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Pinnacle® Plus+ 10 kW Power Supply 325 VDC – 800

1. Ir BING PIN 1 PIN9 23 PIN 5 g E l 57 lead tT fi PIN 5 PIN 9 i PIN HEHH PN 6 o j lt r 4 r o FT PIN 1 A kel j d PINS Hte9 Ne 4 lead i j 9 Figure 4 10 Sync Pulse cable 57000097 00B Communication Interfaces 4 53 Advanced Energy DEVICENETTM PORT The rear panel of your Pinnacle Plus power supply features a DeviceNet M port for interfacing with a DeviceNet network The DeviceNet port is a round five pin male micro connector which is electrically isolated from the power supply see Figure 4 11 Note Dual Pinnacle Plus units units containing two separate inverters share the common DeviceNet network micro connector but each side is controlled and operated independently through this port The following discussion describes the operation of one side of the unit The other side operates the same way 1169 5 Figure 4 11 DeviceNet port with pin designations Installation Use the appropriate female micro connector and cable to connect to the DeviceNet port connector See the DeviceNet Specification revision 2 0 from the Open DeviceNet Vendor Association Inc for specifics on the mating connector and cable Use the rotary switches to select a baud rate and s
2. 3188 CONFIGURING A MASTER SLAVE SYSTEM The following sections provide information on configuring and connecting your power supplies for master slave operation Note The master slave feature is only available on Pinnacle Plus 10 kW units This feature is not available on Pinnacle Plus 5 kW or dual units Configuring the Master Unit To Configure the Power Supply as a Master Unit 1 Remove all input power from the power supplies in your master slave system 2 If the Pinnacle Plus power supply includes a User card ensure that the interlock inputs are satisfied Refer to the Chapter 4 in the Pinnacle Plus power supply user manual for specific User port pin descriptions and required voltage levels 3 Set the MSTR SLV switch in the up MSTR position 4 Connect the master slave interface cable with the modular plug ends between port P1 the MSTR port on the master unit and port P2 the SLV port on the first slave unit The master slave interface cable is included with the unit Note The master unit will not have an interface cable connected to port P2 5 Connect the included master slave pulse interface cable with the 15 pin subminiature D plug ends between the Master Slave Pulse port on the master unit and the Master Slave Pulse port on the associated slave units 6 Use a grounding strap to connect an equi potential ground stud on the master unit to an equi potential ground stud on the first
3. 4 1 Single 15 V 37 Pin User Port 2ca6ccekardas de KK KK KK KK KK KK KI K KI KIR KK KI KK des 4 2 Installation asse apna aia ea EE Hu RE A a 4 3 Signals ka K al au irra d a alan a di alal ark a d ava DEA DER ews Kahan ee eR a REA 4 3 Anal g Signals 4 08 a aha kla ala a kya le al k dk al k be a ara ar aa ala aa a al a anka 4 3 Digital signals kk kk kk kK KK KK KK KK KK KK KK KK KIRI baw keen eS 4 5 Pin Description Table anaana kk kk kk kK kk KK KK KK KK KI KI KK KI KI KIR KK KK KIR 4 5 User Port Output Enable Disable Behavior and Signal States 4 14 Reporting the Active Target Setting to an External Device 4 15 Setting the Active Target Life Counter 0000000 4 15 Setting the Regulation Mode WW KK KK KK KK eee eee ee 4 16 Single 24 V 37 Pin User Port Jk kk kk KK KK KK KK KK KI KK ee KK IK IK 4 16 G nhDneGIOF lt w a kn kesa Wl bd Hew Gela Bi W bela n K la Ki k A D ya Aij 4 17 Interlock Requirements kk kk kk kK KK KK KK KK KK KK KK KK KK KK 4 18 User Supplied Power Requirements 000000 e eee eee 4 18 Signals O w YPPNPe gt r rrrmmmmmmmmmmmmmuUr 4 18 Analog signals A case kk KK et KK KK KK KK KK K KK KK KK venkat 4 18 Digital SIQNAIS s i aa domaa Cane al kl aE dirana ana ar aa al daa W eH 4 19 Pin Descriptions kk kk kk nanana 4 19 Single 15 V 25 Pin User Port Jk kk kk kk KK KK KK KK KK KI KK
4. Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 147 Requests pulse reverse time read in 0 1 us 0 1 increments the returning packet contains 1 request pulse byte reverse time e 04 0 4 us e 05 0 5 us e 06 0 6 us 07 to 49 follow the established pattern e 50 5 0 us This value is set with command 93 152 Requests the ramp start set point percentage 0 1 returning packet contains 1 data byte 8 bit request ramp between 0 and 95 start set point i i i percentage Note This setting only applies to regular ramp mode It does not apply to ramp mode in a timed recipe This value is set with command 32 153 Requests joule mode status the returning 0 1 packet contains byte request E joules status 0 Inactive e Non zero value Active This value is set with command 5 154 Requests the output regulation mode the 0 1 returning packet contains data byte 8 bit request value regulation mode e 6 Power e 7 Voltage e 8 Current Note Output power must be off that is output must be deenergized to switch between regulation modes This value is set with command 3 57000097 00B Communication Interfaces 4 197 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 155 Requests control mode the returning packet 0 1 contains
5. Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 130 Requests the maximum power voltage and 0 6 request current levels The returning packet contains maximum six data bytes three 16 bit values voltage and current e Bytes 0 and 1 Power level in watts e Bytes 2 and 3 Voltage level in volts e Bytes 4 and 5 Current level in hundredths of amps 131 Displays most recent entry 40 characters to 0 40 scratch pad memory request j scratch pad Set with command 127 memory 136 Requests the output level that needs to be met 0 2 before the Joule output energy calculation request joule begins threshold This level is set with command 26 The joule threshold type power voltage or current is set with command 64 140 Requests the AE Bus time out value the 0 2 returning packet contains 2 data bytes 16 bit request value indicating the time in ms a value of 2 AE Bus time indicates 20 ms out value This value is set with command 40 141 Requests the output power limit Accuracy is 0 2 0 3 of the full rated output voltage for the request user supply power limit The returning packet contains 2 data bytes 16 bit value indicating the limit in kilowatts The value implies 3 decimal places for a stand alone unit 5000 5 000 kW and 2 decimal places are implied for a master slave unit 2000 20 00 kW This value is set with command 49 57000097 00B Communication Inte
6. 3 14 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply Table 3 5 Reverse Time as a Function of Voltage Limit V Limit V Limit Corresponding Reverse Time in Volts 555 5 8 us 560 5 8 us 565 5 7 us 570 5 7 us 575 5 6 us 580 5 6 us 585 5 5 us 590 5 5 us 595 5 4 us 600 5 4 us 605 5 3 us 610 5 3 us 615 5 2 us 620 5 2 us 625 5 2 us 630 5 1 us 635 5 1 us 640 5 us 645 5 us 650 5 us 655 4 9 us 660 4 9 us 665 4 8 us 670 4 8 us 675 4 8 us 680 4 7 us 685 4 7 us 690 4 7 us 695 4 6 us 700 4 6 us 705 4 6 us 710 4 5 us 715 4 5 us 57000097 00B Product Specifications 3 15 Advanced Energy Table 3 5 Reverse Time as a Function of Voltage Limit V Limit V Limit Corresponding Reverse Time in Volts 720 4 5 us 725 4 4 us 730 4 4 us 735 4 4 us 740 4 3 us 745 4 3 us 750 4 3 us 755 4 3 us 760 4 2 us 765 4 2 us 770 4 2 us 775 4 1 us 780 4 1 us 785 4 1 us 790 4 1 us 795 4 us 800 4 us Operating and Impedance Range Illustrations The following graphs illustrate the output power operation range and output impedance range for your Pinnacle Plus power supply 3 16 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply Pinnacle Plus 10 kW 325 800 V Output Power Rang
7. 57000097 00B Communication Interfaces 4 5 Advanced Energy Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Continued Signal Pin 4 Return Pin 36 Pin Name Signal Type digital input TARGETO D Description This signal is used with TARGETL D pin 35 and TARGET2 D pin 34 to select the active target life counter See Setting the Active Target Life Counter on page 4 15 for more information 36 IREG D digital input This signal is used with PREG D pin 6 to set the regulation mode See Table 4 6 on page 4 16 for more information 36 PREG D digital input This signal is used with IREG D pin 5 to set the regulation mode See the description of pin 5 for the logic table associated with this signal 4 6 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 7 36 ON D digital This signal is used with input OFF D pin 14 to enable disable output power Pin 14 must be low to turn the unit on If OF F_D pin 14 is low amomentary low on pin 7 turns output power on If pin 14 is high pin 7 cannot enable output Once the on is issued via ON D pin 7 pin 14 has priority to override all commands to turn the unit off When pin 14 transitions high after the
8. Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 160 Requests the status of the logic board The 0 6 information in the returning packet is used by request AE Global Services status The returning packet contains 6 data bytes Ist and 2nd bytes SW_OPTS1 16 bit value e Bit 0 Single Inverter Unit read only e Bit 5 500ns Gate Drive Unit read only Bit 7 100 ms ramp bit clear 10 ms ramp Bit 8 Joule recipe definition bit clear normal e Bit 12 Measurement balance bit set feature enabled 3rd and 4th bytes SW_OPTS2 16 bit value e Bit 1 Voltage ignition bit set feature enabled e Bit 2 User port End of Target Life EOTL indicator is READY signal bit set feature enabled e Bit 3 High Speed Baud Rate 19200 38400 57600 115200 bit clear normal Bit 9 No explicit fault clearing requires power cycle to clear bit clear off and reset command clears fault Bit 11 Maximum on timer bit set feature enabled 5th and 6th bytes Always 0 57000097 00B Communication Interfaces 4 199 Advanced Energy Table 4 48 AE Bus Commands Continued e 0 Output on sequence OK e 1 Control mode invalid e 2 Unit is already on e 7 Active fault exists e 11 Bus is not ready 16 End of target life event e 17 Minimum off time is active e 31 User port reset line active e 32 Con
9. 57000097 00B Troubleshooting and Global Services 6 9 Advanced Energy Table 6 3 Help Code Troubleshooting Table Help Help Code Problem Indicated Suggested Action Code Message Number H001 Wrong Control The action requested was Check the control mode Set Mode not from the control source it to the desired control For example an AE Bus source command was issued but the unit is in Local control mode H002 Can t Change The action requested cannot Turn off output power and While be performed because the try again Output is On power supply output is on Output is You have attempted to turn Turn off output power and Already On on the output but output try again power is already on 6 10 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Table 6 3 Help Code Troubleshooting Table Help Help Code Problem Indicated Suggested Action Code Message Number H004 User Limit You have attempted to seta Retry setting the limit using Out of Range power voltage or current an acceptable value limit to a value outside the allowable range Timer Out of You have attempted to seta Retry setting the timer using Range timer to a value outside the an acceptable value allowable range Arc Count Limit You have attempted to set Retry setting the limit using Out of Range the arc count limit toa value an acceptable value
10. kk kk kk kk kK KK KK KK KK KI K K K KIR KI K KI KOK K KK K 4 149 Setting the Micro Arc Trip Level 2 0 0 2 RR KK KK 4 149 Setting the Arc Count Limit KK KK eee eee 4 150 Setting the Hard Arc Shutdown Time 2 000 KK eee 4 150 Viewing the Arc Density 2 kk kk kK KK KK KK K ee 4 150 Setting the Sequential Micro Arc Count and Time 4 151 Enabling Arc Handling 22 2hiecs capa haagoe Ra Sea hek eax eaeee 4 151 Setting Control Parameters kk kk kk kK KK KK KK KK ee 4 152 Setting Recipes kk aca ka ka kk kk kk kk k ak ka ak kk kk a kk OR EERE 4 152 Setting Joule MOUS ics canteen neki a kaka kak lk kala kaka kk kk kk kk k 4 155 Setting the Joule Set point n kk kk kk kk KK KK KK KI KK ee 4 155 Setting the Joule Threshold 0 00 0 cece K KK 4 155 Setting the Ramp kk kk kk kk kk deck ee aeons a ee kk kk kk kk ees 4 156 Standard Serial Flash Port kk kk kK KK KK KK KK KK KK KK KK KK KK 4 157 Standard Serial Port Description KEK KK RR RR RR KK KK 4 157 Standard Serial Port Pin Descriptions 4 158 Transmission Parameters 00 00 cece eee 4 158 AE B s Host Poms i102 cenceesstene sc oaie te debe dd Qata R ees 4 159 Pin Descriptions ll kak kk kk kk ccc eee 4 159 Transmission Parameters nananana KK KK KK KK KK KK K KR KR eee 4 160 Switch Settings lk kk kak kak kk lk k
11. Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 52 Sets a maximum strike voltage Send 1 data 1 CSR only byte representing a strike voltage range user strike 7 voltage limit e 0 low e 1 medium e 2 high The values associated with each range depend on the output impedance range of your unit Strike Standard Z Unit High Z Unit Voltage 325 650 V 325 800 V Setting Low 800 V 100 V 1 000 V 100 V Medium 1 100 100 V 1 200 V 100 V High 1 450 150 V 1 450 V 150 V Read back this value with command 144 59 Sets the number of times a continuous jole 2 CSR only joule recipe recipe repeats before turning output off and repetition completing 4 188 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 61 Enables or disables micro arc handling feature 1 CSR codes Hard arc handling is always enabled 0 1 enable disable micro Send 1 data byte 8 bit value arc handling 0 Disable Non zero Enable Note Cycling power to the unit resets arc handling mode to enabled Read this value with command 163 64 Sets the joule mode counter threshold type 1 CSR codes 0 1 2 4 9 threshold Send one data byte 8 bit value type e 0 Power e 1 Voltage e 2 Current Read back this setting w
12. DANGER Connecting to the User port does not require removing the Pinnacle Plus unit s cover Removing the cover from any power supply could result in severe personal injury and or damage to the unit Do not attempt to change any of the potentiometers or jumpers on the User port board Note Signals at the User port can be sensitive to noise We recommend that you take standard preventative measures against electro magnetic interference EMI including using shielded cabling on the User port Note Turn off ac input power to the Pinnacle Plus unit before connecting a cable to the User port connector Note that we recommend taking standard preventative measures against electro static discharge ESD around all Pinnacle Plus units Note Grounding the User port at the power supply reduces noise interference To avoid ground loop problems you should typically ground only one end Connect your system s 24 V supply to pins 10 26 and 31 on the Pinnacle Plus supply s User port Your 24 V supply must meet the following requirements Voltage nominal 24 V dc e Ripple 3 6 V ac maximum Permissible voltage range 20 V to 30 V e V surge t lt 0 5 s 35 V Current depends on loading of outputs 5 0 A maximum Before operating your unit from the User port ensure that the control mode is set to the User port The default is User port on units which feature the User port as the sole interface If you have been using ano
13. Signal Pin 26 Return Pin 5 Pin Name 24 VSUPPLY Signal Type input Description Connect your system s 24 V power supply to this pin 27 28 A _OUTPUT D digital output When high this signal indicates that the contactor is closed and output power is on 28 n a A_OUTCOM D This signal is a dedicated return for digital outputs Reference A ARC D pin 8 A_SETPOINT D pin 9 and A_OUTPUT _D pin 27 to this pin 29 n a B_OUTCOM D n a This signal is a dedicated return for digital outputs Reference B SETPOINT D pin 11 B_ARC_D pin 12 and B OUTPUT D pin 30 to this pin 30 29 B_OUTPUT D digital output When high this signal indicates that the contactor is closed and output power is on 31 24 VSUPPLY input Connect your system s 24 V power supply to this pin 32 15 B_IREG D digital input This pin is used with B_PREG D pin 13 to set the regulation mode See description of pin 13 for logic table associated with this signal 33 15 B_RESET D digital input A high on this pin will reset active explicit clear faults for unit B provided that the fault conditions are no longer present This pin must be returned to the inactive state low to enable the unit output 4 48 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4
14. Table 3 4 Reverse Time Given a Self Run Frequency Continued Requested Actual Pulse Duty Cycle Duty Cycle Frequency Frequency Reversal Time min max kHz kHz Maximum us Reverse Reverse Period Period 295 294 118 1 3 11 76 38 2 300 298 507 1 3 11 94 38 8 305 303 03 1 3 12 12 39 4 310 307 692 1 3 12 31 40 315 312 5 1 2 12 50 37 5 320 317 46 1 2 12 70 38 1 325 322 581 1 2 12 90 38 7 330 327 869 1 2 13 11 39 3 335 333 333 1 2 13 33 40 340 338 983 1 1 13 56 37 3 345 344 828 1 1 13 79 37 9 350 350 877 1 1 14 04 38 6 Reverse Time As A Function of Voltage Limit Note Not all Pinnacle Plus units are shipped with reverse time as a function of voltage limit This is a special feature that your power supply must be configured for at the factory Some processes require that the Pinnacle Plus power supply allow a longer duration when reversing the voltage By utilizing the V Limit function of your power supply you may be able to increase the reverse time to a maximum of 10 us when voltage is limited to 325 V When the unit is set for 650 V or higher in Hi Z models the maximum reverse time is 5 us As you decrease process voltage using the V Limit function the reverse time increases linearly until it reaches the maximum allowable value of 10 us Note The maximum reverse time duty cycle is still 45 Figure 3 3 on page 3 13 is a graph of pulse reversal times as
15. A PULSEON D is an active high digital input signal If Switch 6 is OFF A PULSEON D is an active low digital input signal 7 This switch affects the input signal of LEVELIN A See descriptions for Pins 6 and 19 in Table 4 11 on page 4 28 for more information Switch 7 in ON position Connects LEVELIN_RET A to COM A analog common This connection creates LEVELIN A as single ended input Switch 7 in OFF position Floats LEVELIN_RET A which provides LEVELIN A as differential input 8 This switch affects how you set your remote common pins For analog common pin descriptions see Pins 5 8 14 15 and 16 in Table 4 11 on page 4 28 For digital common pin descriptions see Pins 17 18 20 21 and 24 in Table 4 11 on page 4 28 Switch 8 in ON position Connects COM A analog common to COM D digital common This connection simplifies interfacing to existing cabling Switch 8 in OFF position Separates COM A analog common from COM D digital common You must wire COM A and COM_D separately 57000097 00B Communication Interfaces 4 35 Advanced Energy SINGLE 15 PIN USER PORT This section applies to Single 15 pin User port You can identify this port using the following characteristics The User port is a 15 pin subminiature D port and is on a single output unit that also has a DeviceNet interface The User port allows you to control the Pinnacle unit through a rem
16. X Table of Contents 57000097 00B Pinnacle Plus 10 kW Power Supply Setting the Panel Mode kK cee ee 4 142 Selecting Remote or Local Mode 2 2020 KK 4 142 Selecting a Lock Code 0 0000 cece 4 142 Selecting the Number of Clicks 000 0c KK KK 4 142 Using Process Functions 0 kK kK kK kK KK KK KK KK KK KK KK KK kk k 4 143 Monitoring Your Process kk kk kk kk kk KK KK KK KK KK KK eee eee 4 143 Viewing the Over Voltage Density sk KK KK KK KK eee ee 4 143 Resetting the over Voltage Density 0 000 4 144 Setting the Over Voltage Timer 0 00000 RR RR eee 4 144 Viewing the Over Current Density 0 0 00 e eee eee 4 144 Resetting the Over Current Density 2 KK KK 4 145 Setting the Over Current Timer 0 00000 eens 4 145 Setting the Out of Set point Timer 000 RR RR eee 4 145 Changing the Target Functions 2 0200e KK KK 4 146 Setting Process Limits owen Puede en ee ea Pah Koh ee wea a ees 4 147 Setting a Strike Voltage Limit 0 0 0 eee ee eee 4 147 Setting a Maximum Limit for Output Voltage 4 148 Setting the Maximum Limit for Output Current 4 148 Setting the Maximum Limit for Output Power 4 148 Setting the Gross Short Circuit Current Limit 4 149 Setting Arc Handling
17. EQUIPMENT SETUP The following figure shows how to set up the equipment for the procedures that follow For units without AFP Control Panel RG393 2 Bird loads Pinnacle Plus in parallel j 20 kW load P5100 probe TOFS09 current probe Oscope 3743 TCPA300 Figure 6 1 Equipment setup for Pinnacle Plus basic functionality test TO CHECK BASIC UNIT FUNCTIONALITY Use these two procedures to test basic unit functionality first with pulsing disabled and then with pulsing enabled If the results of these tests are not within the noted tolerances contact AE Global Services WARNING 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 A CAUTION Follow proper ESD precautions during this test Test with pulsing disabled 1 Ensure that the test equipment is set up as described in the preceding section 57000097 00B Troubleshooting and Global Services 6 5 Advanced Energy N Disable pulsing mode on the Pinnacle Plus unit W Set up the oscilloscope to measure the low of the output voltage and the low of the output current 4 Set the Pinnacle Plus unit to local control mode and power regulation mode 5 Set the set point
18. RS 232 1200 4800 9600 19 200 RS 422 RS 485 9600 19 200 38 400 57 600 High speed baud rates same for RS 232 RS 422 and RS 485 19 200 38 400 57 600 115 200 Odd parity 1 start bit 8 data bits one stop bit Low order bytes are transmitted before high order bytes The time out period for Pinnacle Plus units is factory set at 0 02 s that is no more than 0 02 s can elapse between bytes or the unit will reset and begin looking for a new message packet This can be changed using Command 40 4 160 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply The host computer must finish one transaction with a Pinnacle Plus unit before it initiates another one either with the same unit or any other unit Note If you have selected RS 232 the Pinnacle Plus unit sends data through pin 2 TXD D This pin must be connected to the receive pin RXD D on the host computer s PC serial connector The receive pin is normally pin 2 for a standard 9 pin PC serial port and normally pin 3 for a standard 25 pin PC serial port Note If you are using RS 422 or RS 485 the Pinnacle Plus supply sends and receives data differentially Thus pin 6 TR or R and pin 7 TR or R are either RS 485 transmit and receiver lines or RS 422 receiver lines Pins 8 and 9 are RS 422 transmit lines Switch Settings The DIP switch see Figure 4 22 on page 4 161 and Figure 4 23 on page 4 162 sets the AE Bus addre
19. 15 lead d PIN 8 PIN 15 PIN 1 PIN 9 o Ga o E PIN9 PIN 1 PIN 15 PIN 8 E PIN 1 PIN 9 n 5 lead wre 0000000 e EZE o PIN 15 N 9 Figure 4 8 Master Slave Pulse port cable SYNC PULSE PORT Connector Figure 4 9 illustrates the 9 pin subminiature D Sync Pulse port connector Pin 5 Pin 1 1017 Figure 4 9 Sync Pulse connector 4 52 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Pin Descriptions Table 4 18 provides pin and signal descriptions for the Syne Pulse port Table 4 18 Sync Pulse Port Pin and Signal Descriptions Pin Associated Pin Name Description Pin 1 6 SYNC_POWER_SE Verifies all units have logic NSE control power 2 6 8V 8V for future distribution box 3 7 HARC SP Hard Arc 100 ns pulse at beginning of each event 4 8 PON SP Pulse On 350 ns pulse pulsing switch close 5 9 POFF SP Pulse Off 300 ns pulse pulsing switch open 6 1 and 2 GND Ground chassis 7 3 HARC return Hard Arc signal return 8 4 PON SP return Pulse On signal return 9 5 POFF SP return Pulse Off signal return Cable Configuration Figure 4 10 illustrates the Syne Pulse port cable configuration
20. CSR only 57000097 00B Communication Interfaces 4 85 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued indicates an arc is occurring Sixteen discrete voltage arc levels are available These levels are trip level represented by the index numbers in the following table Send one data byte 8 bit value identifying the appropriate index value for the desired trip level The table below shows standard index values Your unit may be configured with different values For information about a specific unit contact AE Global Services Index Trip Level data byte result in volts 0 10 1 20 2 30 3 40 4 50 5 60 6 70 7 80 8 90 9 100 10 125 11 150 12 175 13 200 14 225 15 250 Read back this value with command 171 Command Description Number Number of of Sent Response Data Data Bytes Bytes 10 Specifies the voltage level at which the unit 1 CSR only 4 86 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number Numberof of Sent Response Data Data Bytes Bytes 11 Specifies which target will be active 1 CSR only Send 1 data byte 8 bit value the value must active target be at least 1 but no greater than 8 Note The User port has priority for target selection Thus to sel
21. Table 4 11 Single 15 V 25 Pin User Port Pin Description Continued Signal Name Signal Description Pin Type 5 COM A Analog This signal is used as a remote analog common common VOUT A pin 2 POUT A pin 1 and JOUT A pin 3 should be referenced to this pin This pin is switch connectable to COM D for previously wired systems Refer to Table 4 12 on page 4 34 Switch 8 description for more information Note This pin is internally connected to User port pins 8 14 15 and 16 6 LEVELIN A Analog This 0 to 10 V signal programs the input power output set point in kW Full scale represents the rating of the supply See the Specifications chapter of this manual for information specific to your unit The setting of Switch 7 affects this pin Refer to Table 4 12 on page 4 34 for more information Note Pin 19 is the dedicated return for this pin 7 unassigned n a n a 8 COM A Analog This signal is used as a remote analog common common VOUT A pin 2 POUTA pin 1 and JOUT A pin 3 should be referenced to this pin This pin is switch connectable to COM D for previously wired systems Refer to Table 4 12 on page 4 34 Switch 8 description for more information Note This pin is internally connected to User port pins 5 14 15 and 16 57000097 00B Communication Interfaces 4 29 Advanced Energy Table 4 11 Single 15 V 25 Pin User Port Pin Description Contin
22. Table 4 30 Configuration of Download Bytes Outbytes Byte Description 0 Command 1 Data byte LSB 2 Data byte 3 Data byte MSB In the packet Bytes 1 2 and 3 comprise the data field and contain information defined by the command Note that when the information extends over more than one byte the packet sends the least significant byte LSB before the most significant byte MSB this arrangement is a departure from previous PROFIBUS options we have offered 4 76 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Upload Packet During every PROFIBUS data exchange the Pinnacle Plus unit supplies a 14 byte response to a download outbytes packet The following list shows the response or upload packet These bytes are also known as inbytes Table 4 31 Configuration of Upload packet inbytes Byte Description 0 Status flags first byte 1 Status flags second byte 2 Actual power low 3 Actual power high 4 Actual voltage low 5 Actual voltage high 6 Actual current low 7 Actual current high 8 Data byte LSB 9 Data byte 10 Data byte 11 Data byte 12 Data byte MSB 13 Data field definition STATUS FLAG BYTES Bytes 0 and 1 of the upload packet contain information about the Pinnacle Plus unit this information appears as status bits or status flags Table 4 32 defines t
23. D suffix appended to a pin name indicates a digital signal An overline on a signal name for example OUTPUT ENABLE D indicates that the signal is true when low Pin Descriptions The User port has priority for selecting targets even when the unit is in local or host control Thus to select targets from the active front panel the Pinnacle Active Remote Panel or a host computer connected to the host port you must set the target to 1 at the User port Leaving the target bits open or leaving the User port pins unconnected causes the target selection at the User port to default to 1 Table 4 13 Single 15 Pin User Port Pin Descriptions Signal Return Pin Name Signal Description Pin Pin Type 1 10 13 24V Input This pin is the collector side 14 15 of the opto couplers for status LEDs 2 6 VOUT A Output This pin provides a fully buffered 0 to 10 V signal representing output voltage 10 V 1000 Vdc When the open circuit output voltage is 1500 Vdc the voltage on pin 2 is 12 Vdc It will sink and source to 10 mA its impedance is 100 Q 3 6 POUT A Output This pin provides a fully buffered 0 to 10 V signal representing output power 10 V 1 20 000 W ina single unit system that is without any slaves connected It will sink and source to 10mA its impedance is 100 Q 57000097 00B Communication Interfaces 4 37 Advanced Energy Table 4 13 Single 15 Pin User Port P
24. Joule Set Point UDINT You can set the joule set point to any value between 0 and 9999999 in 1 joule increments If you attempt to change the joule set point while output power is on the unit returns a Device State Conflict error If you send a value outside the allowable range for the attribute the unit returns an Invalid_Attribute_ Value error Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 4 66 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 26 Instance 1 attributes Attribute 90 Access Set Get Name Hard Arc Count History Type UDINT Value The number of hard arcs detected The default is 0 when the DeviceNet interface is energized Writing a 0 to this attribute sets all hard arc history to 0 Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 91 Set Get Micro Arc Count History UDINT The number of micro arcs detected The default is 0 when the DeviceNet interface is energized Writing a 0 to this attribute sets all micro arc history to 0 Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 93 Set Get Arc Trip Limit Voltage UDIN
25. Pin Descriptions kk KK KK EKE KEK RR eee 4 54 Table 4 20 Assembly object data poll instance 1 2 20005 4 57 Table 4 21 Assembly object data poll optional instance 1 and instance 101 4 58 Table 4 22 Assembly object data poll legacy instance 1 4 58 Table 4 23 Assembly object data response instance 2 4 59 Table 4 24 Assembly object data response optional instance 2 4 60 Table 4 25 Assembly object data response instance 102 4 61 Table 4 26 Instance 1 attributes kk kk kk kK KK KK ee 4 63 Table 4 27 Common services codes WW kk kk KK KK KK KK KK cette 4 70 Table 4 28 MOD Status LED kk kk kk kk kk kK kk KK KK KK KK KK K KI K K KK KK IK KK KK Ke 4 70 Table 4 29 Network Status LED Jk kk kk kk kk kK KK KK KK KK KIR K K KK K K KIR K K KI KIRI KS 4 71 Table 4 30 Configuration of Download Bytes Outbytes 4 76 Table 4 31 Configuration of Upload packet inbytes 00000 4 77 Table 4 32 Upload Status Bytes Wk kk kk KK KK KK KK KI KK KIR KK KI ees KK KK Ke 4 78 Table 4 33 Upload status bytes joule recipe configuration 4 79 57000097 00B List of Tables xvii Advanced Energy Table 4 34 Command Status Response CSR Codes 220005 4 81 Table 4 35 PROFIBUS Commands 0 to 127 kk kk kk kk KK KK KI K KI cee ee 4 83
26. This condition has existed for the detection time If the algorithm determines that a gross short circuit exists SC flashes on the front panel and then error E088 Short Circuit Fault or E089 Fatal Short Circuit Fault appears on the front panel HIGH SPEED AEBUS Changes the baud rates that are available for AE Bus communication between standard rates and high speed rates For the available rates see the AE Bus Host port information EXPLICIT FAULT CLEARING Changes the fault clearing method changes immediately When method is set to DISABLED input power must be cycled on the unit to clear the fault When method is set to ENABLED the OFF or RESET command will clear the fault 57000097 00B Communication Interfaces 4 137 Advanced Energy VOLTAGE IGNITION Allows you to set the voltage ignition threshold to enable pulsing Set to ENABLED if the option is available through the installed configuration file Checking Your ROM SERVICE gt MEMORY To perform ROM cyclic redundancy check CRC checking Note There is a momentary delay before the CRC will display 1 To calculate and display the active panel local or remote CRC press PANEL 2 To calculate and display the DSP CRC press DSP 3 To calculate and display the logic board CRC press LOGIC Checking Your Software Versions SERVICE gt SW_REV To find out the software number and version of your system software components 1 Press SERVICE SW_
