APS APS-1000 Series User manual

Operations Manual
OM-001-01000-000-04.1
APS-1000 Series
Power Converters
Entire Contents Copyright

2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
ADAPTIVE Power Systems
Worldwide Supplier of Power Conversion Equipment
TM

CONTENTS
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series ii OM-001-01000-000-04.0
Contents
Front Matter
Contents ....................................................................................................... ii
Contact Information..............................................................................v
Warranty Information......................................................................... vi
Chapter 1 Introduction
Introduction............................................................................................... 1-1
Overview ........................................................................................... 1-1
Safety Notices .................................................................................. 1-2
Preparation for Installation............................................................... 1-5
Installation Instructions .................................................................... 1-6
Example Wiring Diagram ................................................................ 1-7
Storage and Transportation .............................................................. 1-8
Chapter 2 Specifications
Overview .................................................................................................... 2-1
Introduction ....................................................................................... 2-2
APS-1000 Specifications ................................................................. 2-2
Input Electrical Specifications ......................................................... 2-3
Output Electrical Specifications ..................................................... 2-3
Power versus Output Frequency Rating Chart ............................... 2-4
Displays and Controls ..................................................................... 2-5
Mechanical Specifications ............................................................... 2-5
Environmental Specifications ......................................................... 2-5
Output Surge-Current Capability .................................................... 2-6

CONTENTS
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series iii OM-001-01000-000-04.0
Chapter 3 Unit Description
Overview .................................................................................................... 3-1
Front Panel Organization .................................................................3-1
Frequency Display and Selection ................................................... 3-3
Voltage Display and Selection ........................................................ 3-4
Current Display and Selection ......................................................... 3-5
Power / PF Display and Selection .................................................. 3-6
Cabinet Controls and Connections ................................................. 3-7
Chassis Details .................................................................................. 3-7
Cabinet Features ............................................................................... 3-9
Chapter 4 Operating Instructions
Overview .................................................................................................... 4-1
Basic Operation ................................................................................ 4-2
Voltage (Display) Setting.................................................................4-3
Frequency (Display) Setting ............................................................ 4-5
Current Limit (Display) Setting....................................................... 4-6
Power / PF (Display) Setting ........................................................... 4-7
Operations ......................................................................................... 4-8
(Persistent) System Parameter Settings.........................................4-10
(Persistent) System Parameter Table.............................................4-11
Setting (Persistent) System Parameters.........................................4-12
Program Memory Procedures (Programming) ............................4-14
Error Messages ...............................................................................4-15
Error Message Table ......................................................................4-16
Interpreting Error Messages...........................................................4-17
Chapter 5 External Interfaces
Overview .................................................................................................... 5-1
PLC External Interface .................................................................... 5-2
Manual Switcher (Three Program Control) ................................... 5-3

CONTENTS
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series iv OM-001-01000-000-04.0
Chapter 6 System Calibration
Overview .................................................................................................... 6-1
Calibration Setup ............................................................................. 6-2
Calibration Instructions ................................................................... 6-4
Low-Voltage Mode (V-LO) Calibration ........................................ 6-6
High-Voltage Mode (V-HI) Calibration ......................................... 6-7
Low-Current Mode (A-LO) Calibration ......................................... 6-8
High-Current Mode (A-HI) Calibration .......................................6-10
Low-Power Mode (P-LO) Calibration ..........................................6-12
High-Power Mode P-HI) Calibration............................................6-14
Chapter 7 System Maintenance
Overview .................................................................................................... 7-1
Introduction ...................................................................................... 7-1
System Design .................................................................................. 7-2
APS-1000 Series System Block Diagram....................................... 7-3

CONTACT INFORMATION
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series vOM-001-01000-000-04.0
Contact Information
Adaptive Power Systems, Inc.
17711 Mitchell North • Irvine, CA 92614 USA
Telephone: [phone]
FAX: [phone]
E-mail: [e-mail]
Web: http://www.adaptivepower.com

WARRANTY INFORMATION
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series vi OM-001-01000-000-04.0
APS-1000 Series Power Converters Limited Warranty
Adaptive Power Systems, Inc. (APS) warrants each unit to be free from defects in material
and workmanship. For the period of one (1) year from the date of shipment to the
purchaser, APS will either repair or replace, at its sole discretion, any unit returned to the
APS factory in Irvine, California.It does not cover damage arising from misuse of the unit
or attempted field modifications or repairs. This warranty specifically excludes damage to
other equipment connected to this unit.
Upon notice from the purchaser within (30) days of shipment of units found to be defective
in material or workmanship, APS will pay all shipping charges for the repair or replacement.
If notice is received more than thirty (30) days from shipment, all shipping charges shall be
paid by the purchaser. Units returned on debit memos will not be accepted and will be
returned without repair.
This warranty is exclusive of all other warranties, expressed or implied..
APS-1000 Series Service and Spare Parts Limited Warranty
APS warrants repair work to be free from defects in material and workmanship for the
period of ninety (90) days from the invoice date. This Service and Spare Parts Limited
Warranty applies to replacement parts or to subassemblies only. All shipping and
packaging charges are the sole responsibility of the buyer. APS will not accept debit
memos for returned power sources or for subassemblies. Debit memos will cause
return of power sources or assemblies without repair.
This warranty is exclusive of all other warranties, expressed or implied.

