Advanced Energy Pinnacle Plus+ User manual

Pinnacle™ Plus+ 10 kW (325–650 Vdc)
Master/Slave AE Bus,
DeviceNet™, MDXL User,
UHF Output
March 2005 5702269-C
User Manual
Samsung Electronics Co., Ltd. v. Demaray LLC
Samsung Electronic's Exhibit 1024
Exhibit 1024, Page 1

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Ex. 1024 Page 2

User Manual
Pinnacle™ Plus+ 10 kW
5702269-C
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Advanced Energy®
COPYRIGHT
This manual and the information contained herein is the proprietary 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 ©2004 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 no
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
TRADEMARKS
Advanced Energy is a registered trademark of Advanced Energy Industries, Inc.
AE is a registered 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. If the equipment is used in a manner
not specified by the manufacturer, the protection provided by the equipment may be
impaired. 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.
®is a registered trademark of Advanced Energy Industries,
Inc.
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Pinnacle is a trademark of Advanced Energy Industries, Inc.
CUSTOMER FEEDBACK
Advanced Energy’s technical writing staff has carefully developed this manual using
research-based document design principles. However, improvement is ongoing, and
the writing staff welcomes and appreciates customer feedback. Please send any
comments on the content, organization, or format of this user manual to:
• [email protected]
To order a manual, please contact Technical Support:
• [email protected]
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Chapter 1. Safety and Product Compliance Guidelines
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Interpreting the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Type Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Danger, Warning, and Caution Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Rules for Safe Installation and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Interpreting Product Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Product Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Product Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety and Compliance Directives and Standards . . . . . . . . . . . . . . . . . . . . . 1-5
Electromagnetic Compatibility (EMC) Directives and Standards . . . . . . . 1-5
Safety Directives and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Chapter 2. Theory
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
DC Chopper Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Remote Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 3. Specifications
Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Table of Contents
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Maximum Allowable Reverse Time For a Given Frequency . . . . . . . . . . . . . . 3-6
Reverse Time As A Function of Voltage Limit . . . . . . . . . . . . . . . . . . . . . . . 3-10
Operating and Impedance Range Illustrations . . . . . . . . . . . . . . . . . . . . . . . 3-13
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Chapter 4. I/O Communication and Control
User Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Pin-description Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DeviceNet™ Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Rotary Switches: Baud Rate and Addressing . . . . . . . . . . . . . . . . . . . . . 4-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Poll Command Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Response Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Explicit Messaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Rear Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Module Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Network Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Passive Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Active Front Panel/ Pinnacle Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Connecting to the Remote Active Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Understanding the Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Control Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Output Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Modify Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Regulation Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
On/Off Buttons & LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Arc LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Control Panel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Output Power Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Control Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Regulation Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Two-Line Output Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Setting the Reverse Time, Frequency, and Set point . . . . . . . . . . . . . . 4-21
Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Modify Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Control Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Understanding the Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Using the Service Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
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Checking Service-type Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking Service-type Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking the Total Energy Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking the Amount of Idle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking the Number of Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Checking the Number of Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Debugging Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Checking Your Master/Slave System Faults . . . . . . . . . . . . . . . . . . . . . 4-26
Checking Your Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Checking Your Communications Card . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Checking Your Software Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Checking Your ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Checking Your Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Using the Supply Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Setting the AE Bus Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Setting the Supply Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Setting Pulse Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Enabling Pulsing at Current Threshold or Always . . . . . . . . . . . . . . . . . 4-30
Setting Sync Pulse Hard Arc Detection Broadcast . . . . . . . . . . . . . . . . 4-30
Setting The Unit as a Sync Pulse Transmitter or Receiver . . . . . . . . . . 4-31
Selecting Constant Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Setting the Program Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Setting the Panel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Selecting Remote or Local Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Selecting a Lock Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Selecting the Number of Clicks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Using Process Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Monitoring Your Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Viewing the Over-Voltage Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Resetting the over-Voltage Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Setting the Over-Voltage Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Viewing the Over-Current Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Resetting the Over-Current Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Setting the Over-Current Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Setting the Out-of-Set point Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Changing the Target Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Setting Process Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Setting a Maximum Limit for Output Voltage . . . . . . . . . . . . . . . . . . . . . 4-37
Setting the Maximum Limit for Output Current . . . . . . . . . . . . . . . . . . . . 4-38