27. Voltage ignition bit set feature enabled Bit 2 User port End of Target Life EOTL indicator is READY signal bit set feature enabled e Bit 3 High Speed Baud Rate 19200 38400 57600 115200 bit clear normal Bit 9 No explicit fault clearing requires power cycle to clear bit clear off and reset command clears fault e Bit 11 Maximum on timer bit set feature enabled 5th byte Always 0 Command Description Number Number of Sent of Data Response Bytes Data Bytes 160 Requests the status of the logic board The 0 5 4 106 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 161 request output on status Reports the status of the most recent output on request since the last power up event on the unit The returning packet contains 1 data byte 8 bit value e 0 Output on sequence OK e 1 Control mode invalid e 2 Unit is already on e 7 Active fault exists e 11 Bus not ready e 16 End of target life reached e 17 Minimum off time was active e 31 User port reset line is active 32 Contactor is open due to fault condition e 44 The Pinnacle Plus unit has not received a request to turn output on since power up 1 57000097 00B Communication Interfa
28. 10 000 kW and 2 decimal places are implied for a master slave system 2000 20 00 kW Note You cannot change the power limit when output is on because this limit is used to establish the type of operation low or high power For values of 10 of the full power or less the operation mode is low for values greater than 10 of full power the operation mode is high Read back this value with command 141 2 CSR codes 0 1 4 9 50 user voltage limit Sets a maximum limit for output voltage as measured at the DC inverter output see Figure 2 1 on page 2 2 Send 2 data bytes 16 bit value value must be between 0 and the maximum rated output voltage for the supply Read back this value with command 142 CSR codes 0 1 4 9 51 user current limit Sets a maximum limit for output current Send 2 data bytes 16 bit value value must be between 0 and the maximum rated output current for the supply Assume 2 decimal places 5000 50 00 A Read back this value with command 143 CSR codes 0 1 4 9 57000097 00B Communication Interfaces 4 187 Advanced Energy Table 4 48 AE Bus Commands Continued Note This command is only valid when you set the continuous joule recipe type Send 2 data bytes 16 bit value Valid input for the joule recipe repetitions are 1 through 65535 Readback this value with command 233
29. 6 low high low 7 low low high 8 low low low SETTING THE REGULATION MODE Table 4 6 on page 4 16 shows the pin state for pins 5 and 6 to select a specific regulation mode Table 4 6 Regulation Mode pin 5 and pin 6 Regulation Mode Pin 5 Pin 6 Voltage high high Power high low Current low high Not valid low low SINGLE 24 V 37 PIN USER PORT This section applies to the Single 15 V 37 pin user port The User port is a 37 pin subminiature D port The User port label is User Port Iso The User port incorporates signals similar to the Pinnacle Plus product Inputs and reference signals are 0 Vdc to 10 Vdc analog The output signals are 0 Vdc to 24 Vdc digital In addition the unit incorporates 4 16 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply A fast response set point input 0 Vdc tol0 Vdc the unit shall respond to the set point signal and adjust the output of the power supply in 50 milliseconds or less e Regulation mode selection voltage current power User reference signals for voltage current and power 0 Vdc tol0 Vdc e Arc counter e Outputs same as Pinnacle Compatiblity with Allen Bradley Siemens and Mitsubishi PLC s Connector The User port is an analog interface that allows the use of a remote controller It is a 24 V interface card with a 37 pin subminiature D connector This connector will be male or female
30. Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 87 set maximum on timer Sets the maximum amount of time that output will stay on in seconds if this feature is enabled If the length of time since the last output on event exceeds this setting the unit will turn output off The timer is reset at each output on event You can set a time in whole seconds from 0 to 65535 A value of zero disables this feature Not all units have this feature available Send 2 data bytes 16 bit value indicating the timer value in seconds Read back this setting with command 243 2 CSR codes 0 1 4 9 12 92 pulse frequency index Sets pulse frequency from 0 to 350 kHz in 5 kHz increments Note Frequency is limited to 150 kHz when the pulse mode is set to be enabled always e 0 Pulsing disabled 1 5kHz e 2 10kHz e 3 15 kHz e 4 to 69 follow the established pattern e 70 350 kHz Read back this setting with command 146 CSR codes 0 1 4 9 93 pulse reverse time Sets pulse reverse time in 0 1 us intervals Send 1 data byte an 8 bit value 04 0 4 us 05 to 49 follow the same format e 50 5 0 us Read back this setting with command 147 CSR codes 0 1 4 9 33 57000097 00B Communication Interfaces 4 193 Advanced Energy Table 4 48 AE Bus Commands Continued scratch pad Ret
31. Digital signals kk kk kk kK KK KK KK KK KK KI dee KK KK KK KK KOK KK 4 41 Pin Description Table 0 0 00 eee 4 42 Master Slave Pulse Port 2 05 04 kk kk kk KK hee eea ben ee KI KK K ee ne chs KK KK 4 50 viii Table of Contents 57000097 00B Pinnacle Plus 10 kW Power Supply Connector fn tite toda aide oath Rede we koe moi 4 50 Pin Descriptions lll kk kk kk kk kK kK KK KK KK KK KK kK KK kk kk kk kk kk lk kk kk 4 51 Cable Configuration kk kk kk kK kK kK KK KK KK KK KK KK KK KK KK KK KK K 4 52 Syn P lse PO 2 ivi a ak a be bee aa na a a Waa a Sb weekend a a nah eee QA 4 52 CONNECION lt s k A kiand A kb a all kn K eR Kae a a 4 52 Pin Descriptions l l kk kk kk kk kK KK KK KIR KOK KK kK KK kK kk kk kk kk lk kk kk 4 53 Cable Configuration csiccccd ree aaan kK kK eee eekee sas KIR KK KK KK KK KK 4 53 DeviceNet M Port i s amp i a a walk a Sed be Wan Rak EAS EPR da Han BE 4 54 Installation s lt 3 kale a 2A eek aes AR A dabi la i Ral aya al a do a A 4 54 Pin Descriptions 454 s n d bl dd end mn kk h r mi eee 4 54 Rotary Switches Baud Rate and Addressing 4 55 Operation gcc dh dd eet seagate Bd 4 55 Poll Command Message 000 KK eee es 4 56 Response Message kk kk kk KK KK KK kK ka a kk lk kk k 4 59 Explicit Messaging oa sen eins Hits kk kk kK KK KK KI KK KK KI KI K K KI KK KI KK KK KK 4 63 Rear Panel LEDS A
32. Dual 24 V 37 Pin User Port Pin Descriptions Continued Signal Pin 20 Return Pin n a Pin Name Signal Type A_INTLKCOM D n a Description This line is a dedicated return for A_INTLK D pin 1 21 A_LEVELIN A analog input This signal is used to program the output level Full scale 10 V represents the maximum power current or voltage of the supply See the Specifications chapter of this manual for more information 22 23 A _VOUT A n a This 0 to 10 V signal represents output voltage Full scale 10 V represents the rating of the supply See the Specifications chapter of this manual for more information 23 n a A_OUTCOM A n a This line is a dedicated return for analog output Reference A_POUT A pin 3 A JOUT A pin 4 and A_VOUT A pin 22 to this pin 24 A_RESET D digital input A high on this pin will reset active explicit clear faults for unit A provided that the fault conditions are no longer present This pin must be returned to the inactive state low to enable the unit output 25 A_IREG D digital input This pin is used with A_PREG D pin 7 to set the regulation mode See description of pin 7 for the logic table associated with this pin 57000097 00B Communication Interfaces 4 47 Advanced Energy Table 4 14 Dual 24 V 37 Pin User Port Pin Descriptions Continued
33. a a Yew al ard x a a a 2 2 n ere a e Ea E E E yb 2 3 Housekeeping Supply kk kk kk kk kk kK KK KK KK KK KK KK KK KK KK kk kk k 2 3 Inverter 20 tenet eee eee 2 3 eno aDzeee eo P _A o D D DPOAo o oaooojbrrnnhnrrrrrrr 2 3 Output Measurement XA kk kk kk kk kK KK KK KK KK KK KK KK KK KK KR KK KK KK 2 3 DC Chopper Section kk kk KK KK KK KK KK KK KK KK KI KIRI eee 2 3 Logic Controls os sa spay dagg 40480004 4 4 440800 q w Wara a ak se wade 2 3 Remote Interfaces i kk kk kk kk kK KK KK KK KK KK KK KK KK KK kk kk kk kk k 2 4 Chapter 3 Product Specifications Functional Specifications i kk kk kk kk kK KK KK KK KK KK KK KK KK KK kk kk k 3 1 Physical Specifications kk kk kk kK kK kK KK KK KK KK KK KI KK KK KK KK KK KK 3 3 Dimensional Drawings Jk kk kk kk kk kK KK KK KK KK KK KK KK KK KK KK KK ke 3 5 Electrical Specifications kk kk kk kK kK KK KK KK KK KK KK KK KK KK KK KK kk 3 6 Maximum Allowable Reverse Time For a Given Frequency 3 9 Reverse Time As A Function of Voltage Limit 3 12 57000097 00B Table of Contents vii Advanced Energy Operating and Impedance Range Illustrations 5 3 16 Environmental Specifications 0 0 0 0 00 cee 3 18 Coolant Specifications 2 0 0 0 ee KK KK KI KK KK 3 19 Chapter 4 Communication Interfaces Identifying the User Port On a Pinnacle Plus Unit
34. depending on which options you specified at the time you ordered your unit ee se e A Pin 1 Female OOOOOOOOOOOOOOOOOO TET EK TETEK TEEN 1385 Figure 4 2 37 pin subminiature D male and female connector Note If you have an isolated 24 V User port card your card provides isolation of more than 500 Vrms from the logic and control circuitry to all 37 pins on the connector Note Signals at the User port can be sensitive to noise We recommend that you take standard preventative measures against electro magnetic interference EMI including using shielded cabling on the User port Note Grounding the User port at the power supply reduces noise interference To avoid ground loop problems you should typically ground only one end If you have a Pinnacle Remote Active Panel or an active front panel and you want to operate the Pinnacle Plus unit from the User port you must set the control mode for USER using the panel See Control Key in the Understanding the Control Panel section of this chapter for more information 57000097 00B Communication Interfaces 4 17 Advanced Energy Signals Turn off ac input power to the Pinnacle Plus unit before connecting a cable to the User port connector Note that we recommend taking standard preventative measures against electro static discharge ESD around all Pinnacle Plus units Note You need to set the pulse frequency and reverse time thr
35. enable feature which waits for command 73 before disable joule beginning the joule countdown countdown i i This setting reverts to disabled when the unit powers up Send 1 data byte e 0 Disable Non zero Enable Read back this setting with command 163 4 190 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 82 set advanced process parameters Sets the voltage ignition threshold and the gross short circuit amp limit Send 3 data bytes The first data byte is the index of the parameter to be set The second and third data bytes are the value to set for the parameter e First data byte gt 0 voltage ignition threshold gt 3 gross short circuit amp limit 2nd data byte and 3rd data bytes 16 bit value gt Voltage ignition threshold valid entries are 325 to maximum user voltage allowed less 50 V For example if the maximum voltage set point is 650 V the maximum threshold is 600 V gt Gross short circuit amp limit valid values are 15 40 to 30 80 in hundredths of amps For more information about pulsing behavior using the voltage threshold see Pulsing Behavior When Using Voltage on page 5 32 Read back this setting with command 235 3 CSR code 0 1 2 4 5 9 84 redefi
36. if an error occurs you will see a numeric code displayed on a passive front panel or a numeric code and message displayed on an active control panel For more information about these error codes and how to respond to them please refer to the Troubleshooting chapter In the event of a PROFIBUS error the Pinnacle Plus unit turns output power off and displays the appropriate error message All PROFIBUS errors are treated as explicit clear type faults thus you must send command 119 the master reset command in the next download packet to clear them Once all faults have been cleared the Pinnacle Plus unit is ready to continue operation 4 74 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Data Consistency Some PLCs using PROFIBUS interfaces have a problem with data consistency We define data consistency as the ability to complete the message packet construction before sending the packet to the Pinnacle Plus unit This problem most often manifests as mysteriously changed values That is values at the Pinnacle Plus unit seem to have changed automatically even though no command has executed or they appear changed because one data byte contained the data that another data byte should have contained The root of the problem is a shared memory block Most PLCs share a memory block with the PROFIBUS interface The PLC places data packet information in the memory block and the PROFI
37. kK KK KK KK KK KI KIR KK KK KK KK KK K 4 134 Checking Service type Statistics kk EKE EKE ees 4 135 Checking the Total Energy Output KK KK RR RR KK KK 4 135 Checking the Amount of Idle Run Time 2 005 4 135 Checking the Number of Faults kk kk kk kK kK RR RI KK cee ees 4 135 Checking the Number of Cycles WL KK KK KK KK KK KK KK IK 4 136 Debugging Your Unit JL AA kk kk kK kk kK KK KK KK KK KK K K K K KK KK wae te ag 4 136 Checking Your Hardware Configuration 0 00000 4 136 Checking Your Software Logic 0 c ee KK KIR KK eee 4 136 Checking Your ROM kk kk kk kk kk kK KK KK KK KK KK KK KK KK KK KK k 4 138 Checking Your Software Versions 0000 KEK KK RR RR KK KK 4 138 Using the Supply Functions kk kk kk kk kK kK kK KK KK KK KK KK KK kK kk k 4 138 Setting the AE Bus Timeout i kk kk kK KK KK KK KK ee 4 139 Setting the Supply Parameters kk kk KK KK KK KK KK KK eee 4 139 Setting Pulse Parameters kk kK KK KK KK KK K KK ees 4 139 Enabling Pulsing MOde kk KK KK KK KK KK KK KK KK KK KK KK 4 139 Selecting Constant Duty Cycle kk kK KK KK KK KK KIR KK KI KK K 4 140 Setting Sync Pulse Hard Arc Detection Broadcast 4 140 Setting The Unit as a Sync Pulse Transmitter Receiver or StandAlone 4 141 Setting the Voltage Threshold 222 0 KK RR RR eee 4 141 Setting the Program Source 0 000 KK KK KK KK KK KK KI KK KK ee 4 141
38. logic CRC control Note During the approximately 2 s it takes to calculate the CRC the Pinnacle Plus unit will not respond to any other commands Read this value back with command 230 26 Specifies the output power level that needs to 2 CSR only be met before the Joule output energy joule calculation begins the joule threshold The threshold joule threshold type power voltage or 4 92 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number Numberof of Sent Response Data Data Bytes Bytes 31 Enables or disables an out of set point timer 2 CSR only and specifies how long you want the power out of set supply to tolerate an out of set point condition point timer before shutting off output e To enable the timer send a value 2 bytes between 1 and 9999 0 1 to 999 9 s To disable the timer send a value of 0 Read back this value with command 187 32 For ramp mode sets the ramp start point as a 1 CSR only percentage of setpoint when output is turned ramp start on Range is 0 to 95 point j percentage Note This setting only applies to regular of set point ramp mode It does not apply to ramp mode in a timed recipe Send 1 byte with a value of 0 to 95 Read back this value with command 152 33 Set the type of recipe The default is Timed 1 CSR only recips type
39. output must be de energized to switch between regulation modes Invalid You have attempted to set Set a valid value for the Parameter an operating parameter to a parameter value outside its allowable range H006 Analog Setpoint You have attempted to Check the program source Selected change the regulation mode setting For more or a set point when the information see host power supply has been set to command 17 respond to an external analog source H007 Faults Are You requested output On Clear fault and try again Active while fault was active H009 Data Byte Count The number of data bytes Check the command s Incorrect sent does not match the requirements and resend the number of data bytes command required by the command H010 User Port Has After selecting a target other Use the User port to select Priority than 1 from the User port the target Or to select the you have attempted to select another target through another interface that is through either a serial port or a panel target through another interface select target 1 from the User port Note When you have selected a target greater than 1 through the User port the User port s target setting has priority 57000097 00B Troubleshooting and Global Services Advanced Energy Table 6 3 Help Code Troubleshooting Table Help Help Code Problem Indicated Suggested Action Code
40. outside the allowable range Arc Timer Out You have attempted to set Retry setting the timer using of Range the arc timer to a value an acceptable value outside its allowable range Arc Trip Level You have attempted to seta Retry setting the trip level Out of Range trip level to a value outside using an acceptable value the allowable range Frequency Out You have attempted to set Retry setting the frequency of Range frequency to a value outside using an acceptable value the allowable range Reverse Time You have attempted to set Retry setting the reverse time Out of Range reverse time to a value using an acceptable value outside the allowable range Continued on next page 57000097 00B Troubleshooting and Global Services 6 11 Advanced Energy Table 6 3 Help Code Troubleshooting Table Help Help Code Problem Indicated Suggested Action Code Message Number H004 Invalid Target You have attempted to Retry setting the target using Selection select a target that is not an acceptable value available Continued f oe Target Life Out You have attempted to set Retry setting the target life previous of Range target life to a value outside using an acceptable value page the allowable range See host command 12 Invalid Recipe You have attempted to enter Retry setting the recipe step Step a recipe step that is invalid using an acceptable value Ramp Start
41. that the accuracies listed in this procedure account for both the factory calibrated accuracy of the Pinnacle Plus unit and the accuracy of the measurement equipment These accuracies are not intended to imply unit specifications 57000097 00B Troubleshooting and Global Services 6 3 Advanced Energy If the results of field testing with this procedure are not within the expected tolerance noted in this procedure contact AE Global Services A WARNING 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 A CAUTION Follow proper ESD precautions during this test EQUIPMENT NEEDED You will need the following equipment to conduct the Pinnacle Plus basic functionality test All quantities in the list are one unless noted otherwise Two Bird 8730 A 10 kW 50 Q loads Tektronix TDS3032 oscilloscope or equivalent Tektronix TCPA300 current amplifier e Tektronix TCP305 50 A current probe Tektronix P5100 high voltage probe e RG393 load cable 9 meters or less in length For Pinnacle Plus units that do not have an active front panel a Pinnacle Plus remote active panel 3152327 000 6 4 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply
42. 0 0 0 0 Current Output AI MSB 6 Run Micro Arc Count 7 Run Hard Arc Count 8 RMP CMode 0 INTS ARCD TS SPS POS 57000097 00B Communication Interfaces 4 59 Advanced Energy Note The 16 bit Power Output value AJ is shifted right four bits and the remaining four bits are filled with 0s This changes the 16 bit AI to a 12 bit AI with a value of 10 V OxOFFF Bytes 6 and 7 The number of micro or hard arcs detected since the last time that output was turned on The count is set to 0 when the DeviceNet interface is energized These values stop incrementing at 255 If the count exceeds 255 the readback will be 255 Note For Byte 8 the abbreviations have the following meanings Note e La POS stands for Power On Status 1 output on 0 output off SPS stands for Setpoint Status 1 setpoint reached 0 setpoint not reached TS stands for Temperature Status 1 good 0 over temperature condition ARCD stands for Arc Detected 1 on 0 off INTS stands for Interlock Status 1 satisfied 0 open 0 Reserved CMode stands for Control Mode 1 Host 0 local or User not all units support this feature RMP stands for Ramp Status 1 Set point ramping 0 Set point not ramping not all units support this feature Table 4 24 Assembly object data response optional instance 2 Byte Bit7 Bit 6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit 0 0 Power Output AI
43. 1 CSR codes transmitter a receiver or a standalone 0 1 2 9 sets synch pulse as Send 1 data byte transmitter e 0 Receiver receiver or f standalone Transmitter 2 Standalone Read back with command 163 4 94 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 49 user power limit Sets a maximum limit for output power Assume 2 decimal places for a master slave units and 3 decimal places for a non master slave unit Send 2 data bytes 16 bit value the value must be between 0 and the maximum rated output power for the supply Note You may set values for all three User output limits commands 49 50 and 51 However the Pinnacle Plus unit responds to the first limit value that impacts output Note You cannot change the power limit when output is on This is because the power limit is used to establish the type of operation low power or high power For values at 10 or less the operation mode is low power for values greater than 10 the operation is mode is high power Read back this value with command 141 CSR only 50 user voltage limit Sets a maximum limit for output voltage Send 2 data bytes 16 bit value value must be between 0 and the maximum rated output voltage for the supply
44. 1 data byte 8 bit value request control mode e 2 Serial Host port e 3 Active control panel Local e 4 User port This value is set with command 14 156 Requests an indication of the active target the 0 1 returning packet contains 1 data byte indicating request target 1 2 3 4 5 6 7 or 8 active target i number This value is set with command 11 157 Requests the amount of target life time 1 4 remaining for the target you specify May return request target life a Send 1 data byte indicating which target the CSR code 4 returning packet contains 4 data bytes 32 bit value indicating the time remaining in kilowatt hours Two decimal places are implied For example a value of 100 indicates 1 kWh This value is set with command 12 158 Requests ramp time Returns a 2 byte value 16 0 2 bits indicating a ramp time of 5 50ms to requestramp 60 000 600 00 s time Note If your unit has 100 ms ramp feature enabled one decimal is implied The range is 0 5 s to 6000 0 s This value is set with command 16 159 Requests how much ramp time is remaining 0 2 ramp time Returning packet contains 2 data bytes remaining 16 bits indicating how many 10 ms intervals remain Note If your unit has 100 ms ramp feature enabled the data indicates how many 100 ms intervals remain 4 198 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued
45. 10 kW Power Supply Table 6 2 Troubleshooting LEDs for Continued LED On Off Status ARC X After the output shuts off this LED lights momentarily to indicate that the hard arc count limit was reached during the previous run However if the arc count limit was set to zero this LED lights for a predetermined time for every hard arc seen by the unit during the process run ARC X During an on cycle this LED remains unlit normally After the output shuts off if this LED remains unlit the hard arc limit was not reached during the previous run Checks if the Output Does Not Turn On Peform the following checks if output does not turn on 1 Verify that the joules mode is disabled or has a valid set point value 2 Verify that the target life counter is disabled or has a valid value 3 For dual models verify that both units are enabled 4 Verify that the user definable power voltage and current limits are set to values reasonable for the process application Q Check for interlock bus fault or over temperature faults 6 From the active front panel main menu press SUPPLY gt DEFAULTS and reset the unit default settings Or send command 126 through the Host port to reset all defaults 7 Try again to turn on output power Help Code Troubleshooting Table If the output does not turn on the active front panel on the unit or a remote panel may display one of the following help codes
46. 72 PROFIBUS protocol 4 72 program logic controllers PLCs 4 73 protocol PROFIBUS 4 72 standard serial port 4 166 Pulsar see product pulse reversal times 3 9 R ramp setting 4 156 rear view illustration 5 29 rear panel switch description 4 26 switch settings 4 33 RECIPE menu 4 152 recipes setting 4 152 refresh rates upload packet 4 80 REGULATION key 4 127 regulation mode 5 31 User port 4 16 4 24 4 49 regulation switches 4 129 remote active panel connecting 5 8 remote control setting 4 142 remote panel connecting 4 125 pin descriptions 4 125 remote passive panel connecting 5 8 repair authorized returns 6 27 replacing Host cards 5 8 requirements before installing 5 5 reset command 4 74 response data bytes PROFIBUS 4 80 returns authorized 6 27 reverse time 5 37 reverse time settings 5 37 reverse time setting 4 131 reverse voltage 3 8 ROM checking 4 138 RS 232 422 485 4 160 S safety conditions of use 1 7 directives and standards 1 6 guidelines 1 2 rules for installation 1 2 rules for operation 1 2 safety warnings floating output 5 15 grounding 5 6 scaling DeviceNet poll command 4 59 DeviceNet response message 4 62 selecting local remote operation 4 142 self run frequencies 3 9 SELV requirements 5 19 serial Host port connecting 5 8 serial communications AE bus 4 159 PROFIBUS Host 4 72 standard flash port 4 157 service menu checking statistics 4 135 debugging your unit 4 13
47. Bit 0 of Byte 4 PO refers to Power On In this bit 1 turns on the unit s Note Note output 0 turns off the unit s output The 16 bit Power Output value AI AO is shifted right four bits and the remaining four bits are filled with 0s This changes the 16 bit AO to a 12 bit AO with a value of 10 V OxOFFF Reserved Write Reserved bits with a 0 for future compatibility 4 58 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Scaling Parts of the message structure are based on binary representations of analog voltages Thus they have analog scaling associated with them The scaling for Power Output is 0 to 10 V where 10 V equals the full rated output power capability of the Pinnacle Plus power system master and slave units For information about determining your power system s maximum output capability see Explicit Messaging on page 4 63 RESPONSE MESSAGE The following tables present the structure of the response message The structure of the response message varies depending on your DeviceNet configuration Table 4 23 Assembly object data response instance 2 Byte Bit7 Bit 6 Bit5 Bit 4 Bit 3 Bit2 Bit1 Bit 0 0 Power Output AI LSB 1 0 0 0 0 Power Output AI MSB 2 Voltage Output AI LSB 3 0 0 0 0 Voltage Output AI MSB 4 Current Output AI LSB 5
48. CFM 94 4 liters second Table 5 2 Approximate Cooling Requirements for Three Pinnacle Plus Power Supplies Mounted in a Cabinet Type of CFM for 3 Total Power Dif in Power Supplies Dissipation Temp Supply Between Coolant amp Exhaust Air 5 kW 300 CFM 1500 W 20 C 100 100 100 300 500 500 500 1500 141 6 liters second 5x5 kW 600 CFM 3000 W 20 C 200 200 200 600 1000 1000 1000 3000 283 2 liters second 10 kW 600 CFM 3000 W 20 C 200 200 200 600 1000 1000 1000 3000 283 2 liters second 57000097 00B Installation and Operation 5 3 Advanced Energy Input Air Through Front Panel Minimum i clearance between rear of 102 00 mm rack and rear of T99 enclosure 25 00 mm Exhaust Air 1 00 Minimum HW clearance between unit and top of rack Minimum 0 0 mm clearance 0 00 between units 1345 76 00mm Minimum clearance from 3 00 enclosure to rack each side Figure 5 1 Clearances for Pinnacle Plus power supplies stacked in a cabinet 5 4 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Installation Requirements Install this unit according to the following requirements DANGER RISK OF DEATH OR BODILY INJURY Disconnect and lockout tagout all sources of input power before working on this unit or anything connected to it WARNING Maintenance personnel must receive proper training before install
49. Compliance Guidelines Important Safety Information kk kk kK KK KK KK KK KI KIRI es 1 1 Danger Warning and Caution Boxes in the Manual 1 2 Safety Guidelines kk kk kak kk kk a Phe ea ka ee kk kk ka hehe kk kk kk aes 1 2 Rules for Safe Installation and Operation 20200055 1 2 Interpreting Product Labels kk kk kk kk kK KK KK KK KK KK ees 1 3 Product Compliance kk nk kn kk kk kk kk KK kK kk KIR KK kk kk kK kk kk kk kk k 1 5 Product Certification kk kk kk kK kK KK KK KK KK KK tee 1 5 Safety and EMC Directives and Standards 20200000 1 6 Electromagnetic Compatibility EMC Directives and Standards 1 6 Safety Directives and Standards KK KK KK KK KR KK KKIK 1 6 Conditions of Use J A kk kk kk kk kk kK KK KK KK ett 1 7 Chapter 2 Theory of Operation General Description lk kk kk kk kk kK kK KK KK KK KK KK KK KK KK KK KK KK KK KK KK 2 1 Output Impedance Range kk kk kk kk kk kK KK KK KK KK tees 2 1 Output Regulation Ak kk kk kk kK KK KK Shes KK KK KI KK KK KK KK KK KK k 2 1 Interfaces iiep ean araea e E E MH HHH H HHEE 2 1 Microprocessor Advantages kk kk kk kK kK kK KK KK KK KK KK KK KK KI KK k 2 2 B VYxX X ewe 7O D PDPPpDpDppD pDmmgrr r rrgggF v 2 2 Arc suppression Feature kk kk kk kK kk kK KK KK KK KK KK KK KK KK KK kk 2 2 Theory of Operation i aa a Wl a Sk k haya k t ak Seed
50. Compliance Guidelines 57000097 00B Pinnacle Plus 10 kW Power Supply Chapter 2 Theory of Operation GENERAL DESCRIPTION The Advanced Energy Pinnacle Plus series of DC power supplies provide the ultimate advantages in DC power They Are light and compact e Are highly efficient low internal heat dissipation Provide excellent regulation and stability e Have a highly reliable solid state design Store very little energy in the output filter e Quickly extinguish and recover from arcs e Deliver full power over a 4 1 impedance range with no taps Provide a very high power factor Output Impedance Range No taps mechanical or electrical exist in the Pinnacle Plus supply The unit delivers full power over a 4 1 range of impedance without the need for tap changes You never need to open the unit or generate signals to control taps Output Regulation The Pinnacle Plus supply can be used as a power current or voltage source depending on the method of output regulation selected Since set point levels are stored in nonvolatile memory you can use them to recover from input power interruptions and to ensure repeatability from run to run Interfaces The Pinnacle Plus series of power supplies can be configured with a variety of interfaces Your Pinnacle Plus supply can be controlled from an active front panel the Pinnacle Remote Active Panel an analog digital connector User port or a serial 57