CHAPTER 1
INTRODUCTION
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series 1 - 1 OM-001-01000-000-04.0
Chapter 1
Introduction
Overview
Chapter 1 contains important information you should read BEFORE attempting to
install and power-up your APS-1000 Series Power Converter. The information in this
chapter is provided for use by experienced operators. Experienced operators
understand the necessity of becoming familiar with, and then observing, life-critical
safety and installation issues. Topics in this chapter include:
Safety Notices
Warnings
Cautions
Preparation for Installation
Installation Instructions
Transportation
Storage
Introduction to the APS-1000 Power Converter
APS-1000 Series Power Converters have been designed for long-life trouble-free
operation in the shop-floor testing environment. The input to APS-1000 units is
commercially available power at fixed voltage and frequency. The output from APS-
1000 units is programmable power at user-controlled voltages and frequencies.
There are several operational modes: (1) front panel manual control; (2) manually
programmed test sequences; (3) external control of the manually programmed
instruction test sequences.

CHAPTER 1
INTRODUCTION
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series 1 - 2 OM-001-01000-000-04.0
The APS-1000 Series of Power Converters have been designed to provide frequency
and voltage conversion in a controlled test environment. Both manually adjustable and
remotely-programmable settings are provided. All APS-1000 Series Power Converters
provide 1-phase output power. Different models cover the power range from 2 kVA to
60 kVA. All units provide user-controlled 1-phase output power within the frequency
range of 45 – 500 Hz.
All APS-1000 Series units operate as double-conversion power converters. The first
conversion is AC to DC. The second conversion is DC back to AC. Three units (APS-
1002, APS-1003, and APS-1005) operate with 1-phase input power. All other units
operate with 3-phase input power. After rectification, filtering removes high-frequency
content. Low-ripple DC is subsequently converted to 1-phase AC by a high-frequency
pulse-width-modulated (PWM) switcher. Precise control is maintained by using a
highly stable digital oscillator.
APS-1000 Series Power Converters are designed for long-term continuous operation
in sheltered (no rain) environments. Because there are no batteries, APS-1000 units
operate reliably over a wide ambient temperature range. Through the use of switching
technology the equipment is efficient (about 85%). Power Converter units are
relatively tolerant of high dust environments.
Safety Notices
APS-1000 Series Power Converters can transfer very large amounts of
electrical energy very quickly.
The rapid transfer of large amounts of electrical energy is fundamental to any
high-performance power source.
Only experienced operators who have both read and understood the
information in this manual should attempt to operate the unit.
The following warnings and cautions herein must be observed at all times.

CHAPTER 1
INTRODUCTION
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series 1 - 3 OM-001-01000-000-04.0
WARNINGS indicate potentially hazardous situations which, if not avoided, could result in
death or serious injury. All warnings throughout this manual will appear as follows:
–
WARNING
IF THIS EQUIPMENT IS NOT USED IN A MANNER SPECIFIED BY THE MANUFACTURER,
THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED
WARNING
THIS EQUIPMENT CONTAINS HIGH ENERGY, LOW IMPEDANCE CIRCUITS!!
LETHAL POTENTIALS ARE CONTAINED WITHIN THE CABINET.
CARE MUST BE EXERCISED WHEN OPERATING, CALIBRATING, OR SERVICING
THIS EQUIPMENT, IN ORDER TO PREVENT SERIOUS OPERATOR INJURY OR
EQUIPMENT DAMAGE.
OBSERVE THE FOLLOWING WHEN SERVICE AND MAINTENANCE ARE REQUIRED:
1) REMOVE ALL JEWELRY FROM ARMS AND NECK WHEN SERVICING THIS
EQUIPMENT. THIS PREVENTS THE POSSIBILITY OF SHORTING THROUGH THE
JEWELRY AND CAUSING BURNS TO THE OPERATOR.
2) WEAR SAFETY GLASSES WHEN SERVICING THIS EQUIPMENT TO PREVENT EYE
INJURY DUE TO FLYING PARTICLES CAUSED BY ACCIDENTAL SHORT CIRCUIT
CONDITIONS.
3) DO NOT REMOVE ANY PANEL OR COVER WITHOUT FIRST REMOVING THE INPUT
POWER BY OPENING ALL CIRCUIT BREAKERS.
4) SERVICE OTHER THAN REGULARLY SCHEDULED CALIBRATION OR EXTERNAL
CLEANING SHOULD BE REFERRED TO PERSONNEL AUTHORIZED BY THE
FACTORY TO SERVICE THIS EQUIPMENT.

CHAPTER 1
INTRODUCTION
Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
APS-1000 Series 1 - 4 OM-001-01000-000-04.0
CAUTIONS indicate a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It also may be used to alert against unsafe practices.
Cautions will appear as shown below. All cautions should be rigorously observed.
CAUTION
Read the INSTALLATION and OPERATION instructions
of this manual before installing or operating this equipment.
To protect the equipment from damage, caution statements are used as follows:
CAUTION
Refer to INDUSTRY STANDARDS for the safe correct size of the power
input cables. The incorrect use of small-gauge input cables may cause
overheating and damage the cables or the equipment.
•Before using this AC converter, please read all the safety labels that are attached
to this unit.
•Before turning on the input power source to this equipment, please check to make
sure that the input voltage selection is correct.
WARNING
Before turning on the input power source to this equipment,
please check to make sure that a good earth ground is con
nected
to the proper terminal.