Setting the Maximum Limit for Output Power . . . . . . . . . . . . . . . . . . . . 4-38
Setting Arc Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Setting the Voltage Arc Trip Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Setting the Arc Count Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Viewing the Arc Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Setting the Arc Shutdown Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Enabling Arc Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Setting Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
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Setting Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Setting Joule Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Setting the Joule Set point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Setting the Joule Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Setting the Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Standard Serial (Flash) Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Standard Serial Port Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Standard Serial Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Transmission Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
AE Bus (Host) Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Transmission Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Setting the Pinnacle Plus+ Unit’s AE BUS Address . . . . . . . . . . . . . . . 4-51
Setting Baud Rates and Communication Mode . . . . . . . . . . . . . . . . . . . 4-53
AE Bus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
AE Bus Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Optional Length Byte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Data (Data Bytes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Creating an Ideal AE Bus Communications Transaction . . . . . . . . . . . . . . . 4-56
Understanding Command Status Response (CSR) Codes . . . . . . . . . . . . . 4-57
AE Bus Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Front Panel Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
Chapter 5. Installation
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Meeting Spacing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cooling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cabinet Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Making Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Connecting a Pinnacle Remote Active Panel . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Connecting a Remote Passive Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Connection for User Port Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Connecting to the Standard Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Connection for Serial (Host) Port Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Contactor Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Connecting Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Output Power Cable Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
UHF Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Military Spec Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
UHF Connection without Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
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UHF Connection with Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Host Port Card (Master/Slave Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Master/Slave Pulse Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Master/Slave Pulse Port Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Master/Slave Pulse Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . 5-13
Master/Slave Pulse Port cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Configuring Your Master Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Configuring Your Slave Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Master/Slave Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Monitoring Your Master/Slave System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Clearing Faults in a Master/Slave System . . . . . . . . . . . . . . . . . . . . . . . 5-17
Master/Slave Input On/Off Combinations . . . . . . . . . . . . . . . . . . . . . . . 5-18
Sync Pulse Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Sync Pulse Port Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Sync Pulse Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Sync Pulse Port Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Configuring For Sync Pulse Transmit/Receive . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Sync Pulse Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Simple Sync Pulse System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Sync Pulse Master/Slave System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Monitoring Your Sync Pulse System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Clearing Faults in a Sync Pulse System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Rear Panel Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Chapter 6. Operation
Operating Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Understanding Pinnacle Plus+ Arc Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Voltage Arc Trip Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Frequency and Reverse Time Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Low Power Operation Versus High Power Operation . . . . . . . . . . . . . . . . . . . . . . 6-4
Low Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
High Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Cable Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Chapter 7. Troubleshooting and Global Customer
Support
Before Calling AE Global Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
First Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Checks with the Unit Powered Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Checks with the Unit Powered On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Passive Front Panel Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Checks if the Output Does Not Turn On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Help Code Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
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Clearing the Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Error Code Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
AE Global Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Returning Units for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Authorized Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
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Figure 2-1. Pinnacle™ Plus+ functional block diagram. . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 3-1. Pulse reversal times and self-run frequencies . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-2. Pulse reversal time as a function of voltage limit (V-Limit) . . . . . . . . . . . . 3-11
Figure 3-3. Operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Figure 3-4. Impedance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Figure 4-5. Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-6. Two-line output display screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 4-7. Control panel main menu functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Figure 4-8. Service menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Figure 4-9. Supply menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Figure 4-10. Process menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Figure 4-11. Standard Serial port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Figure 4-12. AE Bus port connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Figure 4-13. Rocker DIP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Figure 4-14. Slide DIP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Figure 4-15. Orientation of the AE Bus port and external DIP switch on the back panel 4-
50
Figure 4-16. Graphic representation of an AE Bus message packet . . . . . . . . . . . . . 4-54
Figure 4-17. AE Bus communications transaction . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Figure 4-18. AE Bus communications transaction example . . . . . . . . . . . . . . . . . . . . 4-59