51. D pin 12 and STPOK D pin 22 should be referenced to this pin Note This pin is internally connected to User port pins 18 20 21 and 24 18 COM D Digital This signal is used as a remote digital common common FLT D pin 9 OUTPUT D pin 10 ON D pin 11 PULSEON D pin 12 and STPOK D pin 22 should be referenced to this pin Note This pin is internally connected to User port pins 17 20 21 and 24 19 LEVELIN_RET A Analog Dedicated return for LEVELIN A return This pin is switch connectable to COM A for single ended inputs in previously wired systems See Table 4 12 on page 4 34 Switch 7 description for more information 20 COM D Digital This signal is used as a remote digital common common FLT D pin 9 OUTPUT D pin 10 ON D pin 11 PULSEON D pin 12 and STPOK D pin 22 should be referenced to this pin Note This pin is internally connected to User port pins 17 18 21 and 24 21 COM D Digital This signal is used as a remote digital common common FLT D pin 9 OUTPUT D pin 10 ON D pin 11 PULSEON D pin 12 and STPOK D pin 22 should be referenced to this pin Note This pin is internally connected to User port pins 17 18 20 and 24 4 32 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 11 Single 15 V 25 Pin User Port Pin Description Continued Signal Name Signal Description Pin
52. LSB 1 0 0 0 0 Power Output AI MSB 2 Voltage Output AI LSB 3 0 0 0 0 Voltage Output AI MSB 4 Current Output AI LSB 5 0 0 0 0 Current Output AI MSB 6 Ramp Rate AI LSB 7 0 0 0 0 Ramp Rate AI MSB 8 RMP CMode 0 INTS ARCD TS SPS POS 4 60 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Note The 16 bit Power Output value AJ is shifted right four bits and the remaining four bits are filled with 0s This changes the 16 bit AI to a 12 bit AI with a value of 10 V OxOFFF Note For Byte 8 the abbreviations have the following meanings POS stands for Power On Status 1 output on 0 output off SPS stands for Setpoint Status 1 setpoint reached 0 setpoint not reached TS stands for Temperature Status 1 good 0 over temperature condition ARCD stands for Arc Detected 1 on 0 off INTS stands for Interlock Status 1 satisfied 0 open 0 Reserved CMode stands for Control Mode 1 Host 0 local or User not all units support this feature RMP stands for Ramp Status 1 Set point ramping 0 Set point not ramping not all units support this feature Table 4 25 Assembly object data response instance 102 Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 0 Power Output AI LSB 1 0 0 0 0 Power Output AI MSB 2 Voltage Output AI L
53. Pin User Port Pin Descriptions Continued Signal Pin 14 Return Pin 15 Pin Name B_ON D Signal Type digital input Description When operating in analog control mode a low to high transition on this signal turns on the output and a high to low transition shuts off the output 15 n a B_INCOM D n a This line is a dedicated return for digital inputs Reference B PREG D pin 13 B_ON_D pin 14 B_IREG D pin 32 and B_RESET _D pin 33 to this pin 16 34 B_IOUT A analog output This 0 to 10 V signal represents output current Full scale 10 V represents the maximum current of the supply See the Specifications chapter of this manual 17 34 B_POUT A analog output This 0 to 10 V signal representing output power Full scale 10 V represents the rating of the supply See the Specifications chapter of this manual 18 n a B_INCOM4 This line is a dedicated return for analog inputs Reference B LEVELIN A pin 36 to this pin 19 37 B_INTLK D digital input A low on this signal inhibits the main contactor from closing or opens the main contactor if it is already closed This pin needs to be pulled up to 24 by between 100 Q and 5 kQ The fault condition is shown on the front panel 4 46 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 14
54. Pinnacle Plus unit and the controller is 10 meters 33 feet To minimize interference from adjacent electrical equipment the EMI shield in the cable must be terminated to the metal shells of the cable s connectors Additionally the chassis of the Pinnacle Plus must be tied to a local earth ground through an adequately sized copper grounding strap Note Advanced Energy Industries Inc does not include the User port cable with the power supply You are required to supply the cable for the User port connection 57000097 00B Communication Interfaces 4 25 Advanced Energy Signals Following is general information about the analog and digital signals For more specific information about each pin on your User port see Figure 4 11 on page 4 28 ANALOG SIGNALS A pin name with a A suffix indicates an analog signal Analog common lines are denoted by the COM 4 suffix Analog outputs can source or sink up to 3 0 mA The input impedance of the analog inputs is 20 kQ DIGITAL SIGNALS A pin name with a D suffix indicates a digital signal Digital commons are denoted by the COM D suffix Digital outputs are short circuit protected Digital signals that are active when low are indicated with an overline on a signal name for example OUTPUT ENABLED The signal levels for digital outputs are the following e Logical 0 3 V maximum with 1 0 mA maximum leakage e Logical 1 Vpos less 1 5 V
55. Returns 14 j Nubiber characters Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 15 Get Pinnacle Plus SHORT_ Pinnacle Plus application Firmware STRING software part number seers odes Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 57000097 00B Communication Interfaces 4 65 Advanced Energy Table 4 26 Instance 1 attributes Attribute 16 Access Get Name Type SHORT _ STRING Returns 14 characters Pinnacle Plus Firmware Configuration Part Number Value Pinnacle Plus configuration software part number Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 81 Set Get Joule Mode Enable BOOL The following parameters apply for the Joule Mode Enable attribute 0 Disable and 1 Enable If you attempt to change the enable status while output power is on the unit returns a Device _State_Conflict error If you send a value outside the allowable range for the attribute the unit returns an Invalid_Attribute_ Value error Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 82 Set Get
56. Specification Output Power Cable For optimal performance it is recommended that you use an output power cable 32 8 feet 10 m in length or shorter Note The output power cable must not exceed 32 8 feet 10 m or you may damage your power supply Input Power Connector Five terminal DIN compression terminal block Maximum wire size 44A WG User Port Connector Please reference Chapter 4 Communication Interfaces Serial Host Port Please reference Chapter 4 Communication Connector Interfaces 3 4 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply Dimensional Drawings 17 m 231 8 Tt 2 96 75 18 yo HHI 22 05 560 07 B 19 J i 482 6 AE MA spinnAcle 3761 18 25 463 6 Figure 3 1 Dimensional drawing 57000097 00B Product Specifications 3 5 Advanced Energy ELECTRICAL SPECIFICATIONS Table 3 3 Electrical Specifications Description 208 VAC Input Voltage wye or delta connection Specification 180 to 229 VAC 3 phase 4 wire 50 to 60 Hz no neutral required Leakage current less than 3 5 mA Maximum phase to phase voltage 208 V 10 Maximum phase to ground chassis voltage 250 V A DANGER RISK OF DEATH OR BODILY INJURY For delta connections considerably more leakage cur
57. Table Error Code Message Problem Indicated Suggested Action E051 PROFIBUS Watch Dog Expired The PROFIBUS master stopped talking to the Pinnacle Plus supply after establishing communications E051 indicates an error in the PROFIBUS card located in the left I O slot located on the back panel of the power supply E151 indicates the same error but in the PROFIBUS card located in the right I O slot of the unit if applicable Have the PROFIBUS master reestablish communications and send a master reset to clear the Pinnacle Plus unit s display E054 PROFIBUS MAC Reset or Offline The PROFIBUS interface has taken itself off line probably in response to another error E054 indicates an error in the PROFIBUS card located in the left I O slot located on the back panel of the power supply E154 indicates the same error but in the PROFIBUS card located in the right I O slot of the unit if applicable Cycle the Pinnacle Plus unit s power off and on and re establish communications between the master and slave If the error code reappears call AE Global Services E055 PROFIBUS Command Buffer Overflow A PROFIBUS command arrived before the last sent command was executed and cleared from memory E055 indicates an error in the PROFIBUS card located in the left I O slot located on the back panel of the power supply E155 indicates the same error but in the PROFIB
58. Table 4 36 PROFIBUS Commands 128 to 255 kk kk kk KK KK KK K KK KK eee 4 102 Table 4 37 Display Panel LEDS 0 ccc eae eee KK KK KK KK KK KK KK K K KK KK KK KO 4 124 Table 4 38 Remote Panel Pin Descriptions kk kk kk KK KK RR KK KK KK 4 125 Table 4 42 Serial Port Pin Descriptions kk kk kK KK KK KRE KK RR KK KK 4 158 Table 4 43 AE Bus Host Port Pin Descriptions 00005 4 159 Table 4 44 AE Bus Address Settings 0 0 2 KK KK KK KK tees 4 164 Table 4 45 Setting Switch 8 scc1 coven we wher kK KK KK pesos KK K Ra ke Bae KK KK KO 4 165 Table 4 46 Baud Rate Settings 0002 es 4 165 Table 4 47 Command Status Response CSR Codes 2000 4 170 Table 4 48 AE Bus Commands 00 KK KK KK KK KK KK KK KK KK kk k 4 172 Table 5 1 Minimum CFM Required for a Pinnacle Plus Power Supply 5 3 Table 5 2 Approximate Cooling Requirements for Three Pinnacle Plus Power Supplies Mounted ina Cabinet kk kk kk kk kK kK KK KK KK tees 5 3 Table 5 3 Low power operation mode 0 ee ees 5 35 Table 5 4 High power operation mode 000 cece eee 5 36 Table 5 5 Errors Associated with the Master Slave System 5 40 Table 5 6 Errors Associated With The Pinnacle Plus Sync Pulse System 5 41 Table 6 1 Passive Front Panel Help Codes 000 0c cece eee 6 7 Table 6 2 Troubleshooting LEDs for kk kk kk KK KK KK K
59. Type 22 STPOK D Digital This signal provides an indication of output when the set point is reached A logic low indicates set point has been reached Note Pins 17 18 20 21 and 24 are the dedicated returns for this pin 23 unassigned n a n a 24 COM D Digital This signal is used as a remote digital common common FLT D pin 9 OUTPUT D pin 10 ON D pin 11 PULSEON D pin 12 and STPOK D pin 22 should be referenced to this pin Note This pin is internally connected to User port pins 17 18 20 and 21 25 unassigned n a n a REAR PANEL SWITCH SETTINGS The following information illustrates the rear panel switch and its available settings The figure below shows the rear panel switch with Switch 6 set OV A switch is considered ON when the switch lever is set towards the number A switch is OFF when the switch lever is set away from the number A switch set towards the number is ON A switch set away from the number is OFF The following table provides detailed information on the function of each switch as it relates to setting specific pin signals for the User port connection 57000097 00B Communication Interfaces 4 33 Advanced Energy Table 4 12 Rear Panel Switch Setting Descriptions Switch Description 1 This switch works in conjunction with Switch 2 to set the analog output signal scaling for VOUT A See the description for Switch 2 below for more
60. Unit lk kk kk kk kk kK KK KK KK KK KI KK page ten KK KK aie 5 5 lastalling the Unit lt A ae ge ei Re ek K h toh end ee A e dnya o ate ye 2 5 5 ill la 2 cad dGhdt genset bp aa a E ESE 5 6 Connecting the Contactor Intlk Port KK KK KK KK RR eee 5 7 Connecting a Remote Passive Panel W K KK KK KK KK KK RR eee eee 5 8 Connecting a Pinnacle Remote Active Panel XAK KK KK RR KK 5 8 Connecting to the Standard Serial Port KK KK KK KK RR RR KK 5 8 Connecting for Serial Host Port Control KK KK KK KK 5 8 Connecting for DeviceNet Control 0 000 KK KK KK KK ee 5 9 Connecting for User Port Control 20 KK KK KK KK KK KK KK eee 5 9 Connecting Input Power x 22s kk kk kk kk ek ee ee Sea Peeks bake Bea RES 5 9 Input Power Cable Requirements 0000 eee KK KK 5 10 Five Terminal Input Connector M kk kK KK KK KK RR RR RR eee 5 10 Connecting Output Power kk kk kk kk kK KK KK KK KK KK KK KK KK KK kk kk 5 10 Output Power Cable Recommendations 000000 KK 5 11 Two Terminal Multicontact Output Connector 5 12 Three Terminal Multicontact Output Connector 5 17 UHF Output Connector 0 0 eee 5 19 Connecting for Master Slave Operation 000000 eee 5 21 Understanding Master Slave Operation 00000 5 22 Master Slave Host Card Interface 0 0 eee 5 22 Configuring a Master Slave System XW KK KK
61. User port Read back these values with command 163 19 Specifies the number of recipe steps in a 1 CSR only recipe recipe steps i Send 1 data byte 8 bit value The value must be between 0 and 8 A value of 0 disables the recipe feature Note For each recipe step you must also set the regulation mode set point ramping time and run time commands 21 22 and 23 Read back this value with command 180 57000097 00B Communication Interfaces 4 89 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 21 recipe ramp time Specifies the length of ramping time for a recipe step that is how long the unit will take to reach the set point you have defined for the selected recipe step Send three data bytes arranged as follows First byte Recipe step a value between 1 and 8 Second and third bytes Value between 5 and 60 000 with two decimal places implied that is between 0 05 s and 600 s Note If your unit has 100 ms ramp feature enabled one decimal is implied The range is between 0 5 s to 6000 0 s Read back these values with command 181 CSR only 22 recipe set point Specifies the set point for a recipe step Send three data bytes arranged as follows First byte Recipe step a value between 1 and 8 Second and third byt
62. a Master Slave System 000 0 eee eee eee 5 39 Sync Pulse Operation 2 iciatawtiatee KK KK KK KI KK KK KK KI KOK K KK KI KOK KK KI KK IK se 5 40 Monitoring the Sync Pulse System kk kK KK KK KK KK KK KK 5 40 Clearing Faults in a Sync Pulse System KK KERR RR 5 41 NMAINGNANCE sec ons aa le ate te aE ash ng R uct ENE em eee ee ee ak Once 5 41 Consumable Parts M K kK KK KK KK kK KK kk KK kk kk KK KK K l 5 41 Chapter 6 Troubleshooting and Global Services Before Calling AE Global Services Ak kk kK KK KK KK KK KK ee 6 1 FIPS CHECK fae eee wee DE SE a ae EW RR eee 6 1 Checks with the Unit Powered Off KK KK KK KK KK KK K K KI KIR es 6 2 Checks with the Unit Powered On k k kk KK KK KK KI KIK es 6 2 Pinnacle Plus Basic Functionality Test 0 002 RR KK 6 3 Equipment Needed 020 KK KK KK KK KK KK KK KK KK KK KK 6 4 Equipment Setup X kk kk kK KK KK KK KK KK K KK KK KRI KR KK KK KK 6 5 To Check Basic Unit Functionality 00 e KK KK KK 6 5 Passive Front Panel Help Codes kk kk kk KK KK KK KK KK KI KK KI eee 6 7 Troubleshooting LEDS kk kk kk kk kK KK KK KK KK KK KK KK KK KI KIR KK KK KK KK 6 7 Checks if the Output Does Not Turn On WWW KK KK RR RR RR KK 6 9 Help Code Troubleshooting Table 0 KK KK KK KK eee 6 9 Clearing the Error Code kk kk kk kk KK KK KK KK KK KK KI KIR KK KK KK IK KK 6 15 Error Code Troubleshooting kk k
63. and 8 Note When joule recipes are enabled recipe step numbers 1 through 8 use the value in the second and third bytes to set the LSW of the joule set point Step numbers 129 through 136 set the MSW of the joule set point where step 129 sets MSW of step 1 step 130 sets MSW of step 2 and so on When command 23 is sent with step numbers through 8 the MSW is cleared To set joule set points greater than 65535 first send command 23 with steps through 8 then send command 23 with steps 129 through 136 Second and third bytes Value between 0 and 60 000 or between 0 and 600 s two decimal places implied Note If you assign 0 run time for the final recipe step the unit will switch to continuous output when it reaches set point for this step In this situation to turn off output you must send an off command using the OFF button or the appropriate User port signal or serial port command or you must have already enabled joule mode and programmed a joule set point Read back these values with command 183 Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 23 Specifies the length of time the unit will run at 3 CSR only recipe run set point for a recipe step If you enable joule time recipe use this command to set the joule set or point joule set point Send 3 data bytes arranged as follows 4 182 Communication Interfaces 57000097 00B Pinnacle Pl
64. arcs This function allows you to set two parameters e SEQCNT The number of sequential micro arcs required to start the hard arc handling routine The AE factory sets the valid range to 7 0 disables the sequential micro arc feature SEQTIME The time in psec between the end of one micro arc and the beginning of the next micro arc This time is the maximum elapsed time that may occur between micro arcs in order for the unit to consider the arcs to be part of a micro arc sequential series Any micro arc that occurs within this time limit is a sequential micro arc The AE factory sets the valid range 1 usec to 7 usec 0 disables the sequential micro arc feature To set the sequential micro arc count and time 1 Press PROCESS ARC gt MORE gt SEQCNT 2 Rotate the MODIFY knob to set the sequential micro arcs count 3 Press ENTER 4 Press SEQTIME 5 Rotate the MODIFY knob to set the sequential micro arcs time in psec 6 Press ENTER to save your settings and exit ENABLING ARC HANDLING PROCESS ARC ENABLE This function enables or disables the micro arc handling functions of the Pinnacle Plus supply 57000097 00B Communication Interfaces 4 151 Advanced Energy A CAUTION Default at power up is micro and hard arc handling enabled If you choose to disable micro arc handling your Pinnacle Plus unit will not respond to micro arcs which could potentially affect your process You cannot disable ha
65. at the factory for Sync Pulse If Sync Pulse hard arc detection broadcast B CAST is enabled all units handle hard arcs in synchronization with each other no matter which unit detects the hard arc or where the hard arc occurs To set Sync Pulse hard arc detection broadcast 1 Press SUPPLY PULSE gt B CAST 2 Rotate the MODIFY knob to select YES or NO to enable or disable this function If your unit is configured with a Sync Pulse port you may set up to six Pinnacle Plus units in a Sync Pulse system See the section titled Master Slave Operation near the end of chapter 5 of this manual for more information 4 140 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply SETTING THE UNIT AS A SYNC PULSE TRANSMITTER RECEIVER OR STANDALONE SUPPLY PULSE gt TX RX Note This feature is only available if your Pinnacle Plus unit was specifically configured at the factory for Sync Pulse To set the unit as a Sync Pulse transmitter receiver or standalone 1 Press SUPPLY PULSE gt TX RX 2 Rotate the MODIFY knob to select TRANSMIT RECEIVE or STANDALONE Note Within a system there must be one and only one transmitter All other units must be set to receive or standalone If your unit is configured with a Sync Pulse port you may set up to six Pinnacle Plus units to operate in a Sync Pulse system See the section titled Master Slave Operation near the end of chapter 5 o
66. capability Pinnacle Plus power supply features two modes of operation low power operation and high power operation These operation modes allow you to manage better the varied process requirements of operating over a large range of power settings Following is the definition of low power operation For 5 kW and 5x5 kW power supplies low power operation is power at less than 500 W per 5 kW inverter For 10 kW power supplies low power operation is power at less than 1000 W Following is the definition of high power operation For 5 kW and 5x5 kW power supplies high power operation is power at 500 W or greater per 5 kW inverter For 10 kW power supplies high power operation is power at 1000 W or greater To select the mode of operation set the user power limit based on the 500 or 1000 W dividing line depending on your power supply as defined above Because the unit cannot switch operation between the two modes while delivering power selecting the power limit and hence operation mode is not allowed when output is on 5 34 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply The operation modes differ in these specific conditions e Initial output on or ignition e Arc shutdown extinguishing the plasma Open load or circuit condition at output Additionally the operational mode voltage limits change slightly if you select voltage as the mode of regulation LOW POWE
67. control and interfaces DC Chopper Section This section uses a patented circuit with a tapped inductor and a shunt switch to chop or pulse the DC before being sent to the output Logic Control The microprocessor in the logic control section uses operator supplied parameters and set points to control the output This section is also responsible for providing status information to the operator through all interfaces and for controlling the input section 57000097 00B Theory of Operation 2 3 Advanced Energy Remote Interfaces The Pinnacle Plus unit supports four types of interfaces a User port Analog Digital a serial Host port RS 232 422 485 an active front panel and a Pinnacle Remote Panel interface All four interfaces communicate operator supplied inputs to the logic control section and provide the operator with status information 2 4 Theory of Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Chapter 3 Product Specifications FUNCTIONAL SPECIFICATIONS Table 3 1 Functional Specifications Description Specification Modes of Control Serial communications Host port User port analog digital interface active front panel and or Pinnacle Remote Active Panel Passive Panel Options Your unit also may feature either a passive front panel remote active panel blank panel or an active front panel Method of Output The regulation mode is the parameter that remains Regula
68. female connector 4 17 25 pin subminiature D female connector 0 0 0 KK KK 4 27 Rear panel switch i kk kk kk kk kk KK KK KK KK KK KI KK KK KK KK KK KK k 4 27 15 pin User port kk kk kk kk kk kk KK KK KK KI KI KI KK KK KI K K K KI RIK K KK KIR KOK 4 36 37 pin subminiature D male and female connector 4 39 Master Slave Pulse port connector 0000 eee KK 4 50 Master Slave Pulse port cable WAY KK RR ees 4 52 Sync Pulse connector icccdaws Kis os Oe eee ee bes wowed KK KK Renee 4 52 Sync Pulse Cable kk a ks kk kk ave hee a a kla ee ke wks a kk lk 4 53 DeviceNet port with pin designations RR RR KK KK 4 54 DeviceNet rotary switches and LEDs 0000 RR KK KK 4 55 Remote active panel connector 00 KK RR RR KK eee 4 125 Control panel lk kk kk kk kk kK KK eee 4 128 Two line output display screen 0 KK KK KK KK RR RR KK 4 130 Control panel main menu functions XW KERR RR KK 4 132 Service menu map kk kk kk KK KK KK KK KK KIR K KR KR RR KR KK KK 4 133 Supply menu Map 2 2 kk kk kK kK KK KK KK KI K K K K K K KIR KIR KK KK K 4 133 Process menu map kk kk kk kk eee 4 134 Standard Serial port kk kk kK KK KK KEK KK KK KK KK KK KK KK KK 4 158 AE Bus port connector kk kk kk kk KK KK KK KK KK KK KK KK KK KK KS 4 159 Rocker DIP switch lk kk kk kk kk kk KK KK KK KE KI K K KK e
69. for certain configurations of the unit If you set the pulsing to enable by using the voltage pulsing begins when the Pinnacle Plus power supply goes below a user specified voltage threshold This feature allows you to have the unit pulse at low current and high voltages while protecting the unit The voltage threshold range is from 325 V to 50 V below the maximum user voltage allowed for your unit For example if the maximum user voltage is 800 V the maximum voltage threshold is 750 V See Pulsing Behavior When Using Voltage on page 5 32 for more information about how the unit uses the voltage threshold to disable and enable pulsing PULSING BEHAVIOR WHEN USING VOLTAGE If you set a unit to pulse using voltage you must set a voltage threshold at which pulsing is enabled or disabled The following information provides further information on how this pulsing feature functions using a voltage threshold set to 750 V as an example 5 32 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Figure 5 18 illustrates how pulsing begins when you first enable output from the Pinnacle Plus power supply When you first turn on output the unit waits 300 ms to allow the voltage to climb above the voltage threshold if needed to ignite After the 300 ms wait time the unit starts pulsing if the voltage is below the threshold 750 V 750 V threshold f A Y axis Output voltage X axis Tim
70. information 2 This switch sets the analog output signal scaling for VOUT A Its function relates to the setting of Switch 1 See Pin 2 description in Table 4 11 on page 4 28 for more information If Switch 2 is ON and Switch 1 is ON VOUT A 10V 1500V output and Switch 1 is OFF VOUT A 10V 750V output If Switch 2 is OFF and Switch 1 is ON VOUT A 10V 1000V output and Switch 1 is OFF VOUT A 10V 500V output 3 This switch sets the analog output signal scaling for JOUT A Switch 3 settings vary depending on the output power of your Pinnacle Plus product See Pin 3 description in Table 4 11 on page 4 28 for more information If you re running a 10kW Pinnacle Plus unit and Switch 3 is ON IOUT A 10V 40A output and Switch 3 is OFF IOUT A 10V 20A output If you re running a 5kW Pinnacle Plus unit and Switch 3 is ON IOUT A 10V 20A output Note The 5kW unit has only one setting for the analog output signal scaling for JOUT A If the switch is left OFF you could have incorrect scaling 4 This switch is unassigned 5 This switch is unassigned 4 34 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 12 Rear Panel Switch Setting Descriptions Continued Switch Description 6 This switch sets the pulse polarity status of PULSEON D See Pin 12 description in Table 4 11 on page 4 28 for more information If Switch 6 is ON
71. joules remaining counter to its 0 CSR only joule count initial value while the output is on reset 57000097 00B Communication Interfaces 4 97 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued index of the parameter to be set The second and third data bytes are the value to set for the parameter First data byte gt 0 voltage ignition threshold gt 3 gross short circuit amp limit 2nd data byte and 3rd data bytes 16 bit value Voltage ignition threshold valid entries are 325 to maximum user voltage allowed less 50 V For example if the maximum voltage set point is 650 V the maximum threshold is 600 V Gross short circuit amp limit valid values are 15 40 to 30 80 in hundredths of amps Read back this setting with command 235 Command Description Number Numberof of Sent Response Data Data Bytes Bytes 74 Enable or disable the joule countdown hold 1 CSR only enable feature which waits for command 73 before disable joule beginning the joule countdown countdown i i This setting reverts to disabled when the unit powers up Send 1 data byte e 0 Disable Non zero Enable Read back this setting with command 163 82 Sets the voltage ignition threshold and the 3 CSR code set advanced gross short circuit amp limit 4 rocess Bl SIE L Send 3 data bytes The first data byte is the 4 98 Communication Interfaces 57000097 00B P
72. list below shows which data are refreshed at each rate In all cases the times shown are the longest possible that is the worst possible the average rate will be shorter e 10 ms handshake refresh timer is reset with every received command This refresh rate is reserved for echoing back the last command sent commands 0 through 127 and when applicable its CSR code 20 ms refresh timer is reset with every received command This refresh rate is reserved for the three high priority signals in the status bytes joules reached output on and faults active 100 ms refresh timer is reset with every received command This refresh rate is used for the following information gt output readback data command echo and data for commands 128 through 230 4 80 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply low priority signals in the status bytes control mode bits live update commands For example commands 157 172 188 189 and 190 are refreshed at this rate provided that no other commands are sent Once another command is sent the upload data field will represent the response to the new command Interpreting Command Status Response CSR Codes The Pinnacle Plus unit sends a Command Status Response CSR code in response to many commands CSR codes are one byte responses containing a value that can be interpreted according to the following table Table 4 34 Command Status Res
73. master slave system if the power supply includes a master slave Host card interface and Master Slave Pulse port For more information on connecting your units for master slave operation see Connecting for Master Slave Operation on page 5 21 5 26 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Simple Sync Pulse System Figure 5 15 illustrates a simple Sync Pulse configuration that allows you to broadcast hard arcs or not broadcast hard arcs In this configuration hard arcs are the only detection shared between the network units In this Sync Pulse system all units pulse at the same frequency but may have their own unique output power set point Additionally all units must have the same duty cycle and reverse time Note If you need different duty cycles and reverse times for your process operate the Pinnacle Plus power supplies as independent units Transmit To Rack Ground and Chamber Ground Receiv e Receive Figure 5 15 Sync Pulse system 57000097 00B Installation and Operation 5 27 Advanced Energy Sync Pulse Master Slav
74. minimum Vpos refers to the 15 V supply output current may range from 0 5 mA to 0 1 A The signal levels for digital inputs are the following e Logical 0 30 V to 5 V with 0 5 mA maximum leakage e Logical 1 13 V to 30 V and 8 5 mA typical All digital input lines incorporate a low pass filter that rejects signals less than 10 ms Connector and Rear Panel Switch USING THE CONNECTOR WITH THE REAR PANEL SWITCH The following figures show the User port connector and the rear panel switch The User port connector and rear panel switch work in conjunction with each other in setting specific connector pin signals Note Refer to Table 4 11 on page 4 28 for more information on the pin signals affected by the switch settings Table 4 12 on page 4 34 provides information on the switch settings and how they affect specific pin signals 4 26 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Pin 13 Pin 1 OOOOOOOOOOO OO QOOOOOOO0000 Pin 25 Pin 14 1045 Figure 4 3 25 pin subminiature D female connector 1750 Figure 4 4 Rear panel switch Note Signals at the User port can be sensitive to noise We recommend that you take standard preventative measures against electro magnetic interference EMI including using shielded cabling on the User port CONNECTOR PIN DESCRIPTIONS Table 4 11 on page 4 28 provides detailed information about the 15 V 25 Pin User port c
75. must acknowledge the condition at the master unit before turning on output For example you must press the OFF button to acknowledge the condition and then the ON button to turn on output 57000097 00B Installation and Operation 5 39 Advanced Energy The following table describes some of the errors you might encounter with a Pinnacle Plus master slave system Table 5 5 Errors Associated with the Master Slave System Condition Possible Cause s Master reports The master slave cable has been removed Master Slave Fault The master slave pulse cable has been removed The master slave cables or switches have been set incorrectly Slave reports The master slave pulse cable has been removed No Master Detected Serial Any unit reports One of the units in the system is not energized that System Input Power is does not have input power Fault Note See the unit troubleshooting information for more error code information SYNC PULSE OPERATION The following sections include information about operating and monitoring Pinnacle Plus power supplies connected for sync pulse operation For information on how to connect and configure the Pinnacle Plus power supplies for sync pulse operation see Connecting for Sync Pulse Operation on page 5 25 Monitoring the Sync Pulse System You can monitor the sync pulse system using the following devices Ifyou have a passive fron
