5702199-A Introduction 1-1
&KDSWHU
Pinnacle™ 20 kW &KDSWHU
1
Introduction
READ THIS SECTION!
We know that some of you want to operate your Pinnacle supply now and that you don’t feel
you have time to read the entire manual. Below is a list of manual subsections you must read
before getting started.
• “Theory of Operation” on page 2-2
• “Electrical Specifications” on page 3-4
• “Operating Overview” on page 6-1
• “Installation” on page 5-1
• “Conditions of Use” on page 1-5
In addition, we recommend that you scan “Interpreting the Manual” on page 1-1. This section
explains the type conventions (what it means when a word appears in capitalized italic type,
for instance) and icon (symbol) definitions.
INTERPRETING THE MANUAL
Type Conventions
To help you quickly find what is being discussed, the manual presents certain words and
phrases in type that are different from the rest of the text. We use the following type
conventions:
• Pin and signal names appear in capitalized italics (DUTY CYCLE.A).
• Labels that are on the unit (switches, indicators, etc.) generally appear in boldface capital
letters (MODIFY). Exceptions are port names, which simply begin with a capital letter
(User port).
• Functions are printed in boldface lowercase letters (analog input filtering).
Icons (Symbols)
This symbol represents important notes concerning potential harm to
people, this unit, or associated equipment. It is found whenever needed in
the manual.
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We include this symbol in Danger, Warning, and Caution boxes to identify specific levels of
hazard seriousness.
The following symbols could appear on labels on your unit.
• Hazardous Voltage
• Short circuit protected
• High voltage
• Protective earth ground
This box identifies hazards that could result in severe personal injury or death.
This box identifies hazards or unsafe practices that could result in personal injury.
This box identifies hazards or unsafe practices that could result in product or property
damage.
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• Earth ground
• Warning (refer to manual)
• CE label
• Non-ionizing radiation
• Hot surface
• NRTL /C label
SAFETY
Do not attempt to install or operate this equipment if you have not first acquired proper
training.
• Ensure that this unit is properly grounded.
• Ensure that all cables are properly connected.
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• Verify that input line voltage and current capacity are within specifications before turning
on the power supply.
• Use proper ESD precautions.
• BE CAREFUL AROUND THIS EQUIPMENT.
PRODUCT SAFETY/COMPLIANCE
This product is designed to meet and is tested for compliance to the following standards and
directives.
Directives
The following tables list the Electromagnetic Compatibility (EMC) and Safety directives.
Standards
This device has been tested for and complies with the following Safety and EMC standard(s):
• EN 50178
• EN 50082-2
• EN 55011 (Class A, Group 2)(CISPR 11)
RISK OF DEATH OR BODILY INJURY. Disconnect all sources of input power
before working on this unit or anything connected to it.
Table 1-1. Electromagnetic Compatibility (EMC)
Directive Description
89/336/EEC EC Council directive on the approximation of the laws of the
Member States relating to electromagnetic compatibility (EMC
Directive)
47 CFR Part 18 Code of Federal Regulations—Limits and Methods of
Measurement of Radio Interference Characteristics of Industrial,
Scientific, and Medical Equipment
Table 1-2. Safety Directives
Directive Description
73/23/EEC EC Council directive on the harmonization of the laws of the
Member States relating to electrical equipment designed for use
within certain voltage limits (LVD—Low Voltage Directive)
SEMI S2-0200 Safety Guidelines for Semiconductor Manufacturing Equipment
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This device must be installed and used only in compliance with the standards listed in addition
to VDE 0113, EN 60204 (IEC 204), and applicable requirements.
For more information, refer to the letter of conformance (US) or declaration of conformity
(EU) accompanying the product.
Installation Requirements
Conditions of Use
To be in compliance with the stated directives and standards, you must meet the following
conditions of use.
• This device must be used in an overvoltage category II installation only.
• Before making any other connection, connect the auxiliary protective earth ground
conductor on the rear panel.
• Use only a shielded cable on the input power connector.
• Use only a shielded power cable on the output power connector.
• Non-standard connectors for input and/or output power must be inaccessible to the user.
• If your unit does not have a circuit breaker, install and operate it with an AE-approved
circuit breaker on the ac input to provide the required over-current protection.
Operating and maintenance personnel must receive proper training before installing,
troubleshooting, or maintaining high-energy electrical equipment. Potentially lethal
voltages could cause death, serious personal injury, or damage to the equipment.
Ensure that all appropriate safety precautions are taken.
• Install and operate this device only in a pollution degree 2 or better environment,
which means an indoor location such as a computer room, office, or factory floor
where only non-conductive pollution occurs during operation. Occasionally, a
temporary conductivity caused by condensation occurs when the device is not
operating.
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