Figure 4-19. Passive front panel (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99
Figure 4-20. Active front panel (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99
Figure 4-21. Remote panel (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Figure 4-22. Remote panel (rear view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Figure 4-23. Remote panel (dimensions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102
Figure 5-1. Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-2. Clearances for Pinnacle™ Plus+ units stacked in a cabinet . . . . . . . . . . . 5-4
Figure 5-3. Contactor interlock connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Figure 5-4. UHF connector and sleeve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Figure 5-5. Rear view of UHF connector housing without interlock (back plate removed)
5-11
Figure 5-6. Rear view of UHF connector housing with interlock (back plate removed) . 5-
11
Figure 5-7. Pinnacle Plus+ master/slave interface Host card . . . . . . . . . . . . . . . . . . . 5-12
Figure 5-8. Master/Slave Pulse port connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Figure 5-9. Master/Slave Pulse port cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Figure 5-10. Master/Slave Pulse system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Figure 5-11. Sync Pulse connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
List of Figures
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Figure 5-12. Sync Pulse cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Figure 5-13. Simple Sync Pulse system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Figure 5-14. Sync Pulse master/slave configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Figure 5-15. Rear view illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
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5702269-C xv
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Table 1-1. Electromagnetic Compatibility (EMC) Directives . . . . . . . . . . . . . . . . . . . . . 1-5
Table 1-2. Electromagnetic Compatibility (EMC) Standards . . . . . . . . . . . . . . . . . . . . . 1-5
Table 1-3. Safety Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Table 1-4. Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Table 3-1. Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-2. Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table 3-3. Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Table 3-4. Reverse Time Given a Self-Run Frequency . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Table 3-5. Reverse Time as a Function of Voltage Limit (V-Limit) . . . . . . . . . . . . . . . 3-11
Table 3-6. Climatic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Table 3-7. Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Table 4-1. User Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Table 4-2. DeviceNet™ Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Table 4-3. Structure of the poll command message . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Table 4-4. Structure of the poll command message . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Table 4-5. MOD Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Table 4-6. Network Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Table 4-7. Display Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Table 4-8. Remote Panel Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Table 4-13. Serial Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Table 4-14. AE Bus Host Port Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Table 4-15. AE Bus Address Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Table 4-16. Setting Switch 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Table 4-17. Baud Rate Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Table 4-18. Command Status Response (CSR) Codes . . . . . . . . . . . . . . . . . . . . . . . 4-58
Table 4-19. AE Bus Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Table 7-1. Passive Front Panel Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Table 7-2. Troubleshooting LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Table 7-3. Help Code Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Table 7-4. Error Code Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Table 7-5. Global Customer Support Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
List of Tables
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5702269-C Safety and Product Compliance Guidelines 1-1
Chapter
Pinnacle™ Plus+ 10 kW Chapter
1
Safety and Product Compliance
Guidelines
This manual documents how to install operate, maintain, and troubleshoot the
Advanced Energy®Apex generator power supply. Retain this manual for future
reference.
IMPORTANT SAFETY INFORMATION
To ensure safe installation and operation of the Advanced Energy®Apex generator,
read and understand this manual before attempting to install and operate this unit. At a
minimum, read and follow the safety instructions and practices documented under
“Safety Guidelines” on page 1-2.
INTERPRETING THE MANUAL
The following sections explain the document type conventions and the danger,
warning, and caution boxes that provide information about the specific levels of
hazard seriousness.
Type Conventions
Please note the following type conventions:
• Pin and signal names appear in capitalized italics (POWER_ON).
• New terms appear in italicized text.
• Unit labels (switches, indicators, and so on) appear in boldface text (MODIFY).
• Commands (162) and command names (set point) appear in boldface, lowercase
text.
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1-2 Safety and Product Compliance Guidelines 5702269-C
Advanced Energy®
Danger, Warning, and Caution Boxes
This symbol represents important notes concerning potential harm to people, this unit,
or associated equipment. Advanced Energy®includes this symbol in Danger,
Warning, and Caution boxes to identify specific levels of hazard seriousness.
SAFETY GUIDELINES
Review the following information before attempting to install and operate the product.
Rules for Safe Installation and Operation
Please note the following rules:
• Do not attempt to install or operate this equipment without proper training.
• Ensure that this unit is properly grounded (see also “Grounding” on page 5-5).
• Ensure that all cables are properly connected (see “Installation” on page 5-1).
• Verify that input line voltage and current capacity are within specifications before
turning on the power supplies (see “Electrical Specifications” on page 3-4).
• Use proper electrostatic discharge (ESD) precautions.
DANGER indicates an imminently hazardous situation that, if not
avoided, will result in death or serious injury. DANGER is limited to the
most extreme situations.
WARNING indicates a potentially hazardous situation that, if not avoided,
could result in death or serious injury, and/or property damage.
CAUTION indicates a potentially hazardous situation that, if not avoided,
could result in minor or moderate injury, and/or damage to property.
CAUTION is also used for property-damage-only accidents.
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5702269-C Safety and Product Compliance Guidelines 1-3
Pinnacle™ Plus+ 10 kW
• Always be careful around this equipment.
Interpreting Product Labels
The following labels may appear on your unit:
The product warranty is
void if you remove the
power supply box cover.
Contact AE Global
Customer Support for
more information (see “AE
Global Customer Support”
on page 7-19).
CE label
Earth ground
Hazardous voltage
High voltage
Hot surface
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1-4 Safety and Product Compliance Guidelines 5702269-C
Advanced Energy®
PRODUCT COMPLIANCE
The following sections include information about unit compliance and certification,
including the conditions of use required to be in compliance with the standards and
directives.
Product Certification
Certain options of this product are certified by:
• CE marking, self addressed by AE Compliance Engineering
• EMC measurements, verified by an independent third-party EMC testing
laboratory.
Nonionizing radiation
NRTL
Protective Earth ground
Refer to manual for more
information
Short circuit protected
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