76. network address setting O ON OFF buttons 4 127 4 128 on off sequences PROFIBUS 4 73 AE Bus port 4 159 DeviceNet 4 54 remote panel 4 125 standard serial port 4 158 User port 4 5 4 37 4 42 Pinnacle Plus remote panel See control panel poll command message 4 56 master slave systems 5 39 operation outbytes 4 76 out of set point timer setting 4 145 safety guidelines 1 2 turning the unit on 5 30 verifying LEDs 5 30 output box and connector diagram 5 13 connecting 5 10 control panel power switches 4 128 impedance range 2 1 3 17 negative 5 14 optimal connection 5 15 positive output voltage 5 15 range 3 17 regulation 2 1 setting current limits 4 148 setting power limits 4 148 setting voltage limits setting output limits 4 148 pollution degree specifications 3 18 positive output 5 15 power connecting input 5 9 POWER switch 4 129 process menu map 4 134 process menu functions using 4 143 product certification 1 5 compliance 1 5 labels 1 3 PROFIBUS command set 4 82 commands 4 75 data consistency 4 75 download packet 4 76 errors 4 74 example command sequences 4 121 handshaking 4 76 master reset command 4 74 setting baud rate 4 73 setting network address 4 73 Index 57000097 00B Pinnacle Plus 10 kW Power Supply termination 4 73 transmission rates 4 76 type GSD files 4 73 upload packet 4 77 watch dog timer 4 74 work around 4 75 PROFIBUS Host 4
77. of inverter faults 5 If you press INTRLOCK the number of contactor user and cable faults appears 6 If you press IRQ the number of predefined and unassigned IRQ faults appears 7 If you press MONITOR the number of set point timer faults appears 8 If you press DSP the number of DSP control and DSP watch dog faults appears CHECKING THE NUMBER OF CYCLES To check the cycles 1 Press SERVICE gt STATS gt EVENTS gt FAULTS and CYCLES options appear 2 Press the CYCLES soft key gt OUTPUT and UNIT options appear 3 To get a report of the number of output on events press the OUTPUT soft key 4 To get a report of the number of power on events press UNIT Debugging Your Unit SERVICE DEBUG Use this option to check the hardware configuration installed cards and logic software options CHECKING YOUR HARDWARE CONFIGURATION SERVICE gt DEBUG gt HW CONFIG To find out whether or not a card is installed in slot 1 or 2 1 Press SERVICE DEBUG gt HW CONFIG gt A report of the personality cards installed in the supply in slot 1 and slot 2 appears CHECKING YOUR SOFTWARE LOGIC SERVICE gt DEBUG gt LOGIC Use this option to find out what software logic options are installed 1 Press SERVICE gt DEBUG gt LOGIC 4 136 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply The configuration options display one at a time Arrows above the first two soft keys allo
78. point contains 3 data bytes regulation mode e First second byte Set point level 16 bit value e Third data byte Regulation mode 8 bit value e 6 Power e 7 Voltage e 8 Current This value is set with command 6 170 Requests the arc shutdown time The 0 2 request arc returning packet contains 2 data bytes shutdown e Byte 1 Unused e Byte 2 Index value set with command 8 refer to command 8 for the shutdown index values 171 Requests the index for the voltage level at 0 1 which the unit indicates an arc is occurring requestvoltage Fora list of the voltage levels indicated by the arc trip level index values see command 10 text The returning packet contains data byte indicating the trip level index This value is set with command 10 172 Requests how many joules remain in the 0 4 current run the returning packet contains 4 request joules data bytes 32 bit value indicating the remaining number of joules 173 Requests the joules set point set with 0 4 4 112 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number Number of Sent of Data Response Bytes Data Bytes 174 Requests the over voltage timer value the 0 2 returning packet contains 2 data bytes 16 bit request over value indicating the value voltage timer i i value This value is set with comm
79. run Note The unit records a hard arc every time the output voltage goes below the voltage arc trip level for longer than the arc detect time The unit then shuts down for the arc shutdown time period All arc counters are updated every 100 ms or 10 times per second 191 Reports the number of overvoltage or 1 4 report overcurrent events that occurred since the overvoltage counter was last reset Rs LAN Send 1 data byte 8 bit value indicating the events desired report 57000097 00B Communication Interfaces 4 211 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 195 Requests the identity of the unit s personality 0 2 cards The returning packet contains 2 data request bytes personality i i card First byte Identity of card in slot 1 gt 0 Card not present gt 01 or 17 Dual User port 03 or 26 PROFIBUS 05 or 21 Single User port 18 or 28 AE Bus 23 or 30 DeviceNet Second byte Identity of card in slot 2 gt 0 Card not present 03 or 26 PROFIBUS 04 Host Protocol Translator 05 or 21 Single User port 18 or 28 AE Bus gt 22 or 29 Master slave card with AE Bus 196 Requests the recipe type set with command 33 0 1 request Returns 1 data byte recipe type eda Timed e 2 Joule continuous e 3 Joule discrete 197 Requests the ve
80. signals adjust to accommodate the most recent change in output capability of the combined units Monitoring the Master Slave System You can monitor the master slave system using the following devices Ifyou have a passive front panel or remote passive panel attached to your master unit you can view the combined output of your master slave system power or current The passive front panel of each slave unit displays the individual unit s output Ifyou have an active front panel or Pinnacle Remote Active Panel attached to your master unit you can monitor the output power current or voltage of your system and the output of each individual unit Ifyou have a host computer connected to a serial port on your master unit you can monitor the output power current or voltage of your system and the output of each individual unit See Chapter 4 in the Pinnacle Plus power supply user manual for more information Clearing Faults in a Master Slave System Ifa slave unit experiences a self clearing fault both the master and slave units display an error code and the master unit shuts off output from all attached power supplies When the fault condition clears the master and slave units reset You may then turn on output If a slave unit experiences an explicit clear fault both the master and slave units display an error code and the master unit shuts off output from all attached power supplies When the fault condition clears you
81. switches 4 128 POWER switch 4 129 REGULATION key 4 127 regulation switches 4 129 selecting control mode 4 142 selecting functions 4 131 setting control parameters 4 152 setting panel mode 4 142 soft keys 4 127 4 131 two line display screen 4 129 VOLTAGE switch 4 129 control switches 4 128 coolant specifications 3 19 cooling requirements 5 1 CSR codes 4 170 CSR see command status response 4 81 CURRENT switch 4 129 customer support contacting 6 26 D data bytes AE bus 4 167 data consistency 4 75 debugging your unit 4 136 DeviceNet addressing 4 55 baud rate setting 4 55 communication 4 56 connecting 5 9 explicit messaging 4 63 installation 4 54 LEDs 4 70 operation 4 55 pin descriptions 4 54 poll command message 4 56 port 4 54 response message 4 59 rotary switches 4 55 scaling poll command 4 59 scaling response message 4 62 digital signals 4 5 4 19 4 41 User port 4 26 dimensions drawing 3 5 DIP switch AE bus 4 161 communication mode setting 4 165 setting baud rates 4 165 directives 1 6 display passive panel 4 123 DISPLAY button 4 123 download packet PROFIBUS specific 4 76 E electrical specifications 3 6 electromagnetic compatability EMC directives and standards 1 6 EMI connecting serial Host port 5 8 connecting User port 5 9 DeviceNet connection 5 9 User port 4 36 enabling arc handling 4 151 environmental specifications 3 18 error codes clearing 6 15 clearing master slave faults 5 39 erro
82. the host commands Clearing the Error Code Error codes Exxx numbers appear on the passive front panel the remote passive panel and the Pinnacle Remote Active Panel These messages contain both the error code and a brief description of the problem The following table explains more about error codes and messages and how to respond to them Error codes are typically generated by two types of faults self clearing or explicit clear When the unit experiences a self clearing fault condition the unit turns off output and displays an error code on the panel When the fault condition is no longer present in the system the panel ceases to display the error code You then can turn on the output When the unit experiences an explicit clear fault condition the unit turns off output and displays an error code Once the fault condition is no longer in the system you must acknowledge the condition from your controlling interface before turning on output To reset the Pinnacle Plus unit do one of the following From the front panel press the OFF button to acknowledge the condition Then press the ON button to turn on output Through the DeviceNet interface send the Poll Command message twice once to turn off output and once to turn on output see the description of Byte 4 57000097 00B Troubleshooting and Global Services 6 15 Advanced Energy Error Code Troubleshooting Use the following information to troublesh
83. the I O port connector I O port connectors are not hot pluggable A CAUTION Signals at the I O port can be sensitive to noise Take standard preventative measures against electro magnetic interference EMI including using shielded cabling on this port The Contactor Intlk port located on the rear panel of the Pinnacle Plus see Rear view on page 5 29 for location is a 9 pin male subminiature D connector To enable the Pinnacle Plus to function pins 3 and 4 of this connector must be shorted together through a cheater plug external switch or relay Pin 4 supplies the signal with 18 V and it can source 60 mA Pin 3 can sink 60 mA The voltage on pins 3 and 4 should not exceed 20 V Figure 5 2 shows the Contactor Intlk port Pin 1 Pin 5 herr Pin 6 Pin 9 1370 Figure 5 2 Contactor Intlk port connector Note The mating connector connector shell and post screws are included in the hardware kit that accompanied the Pinnacle Plus unit 57000097 00B Installation and Operation 5 7 Advanced Energy Connecting a Remote Passive Panel Connect the remote passive panel at the female 15 pin subminiature D connector labeled MONITOR on the rear panel of the Pinnacle Plus power supply The rear of the remote passive panel features a male 15 pin subminiature D connector Use the cable provided with the remote passive panel to connect the panel to your Pinnacle Plus power supply See Chapter 4 for more inf
84. the dimensional drawings in Chapter 3 for more information on the spacing requirements of the Pinnacle Plus power supply The clearance between either side of the Pinnacle Plus power supply and the enclosure must be 76 mm 30 The clearance between the top of the Pinnacle Plus power supply and the top of the enclosure must be 25 mm 10 No clearance is required between power supplies The clearance between the rear of the Pinnacle Plus power supply and the enclosure must be 102 mm 4U with adequate ventilation Cooling Requirements To sufficiently cool the Pinnacle Plus power supply install the cabinet as follows e 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 nonconductive pollution occurs during operation Occasionally condensation causes temporary conductivity when the device is not operating Bring in sufficient coolant air of the correct temperature 0 C to 40 C 32 F to 104 F maximum e Distribute coolant air to the power supplies e Prevent air exhausted from the cabinet from circulating and becoming input air e Exhaust the hot air from the cabinet with minimal airflow restriction See Figure 5 1 on page 5 4 for a dimensional diagram 57000097 00B Installation and Operation 5 1 Advanced Energy CABINET DESIGN The following i
85. the supply 5 Press ENTER the display progresses to a screen requesting a RUN TIMER value 57000097 00B Communication Interfaces 4 153 Advanced Energy 6 Rotate the MODIFY knob to select a value between 0 00 s to 600 s in 0 01 s increments Note If you turn the MODIFY knob quickly the counts per click setting takes effect Press ENTER if you have indicated that your recipe contains more than one step the display returns to the RAMP TIMER screen so that you can enter recipe values for the next step Repeat Steps 2 through 7 as needed Note If you assign 0 run time for the final recipe step the unit will switch to continuous output when it reaches set point for this step In this situation to turn off output you must send an off command using the OFF button or the appropriate User port signal or serial port command or you must have already programmed a joules set point To set the number of joules and the set point value for each step 1 6 If you set the TYPE as JOULE CONTINUOUS or JOULE DISCRETE after you have set the number of recipe steps a screen that requests a JOULE value displays Rotate the MODIFY knob to select a value Note With JOULE CONTINUOUS or JOULE DISCRETE types the display includes a multiplication factor button 1X 10X 100X or 1000X Use it to multiply the JOULE value by the indicated factor Press ENTER the display progresses to a screen requesting a SETPOI
86. to 10 of full rated output power 6 Turn output on 7 On the Pinnacle Plus active front panel or the remote active panel verify that the power readback is within 1 of the set point 8 Verify that the actual power measured from the oscilloscope voltage x current is within 6 of the set point The 6 range accounts for the accuracy of the oscilloscope probes 9 Repeat the previous two steps with the set point set to 25 50 and 100 of full rated output power 10 Turn output off and set the set point to 0 Test with pulsing enabled 1 Enable pulsing mode on the Pinnacle Plus unit 2 Set the oscilloscope to measure the following The mean of the output voltage The amplitude of the output current The frequency of the output voltage The positive pulse width of the output voltage 3 On the Pinnacle Plus unit make the following settings Frequency 100 kHz Reverse time 4 us gt Set point 10 of full rated output power 4 Turn on the output 5 Verify the following measurements Measured frequency is within 3 5 of the frequency set point Measured output positive pulse width is within 3 5 of the reverse time set point The power readback on the Pinnacle active front panel or remote active panel is within 1 of the power set point The actual power is within 6 of the power set point mean of output voltage x amplitude of output current 6 6 Troubleshooting and Globa
87. unit is turned on it forces a power off If pin 14 transitions low when pin 7 is low pin 14 will enable output power For more information on these two signals see User Port Output Enable Disable Behavior and Signal States on page 4 14 8 nla unassigned n a n a 9 nla OUTCOM A n a Dedicated return for analog output Reference pins 23 24 25 31 and 32 to this pin 10 n a INCOM A n a Dedicated return for analog input Reference pin 27 to this pin 57000097 00B Communication Interfaces 4 7 Advanced Energy Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 11 19 AUX D digital This signal with VAC D input pin 12 and WATER D pin 13 monitors the system interlock string If the interlock conditions are not all satisfied either the main contactor will not close or it will open if it is already closed when the interlock string is interrupted 12 19 VAC D digital See description of pin 11 input AUX D 13 19 WATERD digital See description of pin 11 input AUX D 14 36 OFF D digital This signal is used with input ON D pin 7 to enable disable output power See Pin 7 description and User Port Output Enable Disable Behavior and Signal States on page 4 14 for more information Pin 14 also resets the Pinnacle Plus unit after all fault conditions exc
88. unit may be configured with different values For information about a specific unit contact AE Global Services Index Trip Level data byte result in volts 0 10 1 20 2 30 3 40 4 50 5 60 6 70 7 80 8 90 9 100 10 125 11 150 12 175 13 200 14 225 15 250 Read back this value with command 171 57000097 00B Communication Interfaces 4 177 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 11 active target Specifies which target will be active Send 1 data byte 8 bit value the value must be at least 1 but no greater than 8 Note The User port has priority for target selection Thus to select targets from the active front panel or from the Pinnacle Remote Panel that is when the Pinnacle Plus unit is in local or host control mode you must set the target to 1 at the User port Leaving the target bits open or leaving the User port pins unconnected causes the target selection at the User port to default to 1 Read back this value with command 156 1 CSR codes 0 1 2 4 9 10 12 target life Sets the life in kilowatt hours of the target you specify Send data byte 8 bit value plus 4 data bytes 32 bit value arranged as follows First byte Target number Second third fourth fifth bytes Target life in kilowatt hours two decimal places are implied that is to g
89. with command 22 183 Requests the run time you set for a specific 1 2 or 4 recipe step or if joule recipe is enabled this May return request command requests the joule set point CSR code 4 recipe step i NEDEN run time Send 1 data byte 8 bit value indicating the or recipe step joul gm na The returning packet contains 2 data bytes indicating the run time in seconds Or if joule recipe is enabled returns 4 data bytes 32 bit value indicating the joule set point With timed recipes two decimal places are implied For example a value of 5 would indicate 0 05 s This value is set with command 23 57000097 00B Communication Interfaces 4 209 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 184 Requests the amount of time remaining on the 0 2 out of set point timer before an error condition request out occurs the returning packet contains 2 data of set point bytes 16 bit value indicating the interval interval value in seconds One decimal place is implied For example a value of 999 would indicate an interval of 99 9 s 186 Requests the over current timer value the 0 2 returning packet contains 2 data bytes 16 bit request over value indicating the value current timer value This value is set with command 35 187 Requests the out of set point timer value the 0 2 returning packet contai
90. your unit s capabilities Note If the ramp feature is enabled commands 15 and 16 sending this command while the output is on will force the unit to ramp from the existing set point to the new requested set point over the time specified in command 16 Thus by using this command and commands 15 and 16 you can generate an output wave form during a process Read back this value with command 164 4 174 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 8 arc shutdown time Send 2 data bytes to set the arc shutdown time e Byte 1 Unused e Byte 2 Se nd the index value that represents the arc shutdown time in us The list below shows standard index values Your unit may be configured with different values For information about a specific unit contact AE Global Services 0 200 1 500 2 1000 3 1500 4 2000 gt 5 2500 6 3000 gt 7 4000 gt 8 5000 Readback this value with command 170 2 CSR only 57000097 00B Communication Interfaces 4 175 Advanced Energy Table 4 48 AE Bus Commands Continued count limit after output shuts off the ARC LED on the passive panel or active control panel lights and if applicable a pulse is sen
91. 0 through 127 change the value of a parameter or direct the power supply to perform a specific function Most of these commands require that the Pinnacle Plus unit be in host control mode Exceptions are noted in the Description column in the following table The last column in the following list indicates how many data bytes of the download packet are needed to support the command For example a 1 in the last column indicates that you must insert data in the first data byte Likewise a 3 would indicate that you must insert data in all three data bytes If a data byte is not defined as containing data its contents will be ignored Thus you do not need to zero data bytes that are not used 4 82 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Command Description Number Numberof of Sent Response Data Data Bytes Bytes 0 Null command Sets DC output off 0 CSR only null Note This request is always honored regardless of which interface has control 1 Sets DC output off 0 CSR only dc off This request is always honored regardless of which interface has control 2 Sets DC output on host control must be 0 CSR only selected see command 14 dc on Read back the status of the last output on event with command 161 3 Sets the method of output regulation power 1 CSR only current or voltage regulati
92. 000097 00B Theory of Operation 2 1 Advanced Energy communications Host port The serial communications port the active front panel and the Pinnacle Remote Panel provide access to all operating parameters and control functions The User port provides limited access to operating parameters and control functions Microprocessor Advantages The internal microprocessor checks for proper circuit operation while supervising all operating parameters System diagnostics run when the unit is initially powered up The most recent power settings and conditions such as producing output are retained in non volatile memory Displays The displays on the passive panels as well as the control panels show power current or voltage levels The displays show levels for unit A and unit B if this is a dual unit They also display information about output pulsing set point interlock bus fault overtemp arcs and error codes Arc suppression Feature The Pinnacle Plus supply s arc handling feature ensures the shortest arc recovery time in the industry You can implement user defined arc handling functions during your normal process cycle Parameters including hard arc count limit voltage trip level enable and disable are selectable through the unit s active control panel optional Pinnacle Remote Active Panel or a serial Host communications port THEORY OF OPERATION The Pinnacle Plus power supply is a sophisticated and intellig
93. 00097 00B Pinnacle Plus 10 kW Power Supply Table 6 4 Error Code Troubleshooting Table Error Code Problem Indicated Suggested Action Message E005 The AC input power line Using all applicable safety precautions dipped below required inspect your AC input power source to Momentary operating conditions This ensure that it is properly connected and Power condition may be due to that the specified voltage is being applied Fluctuation an AC power black out or to the Pinnacle Plus unit See the brown out Specifications chapter for AC input power specifications E006 The DSP has failed Call AE Global Services DSP Watch Dog Failure E007 The unit has not been 1 Some units will allow you to clear properly initialized this error To clear the error Initialization i Fault Note This error is not For a active or remote panel press reported by all the Off button oe For a passive panel press the Display button three times within one second If the error does not clear proceed to the next step 2 Cycle power to the unit 3 If the error recurs call AE Global Services E009 Output positive terminalis Connect output positive terminal to PE not PE grounded ground available only on certain Output Ground options Fault Detected 57000097 00B Troubleshooting and Global Services 6 17 Advanced Energy Table 6 4 Error Code Troubleshooting Table Side A Invert
94. 0097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 21 recipe ramp time Specifies the length of ramping time for a recipe step that is how long the unit will take to reach the set point you have defined for the selected recipe step Send three data bytes arranged as follows First byte Recipe step must be a value between 1 and 8 Second and third bytes Value between 0 and 60 000 or between 0 s and 600 s two decimal places implied Note If your unit has 100 ms ramp feature enabled one decimal is implied The range is 0 s to 6000 0 s Read back these values with command 181 3 CSR codes 0 1 2 4 9 22 recipe set point Specifies the set point for a recipe step Send three data bytes arranged as follows First byte Recipe step must be a value greater than 0 but no greater than 8 Second and third bytes Value between 0 and the full rated output of the supply Note See the Specifications chapter for your unit s capabilities and see command 6 for the format of the value Read back these values with command 182 CSR codes 0 1 2 4 9 57000097 00B Communication Interfaces 4 181 Advanced Energy Table 4 48 AE Bus Commands Continued First byte Recipe step a value between 1
95. 097 00B Pinnacle Plus 10 kW Power Supply Maximum Allowable Reverse Time For a Given Frequency Note Frequency is limited to 150 kHz when the pulsing enabled mode is set to be enabled always 12 9 maximum allowable reverse time usec 0 TM DO PPD GPP MP PH PD LK ae ae 4 i 9 j self run frequency kHz Figure 3 2 Pulse reversal times and self run frequencies Table 3 4 Reverse Time Given a Self Run Frequency Requested Actual Pulse Duty Cycle Duty Cycle Frequency Frequency Reversal Time min max kHz kHz Maximum us Reverse Reverse Period Period 5 5 10 0 20 5 0 10 10 10 0 40 10 0 15 15 004 10 0 60 15 0 20 20 10 0 80 20 0 25 25 10 1 00 25 0 30 29 985 10 1 20 30 0 57000097 00B Product Specifications 3 9 Advanced Energy Table 3 4 Reverse Time Given a Self Run Frequency Continued Requested Actual Pulse Duty Cycle Duty Cycle Frequency Frequency Reversal Time min max kHz kHz Maximum us Reverse Reverse Period Period 35 35 026 10 1 40 35 0 40 40 10 1 60 40 0 45 45 045 9 9 1 80 44 6 50 50 9 0 2 00 45 0 55 54 945 8 1 2 20 44 5 60 60 06 7 4 2 40 44 4 65 64 935 6 9 2 60 44 8 70 69 93 6 4 2 80 44 8 75 74 906 6 0 3 00 44 9 80 80 5 6 3 20 44 8 85 85 106 5 2 3 40 44 3 90 90 09 4 9 3 60 44 1 95 94
96. 1 Functional Specifications Continued Description Specification Fault Conditions Several fault conditions either cause the Pinnacle Plus supply to shut off output or prevent output from being turned on These conditions include open interlock loops input power failure over temperature and user controlled timers Gross Short Circuit When this feature is factory enabled it will Detection operate in power and voltage regulation modes With this feature the gross short circuit algorithm starts if the following condition exists Output readback is less than the out of set point lower limit The unit has detected no hard arcs e The current A is greater than the gross short circuit current limit This condition has existed for the detection time If the algorithm determines that a gross short circuit exists SC flashes on the front panel and then error E088 Short Circuit Fault or E089 Fatal Short Circuit Fault appears on the front panel PHYSICAL SPECIFICATIONS Table 3 2 Physical Specifications Description Specification Size 133 mm H x 483 mm W x 639 mm D including connectors 5 22 in H x 19 in W x 25 18 in D Weight 30 kg 66 Ib Output Connector Two terminal multi contact pluggable connector or UHF connector 57000097 00B Product Specifications 3 3 Advanced Energy Table 3 2 Physical Specifications Continued Description
97. 10 kW Power Supply Table 4 13 Single 15 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 13 n a NET GREEN Output This pin is the emitter side of an opto coupler for NET LED 14 n a MOD AMBER Output This pin is the emitter side of an opto coupler for the MOD LED 15 n a NET AMBER Output This pin is the emitter side of an opto coupler for the NET LED DUAL 24 V 37 PIN USER PORT This section applies to the dual 24 V 37 pin User port e The User port is a 37 pin subminiature D port The User port label is Dual Iso User Port The User port is an analog interface that allows the use of a remote controller It is a 24 V interface card with a 37 pin subminiature D connector This connector will be male or female depending on which options you specified at the time you ordered your Pinnacle Plus unit Pin 1 Pin 1 Female OOOOOOOOOOOOOOOOOO es 1385 Figure 4 6 37 pin subminiature D male and female connector Note If you have an isolated 24 V User port card your card provides isolation of more than 500 Vrms from the Pinnacle Plus unit s SELV logic and control circuitry to all 37 pins on the connector 57000097 00B Communication Interfaces 4 39 Advanced Energy Installation A DANGER Disconnect all sources of input power before working on this unit or anything connected to it
98. 14 0x0E Yes Yes Get_Attribute_ Single 16 0x10 No Yes Set_Attribute_Single Rear Panel LEDs The rear panel of the Pinnacle Plus unit features two bi color LEDs see Figure 4 12 One is labeled MOD and indicates module status The other is labeled NET and indicates network status MODULE STATUS LED The MOD bi color amber green LED provides device status It indicates whether the device has power and is operating properly Table 4 28 MOD Status LED Flashing Green If the LED is the state indicated is which means that Off No power The unit is not receiving power Green steady Operational The unit is operating normally Standby The unit needs maintenance because the configuration is missing incomplete or incorrect Unrecoverable Fault The unit has experienced a fault from which it Amber cannot recover you may need to replace the unit Flashing Amber Device Self Testing The unit is running self Green diagnostics For information on LED flash rates refer to section 8 2 8 of the DeviceNet Specification revision 2 0 4 70 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply For information about Module Status LED indications during power up refer to Section 8 2 4 of the DeviceNet Specification revision 2 0 NETWORK STATUS LED The NET bi color amber green LED indicates the status of the communic
99. 14 Dual 24 V 37 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 34 nla B_OUTCOM A n a This line is a dedicated return for analog outputs Reference B JOUT A pin 16 B POUT A pin 17 and B_VOUT A pin 35 to this pin 35 34 B_VOUT A analog This signal provides a fully output buffered 0 to 10 V signal representing output voltage Full scale 10 V represents the rating of the supply See the Specifications chapter of this manual 36 n a B_LEVELIN A analog This signal is used to input program the output level Full scale 10 V represents the rating of the supply See the Specifications chapter of this manual 37 n a B_INTLKCOM D n a This signal is a dedicated return for B_INTLK D pin19 Table 4 15 Regulation Mode pin 7 and pin 25 Controlling Unit A Regulation Mode Pin 7 Pin 25 Voltage low low Power high low Current low high Invalid State high high Table 4 16 Regulation Mode pin 13 and 32 Controlling Unit B Regulation Mode Pin 13 Pin32 Voltage low low Power high low 57000097 00B Communication Interfaces 4 49 Advanced Energy Table 4 16 Regulation Mode pin 13 and 32 Controlling Unit B Continued Regulation Mode Pin 13 Pin32 Current low high Invalid State high high MASTER SLAVE PULSE PORT Note The master slave fea
100. 3 Advanced Energy SETTING THE PINNACLE PLUS UNIT S AE BUS ADDRESS Use the DIP switch see Figure 4 22 on page 4 161 and Figure 4 23 on page 4 162 to set the unit s AE Bus address see Table 4 44 on page 4 164 For units with a single output an allowable address is between 1 and 31 Table 4 44 AE Bus Address Settings Address A4 A3 A2 A1 A0 0 Don t assign this address to a unit it is the AE Bus broadcast address all Pinnacle Plus units receive a message sent to this address by the host but will not reply 1 up up up up down 2 up up up down up 3 up up up down down 4 up up down up up 5 up up down up down 6 up up down down up 7 up up down down down 8 up down up up up 9 up down up up down 10 up down up down up 11 up down up down down 12 up down down up up 13 up down down up down 14 up down down down up 15 up down down down down 16 down up up up up 17 down up up up down 18 down up up down up 19 down up up down down 20 down up down up up 21 down up down up down 22 down up down down up 23 down up down down down 4 164 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 44 AE Bus Address Settings Continued Address A4 A3 A2 A1 A0 24 down down up up up 25 down down up up down 26 down down up down up 27 down down
101. 3 Request the number of recipe repetitions 0 4 request number of Returns 4 data bytes recipe e Bytes 1 and 2 Number of repetitions set repititions NENE e Bytes 3 and 4 Current repetition in process reports 0 if output is off This value is set with command 59 57000097 00B Communication Interfaces 4 119 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 235 request advanced process parameters Requests the operating parameter selected in the send data byte Send 1 data byte to identify the parameter to be read Send byte value 0 Reports the voltage ignition threshold e Send byte value 1 Micro are count Reports the number of sequential micro arcs needed to trigger a hard arc count Send byte value 2 Microsecond count Reports the maximum elapsed time in microseconds between the end of one micro arc and the beginning of the next micro arc during which the unit considers the micro arcs to be sequential Micro arcs that occur within this timeframe are sequential Send byte value 3 Reports the gross short circuit current limit in hundredths of amps Send byte value 4 Reports the gross short circuit time out in tenths of seconds 2 May return CSR codes 0 5 9 12 243 request maximum on timer Reports the maximum amount of time that output w
102. 34 and never counts down 0 4 or 6 180 request recipe steps Requests the number of recipe steps the returning packet contains data byte 8 bit value indicating the number of steps Note Recall that a value of 0 sent with command 19 disables the ramping recipe feature This value is set with command 19 4 208 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 181 Requests the amount of ramping time you have 1 2 set for a specific ramping recipe step May return request CSR code 4 Maa step Send 1 data byte 8 bit value indicating the ramp time recipe step The returning packet contains 2 data bytes 16 bit value indicating the time in seconds Two decimal places are implied For example a value of 5 would indicate 0 05 s This value is set with command 21 182 Requests the set point level you have set for a 1 3 specific ramping recipe step May return request NEN CSR code 4 recipe step Send 1 data byte 8 bit value indicating the set point and recipe step The returning packet contains 3 regulation data bytes m z ode First and second bytes Value of set point in the mode indicated Third byte Regulation mode gt 6 Power 7 Voltage gt 8 Current This value is set
103. 4 Out of set point timer expired e 5 Ground fault detected if your Pinnacle Plus supports this feature e 6 Short circuit fault active e 7 Fatal short circuit active 57000097 00B Communication Interfaces 4 109 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued request config status Returns 4 data bytes 1st status byte 0 Host program source 0 internal 1 external 1 Local program source 0 internal 1 external 2 Analog program source 0 internal 1 external 3 Master 4 Slave 5 Unassigned 6 Program source 0 internal 1 external 7 Target life status 0 inactive 1 active 2nd status byte La 0 Profibus Status Bit Definition 0 normal 1 Joule Recipe 1 Front panel access 0 unlocked 1 locked 2 Joule mode 0 disabled 1 enabled 3 Contactor status 0 open closed 4 Unassigned 5 Ramp mode 0 disabled 1 enabled 6 Unassigned 7 Pulsing enabled 0 disabled 1 enabled Command Description Number Number of Sent of Data Response Bytes Data Bytes 163 Requests the system configuration status 0 4 4 110 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 163 request co
104. 5 Continued Command Description Number Number of Sent of Data Response Bytes Data Bytes 184 Requests the amount of time remaining on the 0 2 out of set point timer before an error request out of condition occurs the returning packet set point contains 2 data bytes 16 bit value indicating interval the interval value in seconds One decimal place is implied For example a value of 999 would indicate an interval of 99 9 s 186 Requests the over current timer value the 0 2 returning packet contains 2 data bytes 16 bit request over value indicating the value current timer value This value is set with command 35 187 Requests the out of set point timer value The 0 2 returning packet contains 2 data bytes 16 bit request out of value indicating the timer value in seconds set point timer One decimal place is implied For example a value of 999 would indicate a timer value of 99 9 s This value is set with command 31 188 Requests the arc density that occurred in the 0 4 previous second returning packet contains 4 request arc data bytes density per second e First second bytes Micro arcs 16 bit value e Third fourth bytes Hard arcs 16 bit value 189 Requests how many micro arcs occurred in 0 4 the previous run returning packet contains 4 request micro data bytes 32 bit value indicating the total arc density per of micro arcs run Note The unit records a micro arc each
105. 6 If the BUS FAULT LED is lit error code E002 should be displayed on the panel If the OVERTEMP LED is displayed E004 should be displayed See Error Code Troubleshooting on page 6 16 for help in troubleshooting these errors If no error code is displayed cycle the Pinnacle Plus unit s power on and off to determine whether the LED is functioning properly 7 Working with the Pinnacle Remote Active Panel verify that the output display screen information is displayed If the display screen shows an error message see Error Code Troubleshooting on page 6 16 If the display remains blank cycle the Pinnacle Plus unit s power on and off If the problem re occurs call AE Global Services 8 Determine whether the cooling fans are functioning and ensure your cabinet allows for adequate ventilation for all the units in the cabinet see Cooling Requirements on page 5 1 for more information If the fans are not functioning properly call AE Global Services 9 If the unit powers up well and communicates you may restore the default settings of the unit through the Active or Remote Front Panel You may also use the Host port 10 Issuing command 0 through the serial communication Host port turns the unit off 11 If the pulsing switch is defective the unit delivers current but not voltage Pinnacle Plus Basic Functionality Test This procedure allows you to verify the basic functionality of the Pinnacle Plus Note
106. 6 map 4 133 using functions 4 134 set point out of setp oint timer 4 145 setting 4 131 5 31 setting arc count limit 4 150 setting control parameters 4 152 setting joule mode 4 155 setting out of set point timer 4 145 setting output current limits 4 148 setting over current timer 4 145 setting over voltage timer 4 144 setting power limits 4 148 setting ramp 4 156 setting supply parameters 4 139 setting voltage arc trip level 4 149 shared memory block 4 75 signals User port 4 37 4 41 soft keys 4 127 4 131 software checking your versions 4 138 57000097 00B Index v Advanced Energy Host commands 4 172 PROFIBUS commands 4 75 spacing requirements 5 1 dimensions 3 5 stacked units 5 4 specifications coolant 3 19 electrical 3 6 environmental 3 18 functional 3 1 overvoltage category 3 18 physical 3 3 pollution degree 3 18 stacked power units spacing requirements 5 4 standard serial flash port connecting 5 8 standard serial port 4 157 communications protocol 4 166 CSR codes 4 170 pin descriptions 4 158 transmission parameters 4 158 standards 1 6 statistics service menu 4 135 status bytes upload 4 79 status flag bytes PROFIBUS 4 77 strain relief fittings 5 17 subminiature D 4 159 supply menu functions 4 138 map 4 133 switches control panel control mode 4 128 control panel power 4 128 control panel regulation 4 129 switches rotary DeviceNet 4 55 symbols in user manual 1 2 on unit 1 3 T target
107. 6 nla unassigned n a n a 17 nla unassigned n a n a 4 20 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 7 Single 24 V 37 pin User Port Pin Description Continued Signal Pin 18 Return Pin 36 Name INCOM D Signal Type input Description Connect your system s 24 V power supply to this pin See Connector on page 4 17 for additional information Must be connected to AUX D INTLK pin 11 in order to satisfy the interlock A pull up resistor of no more than 5 kO can be used 19 n a INTLKCOM D n a This pin is the dedicated return for the AUX D INTLK pin pin 11 20 37 CS2 D output This signal is used with pin 1 CS7 D to tell an external device such as a cathode switch box which of the Pinnacle Plus supply s target life counters is active See the description of pin 1 for the logic table 21 37 ARC D output A pulse of a predetermined width normally 100 ms will be seen on this pin under 2 different conditions Note Both conditions can be active during the same run e Ifthe hard arc count limit is non zero and the number of hard arcs seen exceeded this limit during the last run the pulse will occur when the output is turned off Ifyou set the hard arc count limit to zero this signal will pulse for a predetermined time for every hard arc seen by the unit If another hard arc
108. 7 low high 4 or 8 low low SETTING THE ACTIVE TARGET LIFE COUNTER Table 4 5 on page 4 15 shows the pin state for pins 34 35 and 4 to select a specific target life counter as the active target When a User card is installed in a unit the User card has priority for setting the active target If the target selection pins are left floating or are inactive the default setting for the target is set to target 1 If the pins are set to any other setting than 1 this setting overrides any other control source to set the active target To enable target selection from the Host port or active front panel a User card must not be installed in the unit or you must actively set the target to target 1 via the User port or leave the User port pins 34 35 and 4 floating After a power cycle if a User card is installed the unit defaults to the User port target settings If you have set the target settings through the Host port or active front panel you must reset the target settings after a power cycle through the appropriate interface Table 4 5 Target Life Counter pin 34 35 and 4 Target Life Counter Pin 34 Pin 35 Pin 4 1 high high high 2 high high low 3 high low high 4 high low low 57000097 00B Communication Interfaces 4 15 Advanced Energy Table 4 5 Target Life Counter pin 34 35 and 4 Continued Target Life Counter Pin 34 Pin 35 Pin 4 5 low high high
109. 787 4 7 3 79 44 5 100 100 4 5 4 00 45 105 105 263 4 2 4 21 44 2 110 109 89 4 4 40 44 115 114 943 3 9 4 60 44 8 120 119 76 3 7 4 79 44 3 125 125 3 6 5 00 45 130 129 87 3 4 5 19 44 2 135 135 135 3 3 5 41 44 6 140 139 86 3 2 5 59 44 8 145 144 928 3 1 5 80 44 9 150 150 376 2 9 6 02 43 6 155 155 039 2 9 6 20 45 160 160 2 8 6 4 44 8 3 10 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply Table 3 4 Reverse Time Given a Self Run Frequency Continued Requested Actual Pulse Duty Cycle Duty Cycle Frequency Frequency Reversal Time min max kHz kHz Maximum us Reverse Reverse Period Period 165 165 289 2 7 6 61 44 6 170 169 492 2 6 6 78 44 1 175 175 439 2 5 7 02 43 9 180 180 18 2 4 7 21 43 2 185 183 486 2 4 7 41 44 190 190 476 2 3 7 62 43 8 195 194 175 2 3 7 77 44 7 200 200 2 2 8 44 205 204 082 2 2 8 16 44 9 210 210 526 2 1 8 42 44 2 215 215 054 2 8 6 43 220 219 78 2 8 79 44 225 224 719 2 8 99 44 9 230 229 885 1 9 9 2 43 7 235 235 294 1 9 9 41 44 7 240 240 964 1 8 9 64 43 4 245 243 902 1 8 9 76 43 9 250 250 1 6 10 40 255 256 41 1 5 10 26 38 5 260 259 74 1 5 10 39 39 265 266 667 1 5 10 67 40 270 270 27 1 4 10 81 37 8 275 273 973 1 4 10 96 38 4 280 281 69 1 4 11 27 39 4 285 285 714 1 4 11 43 40 290 289 855 1 3 11 59 37 7 57000097 00B Product Specifications 3 11 Advanced Energy
110. 8 high high Table 4 9 Select Target Life Counter Pin 34 Pin 35 and Pin 4 Target Pin 34 Pin 35 Pin 4 1 low low low 2 low low high 3 low high low 4 low high high 57000097 00B Communication Interfaces 4 23 Advanced Energy Table 4 9 Select Target Life Counter Pin 34 Pin 35 and Pin 4 Continued Target Pin 34 Pin 35 Pin 4 5 high low low 6 high low high 7 high high low 8 high high high Table 4 10 Regulation Mode pin 5 and pin 6 Regulation Mode Pin 5 Pin 6 Voltage low low Power low high Current high low Invalid Setting high high SINGLE 15 V 25 PIN USER PORT This section applies to the Single 15 V 25 pin User port The User port is a 25 pin subminiature D port Overview A CAUTION Turn off AC input power to the Pinnacle Plus unit before connecting a cable to the User port connector The User port is a 15 V interface card with a 25 pin female subminiature D connector It has an analog interface that allows you to use a remote controller All anolog input and output signals are between 0 Vdc to 10 Vdc All digital input and output signals are between 0 Vdc to 15 Vdc In addition the unit incorporates the following features 4 24 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply e A fast response set point input 0 Vdc to 10 Vdc Power reg
111. 9 The product warranty is void if you remove the power supply box cover Contact AE Global Services for more information Capacitor discharge warning 5 minutes Capacitor discharge warning 10 minutes CE label Earth ground 57000097 00B Safety and Product Compliance Guidelines 1 3 Advanced Energy 1029 HAZARDOUS VOLTAGE Risk of death or bodily injury Disconnect all sources of input power before working on this unit or anything connected to it ALLENLLON There are no user serviceable parts or adjustments inside DO NOT REMOVE COVER A 1030 NRTL C LR 106911 xx 1101 1154 A 1027 Protective earth ground Hazardous voltage Hazardous voltage Hot surface No user serviceable parts Nonionizing radiation NRTL Nationally Recognized Testing Laboratory Refer to manual for more information Safety and Product Compliance Guidelines 57000097 00B Pinnacle Plus 10 kW Power Supply SEMI F47 compliant gM FAT COMPLIAy gt Ar 2105 Short circuit protected 1024 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 may be certified by e CE Marking Self declaration assessed by AE Corporate Compliance e E
112. AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 43 Sets the unit s synch pulse feature as a 1 CSR codes transmitter a receiver or a standalone 0 1 2 9 sets synch bi Send 1 data byte transmitter e 0 Receiver receiver or standalone e 1 Transmitter 2 Standalone Read back with command 163 44 Lets you write up to 40 characters of text to 0 to 40 CSR codes line one top line of an active control panel 0 9 panel text line 1 45 Lets you write up to 40 characters of text to 0 to 40 CSR codes line two bottom line of an active control 0 9 panel text panel line 2 46 Erases text displayed with commands 44 and 0 CSR codes 45 and refreshes the display 0 9 erase panel text You may set values for all three user output limits commands 49 50 and 51 however the Pinnacle Plus unit responds to the first limit value that impacts output 4 186 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 49 user power limit Sets a maximum limit for output power Send 2 data bytes 16 bit value value must be between 0 and the maximum rated output power for the supply 3 decimal places are implied for a stand alone unit 10000
113. AL STATES As described in the preceding table pins 7 ON D and 14 OFF D are used to enable disable output power The following table illustrates the output enabled disabled behavior of the unit depending on the state of these two pins In the table H High state e L Low state e The lines represent transitions between high and low Note that these state changes apply only when the User port is the active control interface and is the only interface used to enable and disable the unit output Table 4 3 User Port Output Enable Disable Behavior and Signal States ON D Pin 7 H OFF D Pin 14 Unit State Output disabled Output disabled Output disabled Output enabled Output enabled No change Output disabled DIJE j b Output disabled 4 14 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply REPORTING THE ACTIVE TARGET SETTING TO AN EXTERNAL DEVICE Table 4 4 on page 4 15 shows the pin state for pins 20 and 1 for a specific target life counter setting This information is used to communicate the active target setting to an external device such as a cathode switch box For more information on setting an active target see Setting the Active Target Life Counter on page 4 15 Table 4 4 Cathode Switch pin 20 and pin 1 Target Life Counter Pin 20 Pin 1 1 or 5 high high 2 or 6 high low 3 or
114. AMPLE 8 Output ON e Byte 0 02h 2 e Byte 1 ma e Byte 2 ma e Byte 3 pa EXAMPLE 9 Readback Hard Arc count per run See upload inbytes for returned value Byte 0 BEh 190 e Byte 1 mpa e Byte 2 ma e Byte 3 n a EXAMPLE 10 Output OFF e Byte 0 01h 1 e Byte 1 mpa e Byte 2 ma e Byte 3 p a PASSIVE DISPLAY PANEL The passive front panel and remote passive panel let you monitor power current or voltage receive error codes and review several other conditions shown by the LEDs Display At any time while the Pinnacle Plus supply is operating you can press the DISPLAY button to the left of the four digit display to find the number of kilowatts volts or amps being delivered or to display the frequency setting or the reverse time setting The LEDs to the right of the screen indicate which value is being displayed When both kW and V are lit frequency is displayed in kHz When both V and A are lit the 57000097 00B Communication Interfaces 4 123 Advanced Energy reverse time is displayed in us Repeatedly pressing the DISPLAY button will cause the display to cycle in the following order kW V A freq frequency in kHz and t rev reverse time in us When a fault or software error occurs the error codes scroll across the display for example E004 E002 E004 E002 These codes scroll indefinitely until you correct the errors For a detailed explanation of the error codes a
115. Ac ADVANCED E ENERGY Pinnacle Plus 10 kW Power Supply 325 VDC 800 VDC July 2010 57000097 00B ____UUE EUkEbvU gt kbha uU UUj OU UU xwu User Manual User Manual Pinnacle Plus 10 kW Power Supply 57000097 00B Aca EME 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 2010 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 WARNING 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 proper
116. BUS interface reads the memory block for the next data packet to transmit The problem occurs when the PLC updates the data from High to Low memory locations and does not signal the PROFIBUS interface when the update is complete If the PLC were to notify the PROFIBUS Interface then there would be data consistency As a result the PROFIBUS interface sends the memory block regardless of where the PLC is in its update of that memory block You can create a work around to this problem with a command sequence For more information about PROFIBUS commands see the Host Pinnacle Software Commands section later in this chapter Here is an example procedure 1 Update the packet with the desired command 2 Update the download packet with data for the desired command 3 Send the download packet 4 Repeat step 1 and continue as needed By creating a procedure like this one you can ensure the data for a command will not be changed before the next download packet is received PROFIBUS SOFTWARE COMMANDS The command based AE PROFIBUS protocol is designed to take advantage of the high transmission rates provided by the PROFIBUS standard The download packet outbytes and the upload packet inbytes as well as the AE PROFIBUS handshake feature are described in the sections that follow A complete command list follows Note The execution time of all individual PROFIBUS commands is less than 200 us If you choose not to us
117. Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 17 program source Tells the Pinnacle Plus supply whether the source of information for regulation mode and set points is internal or external the source can be set independently for each of the three control modes Send 3 data bytes arranged as follows e First byte Program source if the serial Host port is active e Second byte Program source if a control panel is the active interface Third byte Program source if the User port is active For each mode send an 8 bit value as follows e 0 Program source is internal e Non zero value Program source is external that is the program source for the regulation mode and the set point is an analog signal from the User port Note A User card must be installed for this feature to be available Read back these values with command 163 3 CSR codes 0 1 2 9 19 recipe steps Specifies the number of recipe steps in your recipe Send 1 data byte 8 bit value the value must be at least 0 but no greater than 8 A value of 0 disables the recipe feature Note For each recipe step you must also set the regulation mode set point ramping time and run time commands 21 22 and 23 Read back this value with command 180 CSR codes 0 1 2 4 9 4 180 Communication Interfaces 5700
118. ED lights green for a predetermined time if the hard arc count limit was reached during the previous run You define this limit through a control panel or with Command 9 You define the voltage trip level for arcs through a control panel or with Command 10 You can enable micro arc handling through a control panel or with Command 61 Note If you set the hard arc count limit to zero the ARC LED lights for a predetermined time and if applicable sends a signal to the User port for every hard arc seen by the unit See Enabling Arc Handling on page 4 151 for more information 57000097 00B Communication Interfaces 4 127 Advanced Energy CONTROL PANEL INTERFACE Your Pinnacle Plus unit may have either an active front panel which is an integrated part of the unit or an active remote panel which is connected to the DISPLAY port on the rear panel of the unit This manual uses the term control panel to refer to either of these panels since they function identically An active control panel has three main sections ON and OFF switches at the far left of the panel CONTROL and REGULATION switches at the far right of the panel A two line display five soft keys and a MODIFY knob Two line display Control Modify Arc O Local AER ofe EBES gpinnacles Regulation g O Power eW OU OU OO DO LO Og SN 3763 Soft keys Figure 4 14 Control panel Output Power Key Use the follow
119. EDs do not light see Chapter 6 for more information If you are using an active front panel or the Pinnacle Remote Panel verify that the ON LED lights Also verify that the display screen shows values for output information If the display screen shows an error code and message see Chapter 6 for error code explanations and troubleshooting suggestions 57000097 00B Installation and Operation 5 31 Advanced Energy Understanding Pulsing Modes When you enable the pulsing feature of the Pinnacle Plus power supply you can set one of the following pulsing modes At current threshold default setting If you set pulsing to enable at the current threshold pulsing is disabled until the Pinnacle Plus power supply detects the current is above the current threshold Once the current is above the threshold pulsing begins For more information see High Power Operation on page 5 36 e Always If you set the pulsing to enable always pulsing begins from the moment you energize the Pinnacle Plus power supply This feature allows you to have the unit pulse at low current and low voltages while protecting the unit For more information see Low Power Operation on page 5 35 Note If you choose to pulse always and set a high power operation power limit the upper end pulsing frequency limit is 150 kHz See High Power Operation on page 5 36 for information about high power operation Use voltage only available
120. FIBUS PROTOCOL PROFIBUS Process Field Bus is an interface that lets you communicate with your Pinnacle Plus unit from a host master AE manufactures a PROFIBUS interface compliant with PROFIBUS masters described in the DIN 19245 PROFIBUS Standard DP part HI Any PROFIBUS master that complies with this standard can communicate with AE s PROFIBUS interface The PROFIBUS connection on the Pinnacle Plus unit is a 9 pin female subminiature D connector next to an eight switch DIP on the rear panel The following sections describe this DIP and aspects of the PROFIBUS protocol Note AE s PROFIBUS protocol does not support the following functions address changing freeze unfreeze modes or sync modes 4 72 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Type Files GSD Files Type files are computer files that some Programmable Logic Controllers PLCs use to compile their PROFIBUS programs These files are device specific and contain information on features found in that device Thus a different type file should be defined for each PROFIBUS device You can download type files from the World Wide Web Support is available on the PROFIBUS Trade Organization web site at www profibus com Setting the Pinnacle Plus Unit s Network Address Use the DIP switch next to the PROFIBUS port on the rear panel to set the Pinnacle Plus unit s address Allowable addresses are even addresses between 0 and 126 sele
121. K KK KK KK ees 6 8 Table 6 3 Help Code Troubleshooting Table 0 0 2 eee 6 10 Table 6 4 Error Code Troubleshooting Table KK KK RR RR RR SK KK 6 16 Table 6 5 AE Global Services contact information 00005 6 27 xviii List of Tables 57000097 00B Pinnacle Plus 10 kW Power Supply Chapter 1 safety and Product Compliance Guidelines IMPORTANT SAFETY INFORMATION To ensure safe installation and operation of the Advanced Energy Pinnacle Plus 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 57000097 00B Safety and Product Compliance Guidelines 1 1 Advanced Energy DANGER WARNING AND CAUTION BOXES IN THE MANUAL or associated equipment Advanced Energy includes this symbol in Danger This symbol represents important notes concerning potential harm to people this unit Warning and Caution boxes to identify specific levels of hazard seriousness 1027 A DANGER 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 A WARNING WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury and or property damage A CAUTION CAUTION indicates
122. KK KI KI KIR KK KI KK dy 4 24 evaya aeaaszszZ Z55 5 gt 55x5xxxyxpx2xxx x lt x_ _mmpmma n ankx_ nannpy pay MyyBDMD DMME RM2 M 4 24 Interlock Requirements kk kk kk kk kK KK KK KI tees 4 25 Cabling Requirements kk kk kk kK KK KK KK KK KI KK KK KK KIR KK KK KK KK 4 25 Signals Asoy Came A PA laye kK KE coke bi E sees Mba w der h eee ate N Qey rd 4 26 Analog signals uso esse se A kk kk kk KK KK KK KK KK KK KK KK KI KOK KK KK KK KK 4 26 Digital signals kk kk kk kK KK ee KK KK KK KI KK KK KI KI ERED KK KK KK 4 26 Connector and Rear Panel Switch WA kK KK KK KK KK KK KK eee 4 26 Using the Connector with the REar Panel Switch 4 26 Connector Pin Descriptions kK KK KK KK eee eee 4 27 Rear Panel Switch Settings kk kk KK KK eee eee ee 4 33 Single 15 Pin User Port kk eis estes nee kk ka kk a a kala ak so aes wd Be 4 36 Installation kk kk kk kk kK kK kK KK KK KK KK KK KK KI K K K KI KI KI K R K KK KK KK KK 4 36 Sel bBg a wawawaa owywowKaKaDXEE e E A E a e a a ada 4 37 Pin Descriptions A kk kk naaa 4 37 Dual 24 V 37 Pin User Port kk kk kk kk kK KK KK KK KI tees 4 39 Installation kk kk kk kk kK kK kK kK KK KK KK KK KK KIR KI K KK KIR KI KIR K KK KK IK KH 4 40 Signal SA su kan y aot donee skate d xelq d bos KO N e t meted 4 41 Analog signals 2 i Ak kk kk kk KK KK KK KK KK KK KK KK KI KOK KK KK KK KK 4 41
123. LTAGE PROCESS LIMITS VOLTAGE This function lets you set a maximum limit for output voltage as measured at the DC inverter output see Figure 2 1 on page 2 2 The maximum allowable value is the maximum rated output for the supply To set the user voltage limit 1 Press PROCESS LIMITS VOLTAGE 2 Rotate the MODIFY knob to select a value between 0 and the maximum rated output voltage for the supply 3 Press ENTER to accept and exit SETTING THE MAXIMUM LIMIT FOR OUTPUT CURRENT PROCESS LIMITS CURRENT This function lets you set a maximum limit for output current The maximum allowable value is the maximum rated output for the supply If a master slave card is installed in the unit you must reset the power and current limits each time you cycle power to the system After a power cycle the system returns the power and current limits to the default settings To set the user current limit 1 Press PROCESS LIMITS CURRENT 2 Rotate the MODIFY knob to select a value between 0 and the maximum rated output current for the supply 3 Press ENTER to accept and exit SETTING THE MAXIMUM LIMIT FOR OUTPUT POWER PROCESS LIMITS gt POWER This function lets you set a maximum limit for output power The maximum allowable value is the maximum rated output for the supply If a master slave card is installed in the unit you must reset the power and current limits each time you cycle power to the sy
124. Limits and methods of measurement of radio interference characteristics of industrial scientific and medical equipment EN 55011 Limits and methods of measurement of radio disturbance characteristics of industrial scientific medical ISM radio frequency equipment Class A Group 2 CISPR 11 EN 61000 6 2 Electromagnetic Compatibility Generic Standards Immunity for Industrial Environments SAFETY DIRECTIVES AND STANDARDS 2006 95 EC EC Council directive on the harmonization of the laws of the Member States relating to electrical equipment designed or use within certain voltage limits LVD Low Voltage Directive 1 6 Safety and Product Compliance Guidelines 57000097 00B Pinnacle Plus 10 kW Power Supply CAN CSA C22 2 No 61010 1 04 Safety requirements for electrical equipment for measurement control and laboratory use EN 61010 1 Safety requirements for electrical equipment for measurement control and laboratory use Conditions of Use To comply with the stated directives and standards you must meet the following conditions of use Before making any other connection to this device connect the secondary Protective Earth ground terminal to a local earth ground terminal with a copper wire that is sized according to the applicable requirements For delta connected mains the primary and secondary Protective Earth ground wire must be connected Install and operate this device in an overvol
125. MC measurements Verified by the AE Corporate Compliance Lab and or an accredited third party lab e NRTL Safety certified by CSA International a Nationally Recognized Testing Laboratory For more information refer to the Certificate or Letter of Conformity US or Declaration of Conformity EU accompanying the product 57000097 00B Safety and Product Compliance Guidelines 1 5 Advanced Energy Safety and EMC Directives and Standards Certain options of this unit may have been tested for and comply with the following electromagnetic compatibility EMC and safety directives and standards and industry guidelines Note This device must be installed and used only in compliance with the directives and standards listed in addition to EN 60204 IEC 60204 and applicable requirements Note This equipment must be installed and used in accordance with the Conditions of Use described in this manual If this equipment is expanded modified or installed into a larger system the user is responsible to guarantee the compliance of the overall system If this equipment is used with external components the user must ensure that the Safety and EMC requirements are not violated ELECTROMAGNETIC COMPATIBILITY EMC DIRECTIVES AND STANDARDS 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
126. Message Number H012 Specified You have attempted switch Select another interface Interface Not to User control when your Local or Host Installed power supply model is not equipped with a User card H016 Reset Target Target life counter is Reset the target life counter Life enabled and has expired H019 Can t Change You have attempted to Delay initiating the desired While Recipe is initiate a unit function that is function until the recipe is Active not allowed while the power complete Or turn off output supply is executing a recipe and disable the recipe function before attempting to initiate the desired function again H021 Joule Delivery The joules delivered counter Delay initiating the desired Not Complete is enabled and running and function until the joule you have turned off output counter expires or disable power before the counter the joule mode expired H025 Configuredasa You have attempted to De assert the slave status of Slave Unit initiate a unit function thatis the unit and retry the not allowed while the power function For information supply is configured as a regarding this procedure see slave Master Slave System Operation on page 5 38 H026 Can t Change You have attempted to Disable the master slave in Master Slave initiate a unit function thatis system and retry initiating System not allowed while the power the unit function For more supply is configured in a information on thi
127. N ED ED O Zaz TI e Je HOd HOd JEH8S pJ8PUE S PA UMOUS pled SOH 9A8 S 19 S8N Figure 5 17 Rear view 5 29 Installation and Operation 57000097 00B Advanced Energy OPERATING THE UNIT The following sections include information about operating the Pinnacle Plus power supply Normal Operation The following list represents a general description of how to operate a Pinnacle Plus power supply You will want to adapt this list to your power supply configuration and your application environment and requirements 1 Turn on the Pinnacle Plus power supply 2 Verify which power supply LEDs are lit If you are using a passive panel verify that the POWER ON and INTERLOCK LEDs light If the INTERLOCK LED does not light an error code should appear see Chapter 6 for more information If you are using an active front panel or a Pinnacle Remote Panel verify that the display screen displays two messages in sequence Advanced Energy Fort Collins Colorado and then Power Up Sequence Please Wait In addition verify that an LED lights to show the control setting and another lights to show the regulation setting Finally verify that the OFF LED lights Note If an error code that is an E nn code appears on the front panel or on the Pinnacle Remote Active Panel refer to Chapter 6 for an explanation and troubleshooting suggestions The unit defaults to the previously selected contr
128. NT value Set the set point a Choose the regulation mode by using the REGULATION key to toggle between power current and voltage b Use the MODIFY knob to select a value between 0 and the full rated output of the supply Press ENTER if you have indicated that your recipe contains more than one step the display returns to the JOULES screen so that you can enter recipe values for the next step Repeat Steps 2 through 5 as needed To set the number of recipe repetitions If you set the recipe type to JOULE CONTINOUS a REPEAT menu option displays It allows you to set the number of times you want the recipe to repeat itself 1 Note The REPEAT feature is available only with the JOULE CONTINUOUS option Select REPEAT 4 154 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply 2 Rotate the MODIFY knob to enter a number between 1 and 65535 3 Press ENTER to save your selection Setting Joule Mode PROCESS CONTROL JOULES This option lets you use joule mode a method of automatically delivering a specified number of joules to the target Choose THRESHOLD to specify an output level to begin calculation and thereby enhance the accuracy of the calculation by disabling the calculation during ignition Choose ENABLE to enable or disable joule mode Choose SETPT to program the number of joules you want to be delivered Note Ifa timed recipe is active the timed recipe overrid
129. R OPERATION For low power operation set the power limit according to the following and the conditions shown in Table 5 3 are true Less than 500 W per 5 kW inverter for 5 kW and 5x5 kW power supplies Less than 1000 W for 10 kW power supplies Table 5 3 Low power operation mode Mode Low Power Operation Ignition Strike voltage is limited to the user defined voltage limit The Pinnacle Plus power supply begins pulsing immediately Hard and Following the shutdown the unit continues to pulse regardless Micro Arc of plasma conditions Shutdown Open The unit continues to pulse Load Circuit 57000097 00B Installation and Operation 5 35 Advanced Energy HIGH POWER OPERATION For high power operation set the power limit according to the following and the conditions shown in Table 5 4 are true 500 W or greater per 5 kW inverter for 5 kW and 5x5 kW power supplies 1000 W or greater for 10 kW power supplies Table 5 4 High power operation mode Mode High Power Operation Ignition Under high power operation Power or Current regulation pulsing is disabled the voltage jumps to maximum voltage 1350 V and is held until the current is detected flowing greater than the following values depending on your power supply 0 25 A for 5 kW and 5x5 kW power supplies e 2 0 A for 10 kW 325 650 VDC power supplies e 0 5 A for 10 kW 325 800 VDC power supplies When the curr
130. REV 2 To display the software version of the configuration press CONFIG 3 To display the software version of the active panel software press PANEL 4 To display the software version of the DSP software press DSP 5 To display the software version of the logic press LOGIC USING THE SUPPLY FUNCTIONS This option lets you modify specific components and parameters of your supply The menu options are e AEBUS e DEFAULTS e PULSE PANEL e PGM SRC 4 138 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Setting the AE Bus Timeout SUPPLY gt AE BUS Use this menu to set the AE Bus timeout setting on the Pinnacle Plus power supply The AE Bus timeout is the amount of time the power supply waits between message bytes A time that is too short results in communication errors and timeouts To set your AE Bus timeout time 1 Press SUPPLY AEBUS 2 Rotate the MODIFY knob to adjust the AE Bus time out value in 10 ms increments 3 Press ENTER to accept and exit Note We recommend you use the default value of 200 ms Setting the Supply Parameters SUPPLY DEFAULTS To set all your supply parameters to the defaults and then store them in non volatile memory 1 Press SUPPLY gt DEFAULTS 2 Rotate the MODIFY knob to display YES or NO 3 Press ENTER to accept and exit Setting Pulse Parameters SUPPLY PULSE Use this menu entry to change the pulsing par
131. RR RR RR KK 5 23 Master Slave Configuration Example 0 eee eee eee 5 24 Connecting for Sync Pulse Operation 02020000005 5 25 Understanding Sync Pulse Operation 02020000 5 25 Configuring for Sync Pulse Operation 000002 cee 5 26 Sync Pulse Configuration Examples 00000 RR 5 26 Rear Panel Drawing 20265405 es ea ee eee ee ee ee ee 5 29 Operating the Unit 12223242c80e dos kk KK KK KER KK KK KEK KE KK kk KK sates 5 30 Normal Operation kk kk kk kK kK KK KK KK KK KK KI K K KK KIR KK KK KIR KIRI KS 5 30 Understanding Pulsing Modes 4 W kk kK KK KK KK KK KK KK eee 5 32 Pulsing Behavior When Using Voltage 000 KK KK eee 5 32 Modes of Operation Low Power Versus High Power 5 34 xii Table of Contents 57000097 00B Pinnacle Plus 10 kW Power Supply Low Power Operation kk kk kk kk KK KK KK KK KK KK KK KI KK KK KRI 5 35 High Power Operation nic ee ee oh KK KK KK KK K KI KIRI K IK KK KK IK IK 5 36 Understanding Arc Handling kk kk kK KK KK KK KK KK KI KI KIR ee 5 37 Voltage Arc V Arc Trip Level 4 kk kk KK KK KK RR RR RR KK KK KK 5 37 Understanding Frequency and Reverse Time Settings 5 37 Master Slave System Operation kk kk kk kk KK KK KK KK ee 5 38 Master Slave Input On Off Combinations KK KK KK KERR 5 39 Monitoring the Master Slave System kK KK KK RR KK KK 5 39 Clearing Faults in
132. RR RR RR RR KK 4 80 Interpreting Command Status Response CSR Codes 4 81 Commands 0 through 127 pcos kk kk kk a abet awa ed KI KI KIR KI KI KI KI eben be 4 82 Commands 128 through 255 kk kk kk kk kK KK KK KK KK KIR KK KK KK KK KK 4 101 Example Command Sequences XV kk KK KK KK KK KK KK KR KK RKIK 4 121 Example 1 si ic k ka kk lana ala dn cn sla aa as A an ee aes Ree aie alg 4 121 Example 2 1 sla en e la al a ka a rd sa d db ak H na he ee ab di 2 ae 4 121 Example 3 A asena many da bakar A A y day ba kk OS d la Alan A r AU A A 4 121 Example 4 2 s a as dar a dll ak alek da ardi nsan ala aw a a ard A l an 4 122 Example 5 icc sx ala kbk xb la es ky anl akan k kao d r eki S WE A r a dl 4 122 Exampl G aeniea xula Sinc Ek id wi ar aad 4 122 Example X a aipa ia salana lak ha ki a blla l o nj dan E E dle da RO xas A 4 122 Example 6 i sna sana G la dr lA ae viele b k Kunda Av heed 4 123 57000097 00B Table of Contents ix Advanced Energy Example 9 i miara ss RoR abe ed edad ed a dod dt 4 123 Example 10 kk kk kk cee 4 123 Passive Display Panel 0 000 KK KK eens 4 123 Display puter neers ewes a eee kek oes Cees See eee ek pence eee 4 123 LEDS iia hohe kes bedi ane Ramee a nn RES keh aaa ee RE Ra 4 124 Active Front Panel Pinnacle Remote Panel kk KK RR RR RR KK KK 4 125 Connecting to the Remote Activ
133. Read back this value with command 142 CSR only 51 user current limit Sets a maximum limit for output current Send 2 data bytes 16 bit value the value must be between 0 and the maximum rated output current for the supply Assume 2 decimal places 5000 50 00 A Read back this value with command 143 CSR only 57000097 00B Communication Interfaces 4 95 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued Non zero Enable Read back this value with command 163 Command Description Number Numberof of Sent Response Data Data Bytes Bytes 52 Sets a maximum strike voltage Send 1 data 1 CSR only byte representing a strike voltage range user strike voltage limit 9 low e 1 medium e 2 high The values associated with each range depend on the output impedance range of your unit Strike Standard Z Unit High Z Unit Voltage 325 650 V 325 800 V Setting Low 800 V 100 V 1 000 V 100 V Medium 1 100 100 V 1 200 V 100 V High 1 450 150 V 1 450 V 150 V Read back this value with command 144 59 Sets the number of times a continuous jole 2 CSR only joule recipe recipe repeats before turning output off and repetition completing Note This command is only valid when you set the continuous joule recipe type Send 2 data bytes 16 bit value Valid input for the joule recipe repetitio
134. SB 3 0 0 0 0 Voltage Output AI MSB 4 Current Output AI LSB 5 OF 0 0 0 Current Output AI MSB 6 Run Micro Arc Count 7 Run Hard Arc Count 8 Ramp Rate AI LSB 9 0 0 0 0 Ramp Rate AI MSB 10 RMP CMode 0 INTS ARCD TS SPS POS 57000097 00B Communication Interfaces 4 61 Advanced Energy Note The 16 bit Power Output value AI is shifted right four bits and the remaining four bits are filled with 0s This changes the 16 bit AI to a 12 bit AI with a value of 10 V OxOFFF Note Bytes 6 and 7 The number of micro or hard arcs detected since the last time that output was turned on The count is set to 0 when the DeviceNet interface is energized These values stop incrementing at 255 If the count exceeds 255 the readback will be 255 Note For Byte 8 the abbreviations have the following meanings POS stands for Power On Status 1 output on 0 output off e SPS stands for Setpoint Status 1 setpoint reached 0 setpoint not reached TS stands for Temperature Status 1 good 0 over temperature condition ARCD stands for Arc Detected 1 on 0 off e INTS stands for Interlock Status 1 satisfied 0 open e 0 Reserved e CMode stands for Control Mode 1 Host 0 local or User not all units support this feature e RMP stands for Ramp Status 1 Set point ramping 0 Set point not ramping not all units support this feature Scaling Parts of t
135. SP 232 Requests the near end joule setting set with 0 2 request near command 72 end joule setting 233 Request the number of recipe repetitions set 0 4 request with command 59 Returns 4 data bytes number of recipe e First and second data bytes Number of repititions repetitions set Third and fourth data bytes Current repetition in process reports 0 if output is off 57000097 00B Communication Interfaces 4 215 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 235 Requests the operating parameter selected in 1 2 request the send data byte May return advanced NON CSR codes process Send 1 data byte to identify the parameter to be 0 5 9 12 parameters read Send byte value 0 Reports the voltage ignition threshold Send byte value 1 Micro arc count Reports the number of sequential micro arcs needed to trigger a hard arc count Send byte value 2 Microsecond count Reports the maximum elapsed time in microseconds between the end of one micro arc and the beginning of the next micro are during which the unit considers the micro arcs to be sequential Micro arcs that occur within this timeframe are sequential Send byte value 3 Reports the gross short circuit current limit in hundredths of amps Send byte value 4 Reports the gross short circuit time out in tenths of second
136. Send 1 data byte e 1 Timed e 2 Joule continuous e 3 Joule discrete Read back with command 196 34 Enables or disables an over voltage timer and 2 CSR only specifies how long you want the power supply over voltage to tolerate an over voltage condition before timer shutting off output To enable the timer send a value 2 bytes between 1 and 9999 0 1 to 999 9 s To disable the timer send a value of 0 Read back with command 174 57000097 00B Communication Interfaces 4 93 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number Numberof of Sent Response Data Data Bytes Bytes 35 Enables or disables an over current timer and 2 CSR only specifies how long you want the power supply over current to tolerate an over current condition before timer shutting off output To enable the timer send a value 2 bytes between 1 and 9999 0 1 999 9 s To disable the timer send a value of 0 Read back with command 186 36 Enables or disables the constant duty cycle 1 CSR only feature constant dut cycle y Send 1 byte 0 Disable e Non zero Enable Read back with command 163 38 Resets micro arcs per run and hard arcs per 0 CSR only run counters to 0 reset arc j density run These counters can be reset at any time and counters resetting them can be useful for measuring arcs over a specific period of time 43 Sets the unit s synch pulse feature as a
137. Single 15 pin The User port is a 15 pin Single 15 Pin User Port on subminiature D port and is on a page 4 36 single output unit that also has a DeviceNet interface Dual 24 V 37 pin The User port is a 37 pin Dual 24 V 37 Pin User Port subminiature D port on page 4 39 The User port label is Dual Iso User Port SINGLE 15 V 37 PIN USER PORT This section applies to Single 15 V 37 pin user ports The User port is a 37 pin subminiature D port The User port label is either 15v User Port or 15v Sng Iso User Port The User port analog digital interface is a 15 V isolated or non isolated interface card with a 37 pin subminiature D female connector This interface emulates the MDX User port and a subset of the MDXII User port O00000000000000000 OOOO O00000000000000 1153 Figure 4 1 37 pin subminiature D female connector 4 2 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Installation A DANGER Disconnect all sources of input power before working on this unit or anything connected to it Note Signals at the User port can be sensitive to noise We recommend that you take standard preventative measures against electro magnetic interference EMI including using shielded cabling on the User port Note Turn off ac input power to the Pinnacle Plus unit before connecting a cable to the user port connector Note that we recommend taking st
138. T Get or set the arc trip limit voltage in V Allowed values are 25 V to 400 V in 1 V increments but may vary depending on your unit configuration Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 57000097 00B Communication Interfaces 4 67 Advanced Energy Table 4 26 Instance 1 attributes Attribute Access Name 94 Set Get Run Arc Count Clear Type USINT Value Set to clear the run hard arc counts and run micro arc counts Bit 0 Clear run micro arc count 0 No effect 1 Clear e Bit 1 Clear run hard arc count 0 No effect 1 Clear e Bits 2 through 7 Not used Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 95 Set Get Run Hard Arc Count 8 bit USINT Get the run hard arc counts When the counter reaches 255 it remains 255 until you clear the count Write a 0 to clear the Hard Arc Run Count Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 96 Set Get Run Micro Arc Count 8 bit USINT Get the run micro arc counts When the counter reaches 255 it remains 255 until you clear the count Write a 0 to clear the Micro Arc Run Count Note If the attribute i
139. US card located in the right I O slot of the unit if applicable 1 Slow down the PROFIBUS communication rate or the rate at which commands are sent 2 Make sure data consistency module consistency is enabled in the PROFIBUS master 6 20 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Table 6 4 Error Code Troubleshooting Table Error Code Message Problem Indicated Suggested Action E059 PROFIBUS Master Released Unit The PROFIBUS master has stopped communicating with the Pinnacle Plus unit using the proper protocol This slave is now available to be owned by another master If output is on the Pinnacle Plus unit turns off and fails safe E059 indicates an error in the PROFIBUS card located in the left I O slot located on the back panel of the power supply E159 indicates the same error but in the PROFIBUS card located in the right I O slot of the unit if applicable To recover from the off state have a PROFIBUS master establish communication with the Pinnacle Plus unit and send a master reset to clear the Pinnacle Plus unit s display E060 AE Bus Command Buffer Overflow An AE Bus command arrived before the last sent command was executed and cleared from memory E060 indicates an error in the AE Bus card located in the left I O slot located on the back panel of the power supply E160 in
140. You have attempted to seta Re adjust the ramp start Point Out of ramp start point to a value point by setting a smaller Range outside the allowable range percentage Ramp Time Out You have attempted to set Retry setting the ramp time of Range ramp time to a value outside using an acceptable value the allowable range Run Time Out of You have attempted to set Retry setting the run time Range tun time to a value outside using an acceptable value the allowable range Joule Setpoint You have attempted to set Retry setting the joule set Out of Range the joule set point to a value point using an acceptable outside the allowable range value Joule Threshold You have attempted to set Retry setting the joule Out of Range the joule threshold toa threshold using an value outside the allowable acceptable value range 6 12 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Table 6 3 Help Code Troubleshooting Table Help Help Code Problem Indicated Suggested Action Code Message Number H005 Invalid Control You have attempted to seta Set the control source to Mode control source other than Local Host or User Local Host or User Invalid You have attempted to set Set a valid mode for Regulation the regulation mode to regulation that is power Mode something other than power current or voltage current or voltage Note Output power must be off that is
141. a Master Detected Slave System on page 5 23 for more information E 185 Incorrect system size Contact Global Services MASTER SLAVE PARAM FLT CONTACTING AE GLOBAL SERVICES Please contact AE Global Services if you have questions or problems that cannot be resolved by working through the provided troubleshooting procedures When you call Global Services make sure to have the unit serial number and part number These numbers are available on unit labels 6 26 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Advanced Energy World Headquarters 24 x 7 Technical Support Table 6 5 AE Global Services contact information Office Contact AE World Headquarters Phone 24 hrs day 7 days week 800 446 9167 or 1625 Sharp Point Drive 1 970 221 0108 Fort Collins CO 80525 USA Fax M F 7 00 am 5 30 pm MST 1 970 407 5981 Email technical support aei com We will respond to email by the next business day For Aera flow product support call 800 MFC AERA 800 632 2372 For Sekidenko thermal product support contact thermalapplications aei com If you would prefer to contact a local or regional sales or service office visit the Advanced Energy web site for current contact information http www advanced energy com and click on Sales amp Support RETURNING UNITS FOR REPAIR Before returning any product for repair and or adjustment
142. a function of the user voltage limit Table 3 5 on page 3 13 provides a detailed list of reverse times and the corresponding user voltage limit 3 12 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply Microseconds 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 325 2127 Output voltage in volts Figure 3 3 Pulse reversal time as a function of voltage limit V Limit Table 3 5 Reverse Time as a Function of Voltage Limit V Limit V Limit Corresponding Reverse Time in Volts 0 to 325 10 us 330 9 8 us 335 9 7 us 340 9 5 us 345 9 4 us 350 9 2 us 355 9 1 us 360 9 us 365 8 9 us 370 8 7 us 375 8 6 us 380 8 5 us 385 8 4 us 57000097 00B Product Specifications 3 13 Advanced Energy Table 3 5 Reverse Time as a Function of Voltage Limit V Limit V Limit Corresponding Reverse Time in Volts 390 8 3 us 395 8 2 us 400 8 1 us 405 8 us 410 7 9 us 415 7 8 us 420 7 7 us 425 7 6 us 430 7 5 us 435 7 4 us 440 7 3 us 445 7 3 us 450 7 2 Us 455 7 1 us 460 7 us 465 6 9 us 470 6 9 us 475 6 8 us 480 6 7 us 485 6 7 us 490 6 6 us 495 6 5 us 500 6 5 us 505 6 4 us 510 6 3 us 515 6 3 us 520 6 2 us 525 6 1 us 530 6 1 us 535 6 us 540 6 us 545 5 9 us 550 5 9 us
143. 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 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 e Ensure that this unit is properly grounded see also Grounding on page 5 6 e Ensure that all cables are properly connected 1 2 Safety and Product Compliance Guidelines 57000097 00B Pinnacle Plus 10 kW Power Supply Verify that input line voltage and current capacity are within specifications before turning on the power supplies see the Electrical Specifications section in Chapter 3 Use proper electrostatic discharge ESD and lockout tagout precautions Always be careful around this equipment INTERPRETING PRODUCT LABELS The following labels may appear on your unit AE WARRANTY VOID IF SEAL IS BROKEN 2911 Internal capacitors may take up to 5 minutes to discharge to a safe level after input power has been removed Wait before removing covers 1745 Internal capacitors may take up to 10 minutes to discharge to a safe level after input power has been removed Wait before removing covers 2197 1020 L 106
144. able 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 31 Enables or disables an out of set point timer 2 CSR codes and specifies how long you want the power 0 1 4 9 out of set supply to tolerate an out of set point condition point timer before shutting off output e To enable the timer send a value 2 bytes between 1 and 9999 0 1 to 999 9 s To disable the timer send a value of 0 Read back this value with command 187 32 For ramp mode sets the ramp start point as a 1 CSR codes percentage of setpoint when output is turned 0 1 4 9 ramp start on Range is 0 to 95 point percentage Note This setting only applies to regular ramp of set point mode It does not apply to ramp mode in a timed recipe Send a 1 byte value of 0 to 95 Read back this value with command 152 33 Set the type of recipe The default is Timed 1 CSR only recipe type Send 1 data byte e 1 Timed e 2 Joule continuous e 3 Joule discrete Read back with command 196 34 Enables or disables an over voltage timer and 2 CSR codes specifies how long you want the power supply 0 1 4 9 over voltage to tolerate an over voltage condition before timer shutting off output To enable the timer send a value 2 bytes between 1 and 9999 0 1 to 999 9 s To disable the timer send a value of 0 Read back with command 174 4 184 Communication Interf
145. aces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 35 Enables or disables an over current timer and 2 CSR codes specifies how long you want the power supply 0 1 4 9 over current to tolerate an over current condition before timer shutting off output e To enable the timer send a value 2 bytes between and 9999 0 1 to 999 9 s To disable the timer send a value of 0 Read back with command 186 36 Enables or disables the constant duty cycle 1 CSR codes feature 0 1 9 constant duty cycle Send 1 byte e 0 Disable Non zero Enable Read back with command 163 38 Resets micro arcs per run and hard arcs per 0 CSR codes run counters to 0 These counters can be reset 0 1 9 reset arc at any time and resetting them can be useful density run for measuring arcs over a specific period of counters time 40 Specifies the amount of time the Pinnacle 2 CSR codes Plus supply waits between bytes from the 0 1 4 9 AE Bus time host out value Send 2 data bytes 16 bit value the value represents increments of 10 ms and must be at least 2 but no greater than 500 20 ms to 5 s That is two decimal places are implied enter 500 for 5 00 Read back this value with command 140 57000097 00B Communication Interfaces 4 185 Advanced Energy Table 4 48
146. al output in kilowatt hours e 1 Total idle time 2 Total run time e 3 Total unit on events e 4 Total output on events e 5 Total over temperature events e 6 Total control circuit faults e 7 Total out of set point events e 8 Total hard bus fault events 9 Total power fluctuation events 10 Total process voltage low events e 11 Total Unit A inverter low events e 12 Total Unit B inverter low events 13 Total user interlock open events e 14 Total cable interlock open events e 15 Total contactor interlock open events 18 Total PROFIBUS fault events 19 Total pre defined interrupt events 20 Total unassigned interrupt events e 22 Total DSP watchdog faults e 24 Total 10 ms Bus fault events 4 May return CSR code 5 223 AE service request request unit s fault status 4 118 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number Number of Sent of Data Response Bytes Data Bytes 230 Requests the crc of the logic the front panel 1 2 or the DSP request logic i q g To receive the logic CRC first send panel or dsp crc command 24 which calculates the value With command 230 send one data byte e 0 Logic 2 DSP 232 Requests the near end joule setting 0 2 n o haa This value is set with command 72 setting 23
147. ameters ENABLING PULSING MODE SUPPLY PULSE gt ENABLE Use this menu function to enable pulsing at the current threshold default setting to enable pulsing always or to enable pulsing using voltage For additional information about the pulsing modes see Understanding Pulsing Modes on page 5 32 To enable a pulsing mode 1 Press SUPPLY gt PULSE gt ENABLE 2 Rotate the MODIFY knob to display the following options AT CURRENT THRESHOLD 57000097 00B Communication Interfaces 4 139 Advanced Energy ALWAYS USE VOLTAGE Note If the unit is set to pulse using voltage you must also set the voltage threshold See Setting the Voltage Threshold on page 4 141 for more information 3 Press ENTER to accept and exit SELECTING CONSTANT DUTY CYCLE SUPPLY PULSE gt DUTY_CYC The constant duty cycle feature automatically updates the reverse time when you change frequency allowing you to maintain the same duty cycle that was present before the change within a limited frequency range Note To change the duty cycle change the reverse time To select the constant duty cycle feature 1 Press SUPPLY gt PULSE gt DUTY_CYC 2 Rotate the MODIFY knob to select YES or NO to enable or disable this function SETTING SYNC PULSE HARD ARC DETECTION BROADCAST SUPPLY PULSE gt B CAST Note This feature is only available if your Pinnacle Plus unit was specifically configured
148. and 34 175 Requests how much time has elapsed since 0 3 output power was turned on the returning request time packet contains 3 data bytes output on i First byte Number of hours Second byte Number of minutes e Third byte Number of seconds 178 Requests the hard are count limit The 0 4 returning packet contains 4 data bytes a 32 request hard bit value indicating the limit arc count limit i i This value is set with command 9 179 Requests the active recipe step number the 0 4 ramp run status and the ramp run time request active remaining the returning packet contains 4 recipe step data bytes 32 bit value indicating the ramp run following status and ramp run time First byte Active recipe step number remaining Second byte Ramp run status 1 ramp 2 run Third and fourth bytes Ramp run time remaining in tens of milliseconds 180 Requests the number of recipe steps The 0 1 returning packet contains data byte 8 bit request recipe value indicating the number of steps steps i Note Recall that a value of 0 sent with command 19 disables the recipe feature This value is set with command 19 57000097 00B Communication Interfaces 4 113 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued step run time or joule set point Send 1 data byte 8 bit value indicating the recipe step The returning packet contains 2 data bytes indicating the run t
149. andard preventative measures against electro static discharge ESD around all Pinnacle Plus units Note Grounding the User port at the power supply reduces noise interference To avoid ground loop problems you should typically ground only one end If you have a remote panel and you want to operate the Pinnacle Plus supply from the User port you must set the control mode for User on the Pinnacle Active Remote Panel See the Main Menu section in the Display and Standard Serial Controls chapter of this manual Signals The following paragraphs give general information about the User port s analog and digital signals The subsequent table provides information about each pin ANALOG SIGNALS A A suffix appended to a pin name indicates an analog signal Analog common lines are denoted by the COM A suffix 57000097 00B Communication Interfaces 4 3 Advanced Energy You can configure your unit s analog signals to be either 5 V or 10 V full scale via three jumpers The following lists indicate where you must place the jumpers to achieve either a 0 to 5 V scaling or a 0 to 10 V scaling DANGER RISK OF DEATH OR BODILY INJURY Disconnect and lockout tagout all sources of input power before working on this unit or anything connected to it A CAUTION Power down the Pinnacle Plus and take proper ESD precautions before removing the unit s top cover to position jumpers Failing to take proper ESD pr
150. ation link Table 4 29 Network Status LED If the LED is the state indicated is which means that Off No power The unit is not on line because 1 it has not completed the Dup_MAC ID test yet or 2 it is not receiving power check the MOD LED Green steady Link Okay The unit is on line and allocated to the master Flashing Green On line Not Connected The unit is on line but has no connections in its existing state because 1 the unit has no established connections to other nodes or 2 the unit is not allocated to the master 57000097 00B Communication Interfaces 4 71 Advanced Energy Table 4 29 Network Status LED Continued If the LED is the state indicated is which means that Connection Time out One or more I O Flashing Amber Critical Link Failure connections are in the timed out state Critical Link Failure Communication has failed that is the unit has detected an error that has made it incapable of communicating on the network Note If you have a dual Pinnacle Plus unit the causes of this failure may be 1 the two DeviceNet cards are not set to the same Data Rate as the network or 2 the two DeviceNet cards have the same Node Address Amber For information about Module Status LED indications during power up refer to Section 8 2 4 of the DeviceNet Specification revision 2 0 AE PRO
151. ature 0 Not ramping 1 Set point ramping Get Max Power UINT The Max Power attribute returns a value in Watts if the unit is operating stand alone For example a value of 20 000 equates to 20 000 W The Max Power attribute scaling is Watts x 10 if the unit is operating as a master in a Master Slave system In this case a value of 2 000 equates to 20 000 W Use the internal status attribute to determine if the unit is in master slave mode 4 64 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 26 Instance 1 attributes Attribute Access Name Type Value 7 Get Max Current UINT The Max Current attribute returns a value in Amperes For example a value of 80 equates to 80 A Depending on your DeviceNet configuration this value is the maximum output current of the transducers not the maximum output current of the unit 8 Get Internal Status USINT Returns 1 8 bit data byte Bit 0 Operation Mode 0 Stand Alone 1 Master Slave e Bits 1 through 7 not used 13 Get DeviceNet SHORT _ DeviceNet application software Application STRING part number SW Part Returns 14 N raber characters Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 14 Get DeviceNet SHORT _ DeviceNet configuration Configuration STRING software part number SW Part
152. ature description 2 2 Index setting 4 73 C cabinet design 5 2 cathode switch User port 4 15 CE marking 1 5 certification 1 5 changing target functions 4 146 checksum AE bus 4 168 command set PROFIBUS 4 82 command status response code table 4 81 codes 4 170 interpreting 4 81 commands AE bus 4 172 PROFIBUS 4 75 communication transaction example AE bus 4 172 communications DeviceNet 4 56 mode setting 4 165 communications protocol standard serial port 4 166 compliance directives and standards 1 6 unit 1 5 conditions of use 1 7 connecting DeviceNet 4 54 5 9 grounding connections 5 6 input power 5 9 master slave 5 22 serial Host port 5 8 standard serial port 5 8 authorized returns 6 27 User port 5 9 connecting see installation B connections baud rate output power 5 10 setting DeviceNet 4 55 remote panel 4 125 setting AE bus 4 165 connector baud rates AE bus 4 159 57000097 00B Index i Advanced Energy Host AE bus 4 159 User port 4 2 4 17 4 26 4 39 Contactor Intlk port connecting 5 7 CONTROL key 4 126 control modes selecting 5 31 control panel 4 125 choosing regulation modes 4 127 CONTROL key 4 126 control mode switches 4 128 controls 4 131 CURRENT switch 4 129 HOST switch 4 129 interface 4 128 LOCAL switch 4 129 menu maps 4 133 options 4 132 selections 4 132 MODIFY knob 4 127 4 131 monitoring your process 4 143 ON OFF buttons 4 127 output display screen 4 126 output power
153. bleshooting this error see E051 PROFIBUS er Watch Dog E151 indicates an error in Expired the PROFIBUS card located in the right I O slot located on the back panel of the power supply E051 indicates an error in the PROFIBUS card located in the left I O slot of the unit if applicable E154 E154 is the same error For more information about documented for E051 E154 indicates an error in the PROFIBUS card located in the right I O slot located on the back panel of the power supply E054 indicates an error in the PROFIBUS card located in the left I O slot of the unit if applicable troubleshooting this error see E054 6 24 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Table 6 4 Error Code Troubleshooting Table Error Code Message Problem Indicated Suggested Action E155 PROFIBUS Command Buffer Overflow E155 is the same error documented for E051 E155 indicates an error in the PROFIBUS card located in the right I O slot located on the back panel of the power supply E055 indicates an error in the PROFIBUS card located in the left I O slot of the unit if applicable For more information about troubleshooting this error see E055 E159 PROFIBUS Master Released Unit E159 is the same error documented for E059 E159 indicates an error in the PROFIBUS card located in the right I O slot located on the back panel of the
154. by the unit 3 Press ENTER to accept and exit SETTING THE HARD ARC SHUTDOWN TIME PROCESS gt ARC gt TIME To set the hard arc shutdown time 1 Press PROCESS ARC gt TIME 2 Rotate the MODIFY knob to select the hard arc shutdown value in microseconds 3 Press ENTER to save your selection and exit VIEWING THE ARC DENSITY PROCESS ARC gt DENSITY The arc counter counts one arc every time the output is shut off due to a hard arc condition The micro arc counter counts one arc every time a micro arc occurs Both counters will reset the next time the Pinnacle Plus unit is powered on To see the arc density of your process 1 Press PROCESS ARC gt DENSITY 4 150 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply SECOND and RUN options appear 2 To see arcs per second press SECOND 3 To see arcs per run press RUN Note This display is not zeroed until you turn the output on again or reset the display 4 Press EXIT to exit Note You may press RESET at any time at this menu level to clear the arc counters SETTING THE SEQUENTIAL MICRO ARC COUNT AND TIME One micro arc may follow the end of the previous micro arc so closely that the unit never enters the hard arc handling routine instead the micro arcs can form an endless chain of sequential micro arcs The time between micro arcs determines whether the arcs are sequential micro arcs or isolated micro
155. ces 4 107 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued process status Ist status byte 0 Unassigned 1 Ramp active 2 Run active 3 Output power 0 off 1 on 4 Illegal regulation mode 5 Cable interlock open 6 End of target life event 7 Set point status 0 within tolerance 1 out of tolerance 2nd status byte 0 Over voltage condition exists 1 Over current condition exists 2 unassigned 3 Control circuit fault 4 Heat sink over temperature event 5 User interlock open 6 User port reset active 7 Main contactor interlock open 3rd status byte 0 Momentary power failure 1 Unassigned 2 Near end joule value setting has been reached 3 Joule Threshold achieved 4 Unit A inverter low 5 Unit B inverter low 6 Unassigned interrupt event 7 PROFIBUS error Command Description Number Number of Sent of Data Response Bytes Data Bytes 162 Requests a report on process status 0 4 request Returns 4 data bytes 4 108 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number Number of Sent of Data Response Bytes Data Bytes 162 4th status byte 0 4 request 0 Hard bus fault process status e 1 Fault active continued e 2 Joules reached 3 Fatal fault active
156. ces 4 145 Advanced Energy Out of Set Point Tolerance Range Set point 0 4 of full scale or 2 of set point whichever is greater When an out of set point condition occurs the unit shuts off output and displays error code E001 See the Error Codes section of the Troubleshooting chapter for more information about error codes To enable the out of set point timer follow these steps to select a value in 0 1 s increments To disable the timer follow these steps and select a value of 0 Note Because the readbacks which are compared to the set point are filtered in the software we recommend you do not use this feature for process runs that are less than 1 s 1 Press PROCESS MONITOR SETPT 2 Rotate the MODIFY knob to adjust the value 3 Press ENTER to accept and exit CHANGING THE TARGET FUNCTIONS PROCESS MONITOR TARGET The target functions let you enable or disable the target life counter ENABLE change the active target SELECT and set the target life LIFE in 0 01 KWh increments PROCESS MONITOR TARGET gt ENABLE To enable or disable the target life counter for the selected target 1 Press PROCESS MONITOR gt TARGET gt ENABLE 2 Rotate the MODIFY knob to select YES or NO 3 Press ENTER to accept and exit PROCESS MONITOR TARGET SELECT To change the active target life counter 1 Press PROCESS MONITOR gt TARGET gt SELECT 2 Rotate the MODIFY knob t
157. ces 4 19 Advanced Energy Table 4 7 Single 24 V 37 pin User Port Pin Description Continued Signal Return Name Signal Description Pin Pin Type 5 36 IREG D input This signal is used with PREG D pin 6 to set the regulation mode See Table 4 10 on page 4 24 for a list of signal conditions for each regulation mode 6 36 PREG D input This signal is used with JREG D pin 5 to set the regulation mode See the description of pin 5 for the logic table associated with this signal 7 36 ON D input A high on this pin turns on output power A low signal turns output power off 8 n a unassigned n a n a 9 n a OUTCOM A n a This pin is a dedicated return for analog outputs Reference pins 23 24 25 and 31 to this pin 10 n a INCOM A na This signal is a dedicated return for analog inputs Reference pin 27 to this pin 11 19 AUX D INTLK input This signal monitors the system interlock string If the conditions are not all satisfied the main contactor is affected in one of two ways it will not close or if it is already closed it will open when the interlock string is interrupted 12 nla unassigned n a n a 13 nla unassigned n a n a 14 36 RESET D input A high on this pin will reset active explicit clear faults provided that the fault conditions are no longer present This pin must be returned to the inactive state low to enable the unit output 15 nla unassigned n a n a 1
158. cess To determine if resonance is a problem use an oscilloscope with an appropriate high voltage probe to measure if the voltage goes below the arc trip level after the cathode voltage is applied Changing the frequency output power cable length and or the reverse time settings can solve this problem Note AE recommends using a TEK 320 380 3054 3012 3032 or better with a 1 100 P5100 voltage probe If you cannot reach a certain output power increased reverse time increases the output power at a given maximum DC output voltage shown at the front panel You need to adjust the ratio of sputter time and reverse time to optimize the rate and film properties for your process To do so you need a good oscilloscope and a high voltage probe 2000 V rated that has been calibrated for the oscilloscope you are using Note AE recommends using a TEK 320 380 3054 3012 3032 or better with a 1 100 P5100 voltage probe MASTER SLAVE SYSTEM OPERATION The following sections include information about operating and monitoring Pinnacle Plus power supplies in a master slave configuration 5 38 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Master Slave Input On Off Combinations Unique logic in the Pinnacle Plus power supply lets you power on and off master and slave units independently of one another During valid on and off sequences the master unit re scales the total output That is its I O
159. chamber wall which must be a safety ground This will give you a negative output See Figure 5 7 on page 5 16 a o o 0i To Chamber Wall To Cathode Ensure spring 1 NAY Aa contacts shield b Gable shielding as well as the connector body Spring yo V Figure 5 7 Optimal output connection 5 16 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Connecting Output To Connect the Output Port 1 Disconnect all sources of input power to the Pinnacle Plus power supply 2 Prepare the appropriate output power cable For optimal performance we recommend using the shortest possible output power cable The cable must not exceed 10 m 33 or damage to your power supply may result 3 Remove the output box see Figure 5 5 on page 5 13 or Figure 5 6 on page 5 14 4 Remove the cover from the output box but note the relative positions of positive and negative see Figure 5 5 on page 5 13 or Figure 5 6 on page 5 14 5 Attach the output cable wires to the two terminals Tighten the two small screws on each compression terminal Note For the M32 output connector in order to maintain CE certification you must fill each output terminal block mounting screw hole with RTV adhesive to the t
160. ck nut in diameter Remove the cover from the output box but note the relative positions of positive Turn the braided shield up over the fitting s sealing insert the shield and clamp in Attach the ouput cable wires to the three terminals for your selected mode of 5 18 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply 8 Replace the output box and cover Lock Nut Output Box Strain Relief 1532 Figure 5 9 PG 36 style output box and connector UHF OUTPUT CONNECTOR ATTENTION Before making your output power connection see Connecting Output Power on page 5 10 for safety information and requirements WARNING To meet SELV Safe Extra Low Voltage requirements you must tie the positive output to chamber ground Do not allow either positive connection to exceed 40 V with respect to ground 57000097 00B Installation and Operation 5 19 Advanced Energy The output connector for your Pinnacle Plus power supply is a female UHF connector as shown in Figure 5 10 If your unit is a dual unit it features two of these connectors Plastic Sleeve Amphenol 83 822 CMM hee WML Sleeve Assembly Not Provided UHF Female Provided 1421 Figure 5 10 UHF connector and sleeve assembly Note We do not provide the sleeve assembly and male connector with your unit at the time of shipment but you can o
161. cksum value The receiving unit accumulates the XOR of all bytes of the packet including the checksum If the result is zero the packet has likely been received intact Only after the checksum of a message packet is validated having no parity errors and the address is valid will the Pinnacle Plus unit act on the message which consists of the contents of the command and if appropriate the data fields Creating an Ideal AE Bus Communications Transaction The figure below is a simplified graphic showing the steps in an ideal communications transaction between a host computer and a Pinnacle Plus unit 4 168 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Host Pinnacle Plus t Transmits message packet W Uy Z 7 Up Receives packet Waits N Sends ACK t S Assembles N CSR byte or N data byte s N hen transmits t Receives ACK N S N N Waits Receives packet t Sends ACK Waits My Ny Z 4 a Receives ACK t time END OF TRANSACTION 1139 Figure 4 26 AE Bus communications transaction First the host computer sends a message packet to the Pinnacle Plus unit The packet contains one of the following e A command that requests data or status information A command and data that change a parameter setting An executable command Once the Pinnacle Plus unit receives the message packet the Pinnacle Plus unit verifies that the message is intended
162. cted in binary format To enter the unit s address set the switch positions for binary representation starting with the switch on the left and proceeding to the right descending order of significance The switches are numbered 1 through 8 Switch 1 is the most significant bit msb and switch 8 is the least significant bit lsb Placing a switch in the up position toward the number is the same as indicating 1 binary The following example demonstrates switch settings for an address of 12 0000 1100 0x0Ch 12 Note You cannot change the unit s address from the PROFIBUS master Termination Please ensure that you follow proper termination procedures if your Pinnacle Plus is the last slave on the PROFIBUS cable The termination resistors should be on the connector housing of the PROFIBUS cable not included Baud Rate The auto baud feature of AE s PROFIBUS interface adjusts automatically to the rate of the PROFIBUS master system Baud rates are available in discrete steps from 9600 bits 9 6 kbits to 12 Mbits The auto baud feature operates much like a modem or FAX machine in that at startup there is a small delay while the interface traverses the different baud rates and then locks in Please ensure that your PROFIBUS master allows for this delay 57000097 00B Communication Interfaces 4 73 Advanced Energy Master Reset Command Send the master reset command Command 119 when the Pinnacle P
163. ctions explain how to connect your Pinnacle Plus power supplies in a master slave configuration Note The master slave feature is only available on Pinnacle Plus 10 kW units This feature is not available on Pinnacle Plus 5 kW or dual units 57000097 00B Installation and Operation 5 21 Advanced Energy UNDERSTANDING MASTER SLAVE OPERATION You can configure up to six Pinnacle Plus power supplies to operate in a master slave system allowing you to increase your total system power up to 60 kW Any Pinnacle Plus power supply that features the master slave Host card can function as either a master unit or a slave unit A Pinnacle Plus power supply without a master slave Host card cannot function as a master or slave When operating a master slave system in voltage regulation mode the maximum pulsing frequency is 250 kHz To configure your power supply for master slave operation use the following connectors e Master slave Host card interface see Master Slave Host Card Interface on page 5 22 e Master slave Pulse port connector see Master Slave Pulse Port in Chapter 4 of the Pinnacle Plus power supply user manual for more information You can also configure your master slave system for synchronized pulsing operation Note When running a master slave system in voltage regulation be aware that the Pinnacle Plus units may not share current or power Note To use the master slave feature the Pinnacle P
164. customer service statistics Send 1 data byte 8 bit value e 0 Total output in kilowatt hours e 1 Total idle time e 2 Total run time 3 Total unit on events e 4 Total output on events e 5 Total over temperature events e 6 Total control circuit faults e 7 Total out of set point events 8 Total hard bus fault events e 9 Total power fluctuation events e 10 Unassigned e 11 Total Side A inverter low events e 12 Total Side B inverter low events 13 Total user interlock open events e 14 Total cable interlock open events 15 Total contactor interlock open events 18 Total PROFIBUS fault events e 19 Total pre defined interrupt events 20 Total unassigned interrupt events e 22 Total dsp watchdog faults e 24 10 ms bus fault events 1 4 May return CSR code 5 223 AE service request request unit fault status 4 214 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 230 Requests the crc of the logic front panel or 1 2 DSP May return request logic j i CSR code 5 Bane or DEP The returning packet contains 2 data bytes 16 CRC bit value To receive the logic CRC first send command 24 which calculates the value With command 230 send one data byte e 0 Logic e 2 D
165. dicates the same error but in the AE Bus card located in the right I O slot of the unit if applicable Slow down the AE Bus communication rate or the rate at which commands are sent E070 Internal DeviceNet Communications Error An internal communications error has occurred on the DeviceNet card No suggested action 57000097 00B Troubleshooting and Global Services 6 21 Advanced Energy Table 6 4 Error Code Troubleshooting Table Master Slave interface card Once the master slave Host card has been successfully initialized the fault self clears Error Code Problem Indicated Suggested Action Message E081 This error occurs at startup Ordinarily if this fault does not clear in units that are configured automatically there is a hardware Initializing with a master slave Host problem Check your master slave cabling E086 Overvoltage The unit was in an overvoltage condition for longer than was set on the overvoltage timer No suggested action Short Circuit Condition circuit conditions occurred a shorted chamber shorted cable or a failed pulsing switch The unit detects a short circuit if the following conditions exist the power current or voltage limit is active or enabled the current is above the current threshold of pulsing the unit detects a hard arc E087 The unit was in an No suggested action overcurrent co
166. e 300 ms wait After the 300 ms wait time pulsing begins 3287 time because the voltage is below the threshold Figure 5 18 Pulsing begins after a 300 ms filter time if below threshold If the Pinnacle Plus power supply is above the threshold at 300 ms after output on the unit continues to try to ignite The unit cycles from 1350 V for 100 ms to 800 V for 900 ms until the unit goes below threshold at which point pulsing begins see Figure 5 19 1350 V z H D Z ini Ignition detected pulsing begins Y axis Output voltage X axis Time 3288 Figure 5 19 Ignition cycle if unit remains above threshold 57000097 00B Installation and Operation 5 33 Advanced Energy Once the unit goes below threshold and pulsing begins the unit monitors the voltage If the voltage goes above the threshold for example 750 V pulsing stops and the unit goes into the ignition profile until the voltage goes below the threshold to start pulsing again see Figure 5 20 1350 V Y axis Output voltage X axis Time 800 V 750 V UU lnm 3289 Unit pulsing unit operating below threshold Voltage goes above the threshold pulsing stops and unit goes into ignition profile p Unit detects ignition voltage goes below threshold so pulsing begins Figure 5 20 Pulsing behavior when using voltage threshold Modes of Operation Low Power Versus High Power The advanced
167. e 1000 800 Voltage Limit Power Limit 325 Operating Range Current Limit Voltage Vdc Measured at the dc inverter output see figure 2 1 50 30 8 12 5 Current Adc 2148 Figure 3 4 Operating range Pinnacle 10 kW 325 800 V Power Limit Voltage Limit Power in kW Current Limit 30 40 50 80 10 6 64 Impedance in Ohms 2149 Figure 3 5 Impedance range 57000097 00B Product Specifications 3 17 Advanced Energy ENVIRONMENTAL SPECIFICATIONS Table 3 6 Climatic Specifications per EN50178 Temperature Relative Humidity Air Pressure Operating 0 C to 40 C 32 F to 104 F 5 to 85 n0te 1 g m to 25 g m 78 8 kPa to 106 kPa 788 mbar to 1060 mbar Equivalent altitude 2000 m to 500 m 6562 ft to 1640 ft Storage 25 C to 55 C 13 F to 131 F 5 to 95 1 g m to 29 g m 78 8 kPa to 106 kPa 788 mbar to 1060 mbar Equivalent altitude 2000 m to 500 m 6562 ft to 1640 ft Transportation 25 C to 70 C 13 F to 158 F 95 note 2 60 g m note 3 65 6 kPa to 106 kPa 656 mbar to 1060 mbar Equivalent altitude 3500 m to 500 m 11480 ft to 1640 ft howl Non condensing no formation of ice note 2 Maximum relative humidity when the unit temperature slowly increases or when the unit temperature directly inc
168. e 8 bit value e 6 Power e 7 Voltage e 8 Current Note Output power must be off that is output must be deenergized to switch between regulation modes Read back this value with command 154 4 Specifies the number of joules to be delivered 4 CSR codes 0 1 4 9 joule set Send a 4 byte 32 bit value the value must be point between 0 and 9 999 999 Read back this value with command 173 5 Enables or disables joule mode 1 CSR codes 0 1 2 9 joule mode Send 1 data byte 8 bit value ave 0 Disable e Non zero value Enable Read back this value with command 153 57000097 00B Communication Interfaces 4 173 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 6 Specifies the output set point level for 2 CSR Codes whichever method of regulation mode has been 0 1 4 6 9 set point selected 19 Send 2 data bytes 16 bit value an output power value implies 3 decimal places for a stand alone unit and 2 decimals for a master slave unit An output current value should imply 2 decimal places and an output voltage value should imply 0 decimal places For example for a 6 kW standard Z stand alone supply send a value between 0 and 6000 6 000 kW decimal is implied or 0 and 1500 15 00 A decimal is implied or 0 and 800 maximum output voltage Please refer to the Specifications chapter of this manual for
169. e Functionality independent units with the Pinnacle Plus Sync Pulse source controls With this feature multiple units may be synchronized at 0 Additionally units connected for Sync Pulse operation can share hard arcs Master Slave Operation By having your Pinnacle Plus supply reconfigured at the factory the unit can become a building block in a master slave system thereby allowing Pinnacle Plus power installations of greater size than 10 kW Target Supervision You can select one of eight target life counters from the active front panel Pinnacle Remote Active Panel User port or serial Host port Target life can be monitored from the Pinnacle Remote Active Panel the active front panel and the serial port Note The User port has priority when selecting targets Arc Control You can monitor micro arc density and hard arc density from the Pinnacle Remote Panel the active front panel and the serial Host port e You can change arc trip level voltage You can enable or disable micro arc handling but hard arc handling is always enabled Monitoring options include arc count per second and arc count per run Additionally you can have the unit indicate when a set number of hard arcs have occurred in the process run Arc Energy 200 uJ kW with micro arc handling active Cooling Air cooled 3 2 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply Table 3
170. e set below 40 V A trip level between 40 V to 60 V can cause the unit to become unstable at start up Understanding Frequency and Reverse Time Settings Advanced Energy AE defines reverse time as the time that the pulsing switch is closed or when no power is transferred to the plasma By action of the pulsing switch and output inductor output voltage is reversed Reverse time is only relevant during pulsing operation See Table 3 4 on page 3 9 for reverse time specifications 57000097 00B Installation and Operation 5 37 Advanced Energy Frequency and reverse time settings can affect the arc and process behavior of the Pinnacle Plus power supply in the following ways Higher frequencies reduce the tendency to arc Note Frequency is limited to 150 kHz when the pulse mode is set to be enabled always Short reverse times allow a higher pulsing rate but may increase the number of micro arcs and possible hard arcs especially if you are using a long output power cable Frequency and reverse time define the maximum peak voltage at the cathode Setting high frequencies and long reverse times raise the plasma voltage during the sputter cycle Plasma voltage can be as much as double the DC voltage Depending on the cable length and the cathode size certain frequencies may cause resonance with the pulsing frequency This resonance can cause the Pinnacle Plus power supply to respond to a false arc or overcurrent event in ex
171. e Panel 0 0020005 4 125 Understanding the Panel 2iidcs0s sivas vidivw ended beeen ew eawads 4 126 Control Key a su xaw dka Raa a a Aaaa lk abal aa dia ook ee eke BGS ke wees 4 126 Output Display Screen kk kk kk kk kk KK KK KK es 4 126 I Oe tee ae aries ae doe Belin ones Sree hls eee ne erties etme ace ed sae 4 127 MODIFY KROD 4 xali sees dc Wack Pile Wate Wikia Mele ech l an la n heed eae 4 127 Regulation Key sn cde kk kk kk he oa kk kk kk ka kk kk kk a kk kk eee 4 127 On Off Buttons amp LEDS kk kk kk kk kk KK KK KIR KK es 4 127 Are EED ocular shes DIDI M MM MWMWMMDMMMDMDMDMNM M IZMVMMVMMIMIMDMDMDunEN E N N EHR 4 127 Control Panel Interface kk kk kk kk KK KK KK KK KK ee 4 128 Output Power Key l kk kk kk kk kk kk kk ka kaka kk kk ka kk ak ke k e 4 128 Control Key s i xas 2 ala nln a a ua yd walk a al a aa alan he h A a a 4k al Reka ala 4 128 Regulation Key 4s a ahk ala a a ala a ad 4 a A csa0edeuwenees aden 4 129 Two Line Output Display Screen WW kk kK KK KK KK KK ee 4 129 Setting the Reverse Time Frequency and Set point 4 131 OM a rer rate t T a oa RE ase me a ec ahaha ee tna Be ae ace 4 131 MODIFY WOO osc ead ie be bn d Cad See aa ees ee De r ei eA 4 131 Control Panel Controls lk kk kk kk kk KK KK KK KK KK eee 4 131 Understanding the Menu Options kk kk kk kk KK KK KK KK KK KK KI KK KK KK 4 132 Using the Service Functions
172. e System Figure 5 16 illustrates a Sync Pulse master slave system configuration In this configuration you can connect a series of master slave Pinnacle Plus systems together in a Sync Pulse system This configuration allows for extraordinary control over hard arcs across a large network of power supplies 2093 Master Slave 1 Slave 2 Figure 5 16 Sync Pulse master slave configuration 5 28 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Rear Panel Drawing Figure 5 17 illustrates the rear view of the Pinnacle Plus power supply pn S PYNOID SN J0 99UU02 Jeuuo sno nd nO 90 19 U J0 98 UO2 pod 1SN Od jeue N Py 9 OoUJ9 SHOd Jeuondo HOd 8HJ9S Hod 1SN pucves JO UOI ISOd euondo pn S punog SW p109 u17 yndu punoo ZE Ob O CO z RRIT o DR LY 29900900 o IRD ol RRE SO
173. e panel until the Local LED lights Placing the unit in local mode gives you full access to the front panel menu see Control Panel Interface on page 4 128 To control the Pinnacle Plus supply from the Serial interfaces or the DeviceNet port press the CONTROL key until the Host LED lights To control the Pinnacle Plus supply from the User port press the CONTROL key until the User LED lights When the Pinnacle Plus unit is in host or user control mode you can view all the menu items but you cannot modify parameters or lock the display OUTPUT DISPLAY SCREEN The first screen that appears on the panel s vacuum fluorescent display when you power up is the output display screen See Two Line Output Display Screen on page 4 129 for more information Viewing Output Information The output display screen shows the actual output level in volts amps and watts See the front panel drawings at the end of the Installation chapter It also displays the set point Selecting Set Point To program the set point level from an active control panel use the panel s CONTROL key to select local control mode the Local LED will light See Setting Control Parameters on page 4 152 Press the set point soft key to to activate the set point value turn the MODIFY knob until the set point you want is displayed then press the set point soft key again 4 126 Communication Interfaces 57000097 00B Pinnacle Plus 10
174. e step is running gt 110b step 7 while the recipe step is running Note 111b step 8 while the recipe step is running Bit 4 End of target life EOTL e Bit 5 Active toggle bit e Bit 6 Set point OK Bit 7 Always set Byte 1 e Bit 0 Fault active When this bit is set 1 faults exist e Bit 1 Overtemperature condition e Bit 2 Interlock open Bit 3 Nearly end of recipe step see explanation below for more information e Bit 4 Joule mode enabled Bit 5 Contactor open e Bit 6 Joules reached Bit 7 Output on Plasma Ignited Bit In the first status byte bit 0 indicates if plasma is ignited As soon as output is turned on and plasma is ignited joule count is started bit 0 is set that is 1 As long as output is off or output is turned on but no plasma is ignited no joule count bit 0 is not set that is 0 Nearly End of Recipe Step Bit In the second status byte bit 3 indicates the recipe step is nearly ending When this bit is set that is equals 1 the joule counter run timer is down to the value set with command 72 The bit will reset to 0 at the start of the next recipe step Your product may function with the end of joule recipe indicator versus the end of each step indicator 57000097 00B Communication Interfaces 4 79 Advanced Energy In the first status byte bit 5 the active toggle bit indicates the status of the PROFIBUS interface After the Pi
175. e that the interlock loop is closed both at the Contactor Interlock and at the User port 10 Ensure that input power meets specifications Checks with the Unit Powered On Perform the following checks with the unit powered ON 1 Check the unit s input and remote power connections to ensure the proper power is being supplied to the unit 2 Check the LEDs on all units to determine that the proper ones are lit 3 Note any error code that is any Exxx number displayed on the front panel or Pinnacle Remote Active Panel See Error Code Troubleshooting on page 6 16 for more information 4 Working with the passive front panel ensure that the front panel LEDs POWER ON INTERLOCK OUTPUT and SETPOINT LEDs are lit see Troubleshooting LEDs on page 6 7 for more information 6 2 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Note which if any of the LEDS are not lit If the INTERLOCK LED is not lit error code E020 E022 or E023 should be displayed on the front panel See Error Code Troubleshooting on page 6 16 for help in troubleshooting these errors 5 If you suspect an LED is malfunctioning cycle the Pinnacle Plus unit s power on and off If the problem reoccurs call AE Global Services 6 Working with the passive front panel note whether the BUS FAULT or OVERTEMP LEDs on the front panel are illuminated see Error Code Troubleshooting on page 6 1
176. e the handshake feature described in Transmission Rates and the Handshake Feature on page 4 76 commands should not be sent to the Pinnacle Plus power supply faster than a rate of one command per 10 ms 57000097 00B Communication Interfaces 4 75 Advanced Energy Transmission Rates and the Handshake Feature Recent technological improvements have made it possible for some PLCs to send commands faster than the Pinnacle Plus unit can respond This situation can cause intermittent failures to respond to or execute commands In response to this issue AE has developed a handshake feature which echoes back the last sent command and Command Status Response CSR code when applicable This feature allows you to send a command and wait for verification that the command was accepted before sending the next command The handshake feature has several benefits for users It simplifies the programming of PLCs that interact with AE products It increases the bandwidth of the PROFIBUS channel by eliminating wasted time e It provides immediate feedback regarding command execution It increases the reliability of PROFIBUS Pinnacle communications Note You can choose not to use the handshake feature but if you do so commands should not be sent to the Pinnacle Plus power supply faster than a rate of one command per 20 ms Download Packet The download packet for the AE PROFIBUS contains four bytes as the following table shows
177. ecautions in this case could result in damage to the unit Q ATTENTION If the product has a Warranty Void if Seal is Broken label you must receive prior approval from AE before you can remove the power supply box cover If you remove the box cover before receiving approval from AE the product warranty is no longer valid Contact AE Global Services for more information To provide for a 0 to 5V scaling e Place the P1 jumper level in signal across pins 2 and 3 e Place the P5 jumper voltage current and power read backs across pins and 2 e Place the P4 jumper level out signal across pins 1 and 2 e Place the P3 jumper REF A across pins 2 and 3 To provide for a 0 to 10V scaling e Place the P1 jumper level in signal across pins 1 and 2 e Place the P5 jumper voltage current and power readbacks across pins 2 and 3 e Place the P4 jumper level out signal across pins 2 and 3 e Place the P3 jumper REF A across pins 1 and 2 Analog outputs source or sink up to 3 0 mA and have an output impedance of 100 Q The input impedance of the analog input is 200kQ 4 4 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply DIGITAL SIGNALS A D suffix appended to the pin name indicates a digital signal Digital commons are denoted by the COM D suffix Digital signals that are active when low are indicated with an overline on the pin name ARC_D Digital outputs are 0 to 15 V a
178. ect targets from a serial port the active front panel or from the Pinnacle Remote Panel that is when the Pinnacle Plus unit is in local or host control mode you must set the target to 1 at the User port Leaving the target bits open or leaving the User port pins unconnected causes the target selection at the User port to default to 1 Read back this value with command 156 12 Sets the life in kilowatt hours of a target 3 CSR only Send 3 data bytes 24 bit value indicating target life for the active target specified with command 11 target life Note Two decimal places are implied that is to get 1 kWh send a value of 100 Read back this value with command 157 13 Enables or disables the target life counter 1 CSR only target enable Send 1 data byte 8 bit value e 0 Target life is inactive e Non zero value Target life is active Read back this value with command 163 57000097 00B Communication Interfaces 4 87 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued Send a 2 byte value between 5 and 60 000 Two decimal places are implied That is to get 1 s send a value of 100 Note If your unit has 100 ms ramp feature enabled one decimal is implied The range is 0 5 s to 6000 0 s Read back this value with command 158 Command Description Number Numberof of Sent Response Data Data Bytes Bytes 14 Chooses the mode of cont
179. ed that System Input Power is does not have input power Fault MAINTENANCE Consumable Parts Some parts in the Pinnacle Plus unit are consumable and may wear out over time For a current list of consumable and wear components in the Pinnacle Plus unit as well as for estimated lifetimes and recommended refurbishment schedules please contact AE Global Services 57000097 00B Installation and Operation 5 41 Advanced Energy 5 42 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Chapter 6 Troubleshooting and Global Services BEFORE CALLING AE GLOBAL SERVICES A DANGER RISK OF DEATH OR BODILY INJURY Disconnect all sources of input power before working on this unit or anything connected to it The following pages contain the following types of troubleshooting sections A general checklist of potential problem areas A Pinnacle Plus unit basic functionality test e A list of error codes and suggested responses Please consult the appropriate section s if you believe you are experiencing trouble with your Pinnacle Plus power supply If the problem continues or if you cannot find an adequate solution in these pages please call AE and ask to speak with a Global Services representative WARNING Operating and maintenance personnel must have the correct training before setting up maintaining or troubleshooting high energy electrical equipment Potentiall
180. ed n a n a 30 n a unassigned n a n a 31 9 LEVELOUT A output This signal represents the programmed set point level Full scale 10 V represents the rating of the supply see the Specifications chapter of this manual for more information 32 n a unassigned n a n a 33 n a unassigned n a n a 4 22 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 7 Single 24 V 37 pin User Port Pin Description Continued Signal Pin 34 Return Pin 36 Name TARGET2 D Signal Type input Description This signal is used with TARGETO D pin 4 and TARGETI D pin 35 to select the active target life counter See the description of pin 4 for the logic table associated with this signal 35 36 TARGETI D input This signal is used with TARGETO D pin 4 and TARGET2 D pin 34 to select the active target life counter See the description of pin 4 for the logic table associated with this signal 36 n a INCOM D n a This pin is a dedicated return for digital inputs Pins 4 5 6 7 14 34 and 35 should be referenced to this pin 37 n a OUTCOM D n a This signal is a dedicated return for digital outputs Pins 1 2 3 20 21 and 22 should be referenced to this pin Table 4 8 Target Life Counter Check Pin 20 and Pin 1 Counter Pin 20 Pin 1 1or5 low low 2 or 6 low high 3 or 7 high low 4 or
181. ee 4 161 e Slide DIP SWIHGN 4x hahaa nan ah n mal aw n all kan eek al 2k E lk n ala 4 162 Orientation of the AE Bus port and external DIP switch on the back panel 4 Graphic representation of an AE Bus message packet 4 166 AE Bus communications transaction 202020005 4 169 AE Bus communications transaction example 4 172 Clearances for Pinnacle Plus power supplies stacked in a cabinet 5 4 Contactor Intlk port connector 0 00000 KK EK EK KRE ees 5 7 Actual size of PG 11 style strain relief fitting 28 mm diameter 5 12 Actual size PG 16 style strain relief fitting 34 mm diameter 5 12 PG style output box and connector kk kk kk kK KK KK KK eee eeee 5 13 M32 style output box and connector 0000 KK KK KK KK ee 5 14 Optimal output connection 0 00 0 5 16 PG 36 style strain relief fitting 0 KK KK KK KK ee 5 18 57000097 00B List of Figures XV Advanced Energy Figure 5 9 PG 36 style output box and connector 00 00 eee KK KK 5 19 Figure 5 10 UHF connector and sleeve assembly 0 00 eee eee eee 5 20 Figure 5 11 Rear view of UHF housing without interlock back plate removed 5 21 Figure 5 12 Rear view of UHF housing with interlock back plate removed 5 21 Figure 5 13 Master slave Host card interface 0 000 eee eee 5 23 Figure 5 14 Master slave system confi
182. eee 4 1 Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions 4 5 Table 4 3 User Port Output Enable Disable Behavior and Signal States kk kk KK KK KK KK KK ee 4 14 Table 4 4 Cathode Switch pin 20 and pin 1 kk KK KK RR RR KK KK KK 4 15 Table 4 5 Target Life Counter pin 34 35 and 4 KK KK KK RR RR KK 4 15 Table 4 6 Regulation Mode pin 5 and pin 6 a nn kk kk kk KK KK KK KIR KK eee eee 4 16 Table 4 7 Single 24 V 37 pin User Port Pin Description 4 19 Table 4 8 Target Life Counter Check Pin 20 and Pin 1 0 5 4 23 Table 4 9 Select Target Life Counter Pin 34 Pin 35 and Pin4 4 23 Table 4 10 Regulation Mode pin 5 and pin 6 kk kk kK KK RR RR KK KII KI 4 24 Table 4 11 Single 15 V 25 Pin User Port Pin Description 4 28 Table 4 12 Rear Panel Switch Setting Descriptions 00 4 34 Table 4 13 Single 15 Pin User Port Pin Descriptions 4 37 Table 4 14 Dual 24 V 37 Pin User Port Pin Descriptions 4 42 Table 4 15 Regulation Mode pin 7 and pin 25 Controlling Unit A 4 49 Table 4 16 Regulation Mode pin 13 and 32 Controlling UnitB 4 49 Table 4 17 Master Slave Pulse Port Pin and Signal Descriptions 4 51 Table 4 18 Sync Pulse Port Pin and Signal Descriptions 4 53 Table 4 19 DeviceNet
183. en Call AE Global Services the logic card and the inverter board has come loose 6 18 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Table 6 4 Error Code Troubleshooting Table Interlock Open Contactor Error Code Problem Indicated Suggested Action Message E022 The unit s Contactor 1 Power off the Pinnacle Plus unit Interlock has not been satisfied 2 Ensure that the Contactor Interlock is properly connected 3 Ensure that all system interlocks have been satisfied 4 Power the unit back on For more information about Contactor Interlock connector see the Installation chapter E024 Invalid Regulation Mode The User port regulation mode for has been set to an invalid value Note Output power must be off that is output must be de energized to switch between regulation modes Set the User port regulation mode to a valid value E027 Maximum On Timer Expired The maximum on timer set with command 87 has expired Either e Clear the fault then turn output on again or Disable the timer by setting it to zero E033 Message Queue Overflow The microprocessor has fallen behind and cannot keep up with events De energize the Pinnacle Plus unit and then restart 57000097 00B Troubleshooting and Global Services Advanced Energy Table 6 4 Error Code Troubleshooting
184. ent DC pulse power supply designed exclusively for use in vacuum environments Figure 2 1 on page 2 2 and the following paragraphs outline the theory of operation 36 Inverter Point of DC DC AC gt eee ml Section SWE Voltage Chopper Pa DG In Unit A Measurement Section Housekeeping Logic Remote Supplies Control Interfaces 1551 Figure 2 1 Pinnacle Plus functional block diagram Front Panel Display 2 2 Theory of Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Input In the input section AC line voltage is applied through the circuit breaker to a three phase contactor The contactor when closed delivers the line voltage to a rectifier bridge where it is converted to DC This bus provides DC voltage to the inverter section The input section also provides power to the housekeeping section Housekeeping Supply The housekeeping supply section provides low voltage to power the electronic circuits within the Pinnacle Plus unit Inverter The inverter section converts DC to high frequency voltage by alternating the current through switching transistors Output In the output section an isolation transformer steps up the high frequency voltage from the inverter section and sends it to a full wave rectifier bridge Output Measurement The output measurement section measures current and voltage These signals are typically scaled to 0 to 10 VDC and sent to the logic
185. ent after startup Use this command for clearing PROFIBUS faults at the Pinnacle Plus Note It will not clear self clearing faults such as interlocks open e Byte 0 77h 119 e Byte 1 pma e Byte2 n a e Byte 3 n a EXAMPLE 3 To set the regulation mode to power Byte 0 03h 3 e Byte 1 06h 6 Regulation mode Power e Byte 2 ma e Byte 3 n a 57000097 00B Communication Interfaces 4 121 Advanced Energy EXAMPLE 4 To set the set point to 5 kW 5000 Watts on a stand alone unit Note The least significant byte is followed by more significant bytes e Byte 0 06h 6 e Byte 1 88h 136 5000 1388h e Byte 2 13h 19 e Byte 3 n a EXAMPLE 5 To enable a target life counter for target number 2 first you must enable target life counting Byte 0 0Dh 13 e Byte 1 01h any non zero value will do e Byte2 n a e Byte 3 n a EXAMPLE 6 Select the target counter you want to load and have active In this example we used target 2 e Byte 0 0Bh 11 e Byte 1 02h 2 e Byte 2 ma e Byte 3 n a EXAMPLE 7 Select load target life command will load target 2 since it is the current active target In this example we used 1000 kWh 2 implied decimal places Byte 0 0Ch 12 Byte 1 A0h 160 1000 00 kWh 100000 0186a0h Byte 2 86h 134 Byte 3 01h or 1 4 122 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply EX
186. ent flows above the specified value for your unit pulsing starts Should 100 ms expire before pulsing begins a duty cycle is imposed on the unit s voltage limit to prevent unit damage This duty cycle is 100 ms at maximum voltage and 900 ms at the user voltage limit This cycle repeats until the current exceeds the threshold for the unit listed above at which time pulsing starts Note If the regulation mode is Voltage the output on voltage jumps to a maximum of the set point plus 12 5 and no duty cycle is imposed Hard Arc Following the shutdown if the unit detects the current has Shutdown dropped below the following values per your unit configuration the unit returns to ignition state 0 25 A for 5 kW and 5x5 kW power supplies 2 0 A for 10 kW 325 650 VDC power supplies e 0 5 A for 10 kW 325 800 VDC power supplies Low current flow is a good indicator that the plasma has extinguished Otherwise the unit continues pulsing if current flow stays above the specified values per your unit configuration Open Should the unit detect an open circuit condition the unit Load Circuit returns to ignition state otherwise the unit continues to pulse 5 36 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Understanding Arc Handling AE ships the Pinnacle Plus power supply with micro arc handling enabled Each time you power off then power on your unit the arc hand
187. enu options 4 132 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply SERVICE STATS gt ENERGY Hl TIME HF IDLE RUN L gt EVENTS j gt FAULTS POWER OVRTMP BUS INVRTR INTRLOCK IRQS MONITOR m SETPT DSP D gt CYCLES T gt OUTPUT UNIT gt DEBUG P HW_ CONFIG LOGIC H MEMORY F gt ROM E PANEL DSP LOGIC Ll SW_REV CONFIG 1648 PANEL DSP LOGIC Figure 4 17 Service menu map SUPPLY r gt AE BUS DEFAULTS gt PULSE VTHRS ENABLE DUTY CYCLE B CAST TX RX L gt PGM SRC PANEL SELECT LOCK CLICKS 1649 Figure 4 18 Supply menu map 57000097 00B Communication Interfaces 4 133 Advanced Energy PROCESS MONITOR r gt OVER V gt OVER I gt SETPT TARGET SELECT LIFE gt LIMITS SC_LIM STRIKE VOLTAGE CURRENT POWER gt ARC gt MORE LEVEL COUNT SEQCNT TIME SEQTIME DENSITY RUN SECOND p ENABLE LP CONTROL gt RECIPE STEPS TYPE gt JOULES THRESHOLD ENABLE gt RAMP ENABLE START_PT Figure 4 19 Process menu map 1650 USING THE SERVICE FUNCTIONS Use this option to view diagnostics and software versions of your supply The menu options are 4 134 C
188. ept interlock over temperature and A D conversion faults Pin 14 does not reset an end of target life signal 15 19 SPAREI D digital spare input input 16 19 SPARE2 D digital spare input input 17 19 SPARE4 D digital spare input input 18 nla I5SV output This protected 15 V dc supply output provides a maximum of 100 mA 4 8 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 19 nla INTLKCOM D n a Dedicated return for interlocks Reference pins 11 12 and 13 to this pin 20 37 CS2 D digital This signal is used with output pin 1 CS D to tell an external device such as a cathode switch box which of the Pinnacle Plus supply s target life counters is active See description of pin 1 for the logic table 57000097 00B Communication Interfaces 4 9 Advanced Energy Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Continued Signal Pin 21 Return Pin 37 Pin Name ARC D Signal Type output Description A pulse of a predetermined width normally 100 ms a few units are configured for 10 ms will be seen on this pin under two different conditions 1 If the hard arc count limit is non zero and the number of hard arcs seen exceeded this limit d
189. equests in less than one millisecond and responds to explicit requests in less than 2 milliseconds The DeviceNet interface uses DeviceNet s Group 2 I O Poll Command message and the associated Group 1 I O Poll Response message to transfer low level I O data between the device slave and the master For more information about this message refer to section 7 6 of the DeviceNet specification revision 2 0 or later ATTENTION Depending on your DeviceNet configuration some features may not be available in the Pinnacle Plus power supply For ordering information contact AE Global Services 4 56 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply One of three types of poll request in available on your unit The poll request available to you depends on your unit s configuration If you do not know the unit configuration contact AE Global Services Table 4 20 Assembly object data poll instance 1 Byte Bit7 Bit 6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit 0 0 Power Output Setpoint AO LSB 1 0 0 0 0 Power Output Setpoint AO MSB 2 Unused Write with Os for future compatibility 3 Unused Write with 0s for future compatibility 4 la GA ae e a Clear Clear PO Run Run Micro Hard Arcs Arcs Note In Bit 0 of Byte 4 PO refers to Power On In this bit 1 turns on the unit s output 0 turns off the unit s outpu
190. er Fault Occurred Error Code Problem Indicated Suggested Action Message E011 Unit A s power inverter 1 Using all applicable safety cannot produce power precautions inspect your AC input power source to ensure that it is properly connected and that the specified voltage is being applied to the Pinnacle Plus unit 2 Check the input power line voltage on all phases to ensure that it meets specifications see the Specifications chapter 3 Run the power supply to a dummy load to determine if it produces voltage or current E012 Side B Inverter Fault Occurred Unit B s power inverter cannot produce power 1 Using all applicable safety precautions inspect your AC input power source to ensure that it is properly connected and that the specified voltage is being applied to the Pinnacle Plus unit 2 Check the input power line voltage on all phases to ensure that it meets specifications see the Specifications chapter 3 Run the power supply to a dummy load to determine if it produces voltage or current E020 Interlock Open The system interlock on the unit s analog User port has not been satisfied 1 Power off the Pinnacle Plus unit 2 Ensure that the interlock pin on the User port connector has been Interlock Open Cable User properly connected 3 Ensure that all system interlocks have been satisfied Power the unit back on E021 The ribbon cable betwe
191. es Value between 0 and the full rated output of the supply Note See the Specifications chapter for your unit s capabilities and see command 6 for the format of the value Read back these values with command 182 CSR only 4 90 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 23 recipe run time or joule set point Specifies the length of time the unit will run at set point for a recipe step If you enable joule recipe use this command to set the joule set point Send 3 data bytes arranged as follows First byte Recipe step a value between 1 and 8 Note When joule recipes are enabled recipe step numbers through 8 use the value in the second and third bytes to set the LSW of the joule set point Step numbers 129 through 136 set the MSW of the joule set point where step 129 sets MSW of step 1 step 130 sets MSW of step 2 and so on When command 23 is sent with step numbers through 8 the MSW is cleared To set joule set points greater than 65535 first send command 23 with steps through 8 then send command 23 with steps 129 through 136 e Second and third bytes Value between 0 and 60 000 or between 0 and 600 s two decimal places implied Note If you assign 0 run time for the final
192. es and settings that you can easily control through the Pinnacle Remote Active Panel If you are using the Pinnacle Remote Active Panel first ensure that it has been properly connected to the Pinnacle Plus supply installation information appears in the following section Connecting to the Remote Active Panel The 9 pin male subminiature D connector labeled REMOTE ACTIVE PANEL on the rear of the Pinnacle Plus power supply lets you connect the supply to the Pinnacle Remote Active Panel Pin 1 Pin 5 heer Pin6 Pin 9 1370 Figure 4 13 Remote active panel connector The pin descriptions for this connector appear in the following table installation instructions follow the pin description table Table 4 38 Remote Panel Pin Descriptions Pin Description 1 Do not connect Do not connect Do not connect Do not connect Ground TR NIO oo BP OTN TR 57000097 00B Communication Interfaces 4 125 Advanced Energy Table 4 38 Remote Panel Pin Descriptions Continued Pin Description 8 R 9 R To connect your Pinnacle Plus power supply to the Pinnacle Remote Active Panel 1 Connect the cable between the REMOTE ACTIVE PANEL connector on the Pinnacle Plus supply and the Pinnacle Remote Active Panel Understanding the Panel CONTROL KEY To control your Pinnacle Plus supply from the panel select local mode by pressing the CONTROL key on th
193. es the joule feature To enable joule mode 1 Press PROCESS gt CONTROL gt JOULES gt ENABLE 2 Rotate the MODIFY knob to select YES or NO to enable or disable joule mode 3 Press ENTER to accept and exit SETTING THE JOULE SET POINT To program the number of joules you want to be delivered joule set point 1 Press PROCESS CONTROL JOULES SETPT 2 Rotate the MODIFY knob to select a value between 0 and 9 999 999 joules in 1 joule increments If you are rotating the MODIFY knob slowly press the appropriate soft key to indicate how quickly you want the display to increment the value x 1000 x100 x10 or xl Note If you turn the MODIFY knob quickly the counts per click setting takes effect 3 Press ENTER to accept and exit SETTING THE JOULE THRESHOLD PROCESS gt CONTROL gt JOULES THRESHOLD This option allows you to set a level of output that must be met or exceeded before Joule calculation begins You can use this feature to improve the accuracy for processes that have long ignition times To set the joule threshold type 1 Press PROCESS gt CONTROL JOULES gt THRESHOLD TYPE 57000097 00B Communication Interfaces 4 155 Advanced Energy 2 3 Rotate the MODIFY knob to select POWER CURRENT or VOLTAGE Press ENTER to accept and exit Note If you select power or current the joule counter counts when power or current which ever you selected is above the thr
194. eshold and stops when this value drops below the threshold If you select voltage the joule counter counts while voltage is below the threshold and stops when voltage exceeds this limit The Joule energy calculation begins after n mS regardless of the output level The time value n mS is set in the configuration and cannot be changed If the output level meets the joule energy threshold prior to the time expiration the joule energy calculation will begin To set the joule threshold level 1 2 Press PROCESS gt CONTROL gt JOULES gt THRESHOLD gt LEVEL If you have selected power as your joule counter threshold type then rotate the MODIFY knob to select a value between 10 W and maximum unit power divided by 8 Note Value is in decawatts if unit is part of a master slave system If you have selected current as your joule counter threshold type then rotate the MODIFY knob to select a value between 0 and the maximum current set point for your unit If you have selected voltage as your joule counter threshold type then rotate the MODIFY knob to select a value between 0 and 650 V Press ENTER to accept and exit Setting the Ramp Use this option to ramp the output to a process set point This option allows you to enable the feature set a ramp start set point percentage and set a ramp time The ramp time is set in 10 ms increments The minimum ramp time is 0 05 s The maximum ramp time is 600 00 s No
195. et 1 kW send a value of 100 Read back this value with command 157 5 CSR codes 0 1 2 4 9 13 target enable Enables or disables the target life counter Send 1 data byte 8 bit value e 0 Inactive e Non zero value Target life is active Read back this value with command 163 1 CSR codes 0 1 2 9 4 178 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 14 Chooses the mode of control for the Pinnacle 1 CSR codes Plus supply 0 2 5 9 12 control mode Send 1 data byte e 2 Serial Host port 4 User port e 6 Active control panel Read back this value with command 155 15 Enables or disables the ramp feature 1 CSR codes 0 1 2 9 19 ramp enable Send 1 data byte 8 bit value 0 Disable Non zero Enable Read back this value with command 163 16 Sets the ramp time in 10 ms increments Range 2 CSR codes is 50 ms to 600 00 s 0 1 4 9 ramp time Send a 2 byte value between 5 and 60 000 Two decimal places are implied To get 1 s send a value of 100 Note If your unit has 100 ms ramp feature enabled one decimal is implied The range is 0 5 s to 6000 0 s Read back this value with command 158 57000097 00B Communication Interfaces 4 179 Advanced Energy Table 4 48 AE Bus
196. et the unit address MAC ID PIN DESCRIPTIONS This table lists the pin numbers and DeviceNet pin names See the DeviceNet Specification revision 2 0 for definitions of these pin names Table 4 19 DeviceNet Pin Descriptions Pin Number Pin Name 1 Drain 2 V 3 V 4 CAN H 5 CAN L 4 54 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply ROTARY SWITCHES BAUD RATE AND ADDRESSING The DeviceNet interface features three rotary switches located on the rear of the Pinnacle Plus unit which are read each time the DeviceNet interface powers up see Figure 4 12 Use the DATA RATE switch to select a baud rate 125 250 or 500 kbaud A switch setting in the PGM region lets you configure the baud rate via DeviceNet Note If your Pinnacle Plus unit is a dual output unit and if it has two DeviceNet cards one for each side it is important that you set the DATA RATE for both sides to the same setting as the DeviceNet network setting Any card not set to the network setting will fault when the network boots up PGM NET i a STATUS Ll X2 M AE gt j li NODE ADDRESS DATA RATE CUSTOM USER PORT 1170 Figure 4 12 DeviceNet rotary switches and LEDs Use the NODE ADDRESS rotary switches MSD and LSD to select the unit s address MAC ID MAC IDs 0 through 63 are valid Use the MSD switch to select the MAC ID s most significant digit use the LSD switc
197. eter or direct the power supply to perform a specific function The Pinnacle Plus supply responds to these commands with a CSR code see Understanding Command Status Response CSR Codes on page 4 170 The codes returned in response to each of these commands is listed in the rightmost column of the table Commands 128 through 255 request a value to be read from the Pinnacle Plus supply The number of data bytes contained in the return packet is listed in the rightmost column ofthe table Some of these commands may return CSR codes those codes are listed in the same column Table 4 48 AE Bus Commands Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 0 Null command 0 CSR Codes 0 9 null off 1 Sets DC output off this request is always 0 CSR Codes honored regardless of which interface has 0 9 DC off control 4 172 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 2 Sets DC output on host control mode must be 0 CSR Codes selected see command 14 0 1 2 7 9 16 DC on 17 31 Read back the status of the last output on event with command 161 3 Sets the method of output regulation power 1 CSR Codes current or voltage 0 1 2 5 regulation 9 29 cra Send data byt
198. f this manual for more information SETTING THE VOLTAGE THRESHOLD SUPPLY PULSE gt VTHRS Note This feature is only available if your Pinnacle Plus unit was configured at the factory to have the voltage ignition option To set the voltage threshold for pulsing 1 Press SUPPLY PULSE gt VTHRS 2 Rotate the MODIFY knob to set the appropriate voltage The selectable voltage range is from 325 V to 50 V less than the maximum user voltage For example if the maximum allowable voltage is 650 V the maximum threshold set point is 600 V For more information about the pulsing behavior when using voltage see Pulsing Behavior When Using Voltage on page 5 32 Setting the Program Source SUPPLY PGM_SRC The program source PGM_SRC feature specifies for each control mode the program source for regulation mode and set point information For each control mode if the program source is set to internal INT the Pinnacle Plus supply uses the information for output regulation mode and set point that has been established through the active front panel the Pinnacle Remote Active Panel or the standard serial port If the program source is set to external EXT the Pinnacle Plus supply uses the set point and output regulation mode that has been established through the pins on the User port 57000097 00B Communication Interfaces 4 141 Advanced Energy To select the desired source and type 1 Press SUPPLY g
199. feature specifies the number of high speed counts per click for the MODIFY knob The value you enter is a multiplier for each click of the knob when you turn the knob quickly When you turn the knob slowly the multiplier does not take effect Valid entries are 1 to 40 If you want a displayed value to change slowly as you turn the knob set the number of counts per click to 1 If you want the value to change quickly set the number of counts to 40 To change the number of counts per click 1 Press SUPPLY PANEL gt CLICKS 2 Rotate the MODIFY knob to set the number of counts per click 3 Press ENTER to accept and exit USING PROCESS FUNCTIONS Use this option to access parameters that control limit or monitor your process The menu options are MONITOR monitor your process LIMITS set limits ARC set arc parameters e CONTROL set process control parameters Monitoring Your Process PROCESS MONITOR This menu allows you to monitor elements of your process such as the life of your target how long the process is running out of set point or whether the process voltage drops below its threshold Note In all cases the voltage and current are measured at the DC inverter output See Figure 2 1 on page 2 2 VIEWING THE OVER VOLTAGE DENSITY PROCESS MONITOR gt OVER_V Use this menu to view the density of unit over voltage responses per run a response is an action taken by the Pinnacle Plus supply to mini
200. first follow all troubleshooting procedures If after following these procedures you still have a problem or if the procedure instructs you to contact AE Global Services and discuss the problem with a representative Be prepared to give them the model number and serial number of the unit as well as the reason for the proposed return This consultation call will allow Global Services to determine if the unit must actually be returned for the problem to be corrected Such technical consultation is always available at no charge 57000097 00B Troubleshooting and Global Services 6 27 Advanced Energy 6 28 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply A active front panel See control panel addressing AE bus 4 161 DeviceNet 4 55 AE bus checksum 4 168 communication mode 4 165 communications transaction example 4 172 connector 4 159 data bytes 4 167 DIP switch 4 161 isolated cards 4 159 message packet 4 166 setting addresses 4 161 setting baud rates 4 165 setting network address 4 164 setting timeout 4 139 timeout period 4 160 AE bus commands 4 172 AE bus host 4 159 AE Bus port pin descriptions 4 159 AE bus port transmission parameters 4 160 air cooling requirements 5 2 analog signals 4 3 4 18 4 41 User port 4 26 arc count limit setting 4 150 arc density viewing 4 150 arc handling overview 5 37 using 5 37 arc handling enabling 4 151 ARC LED 4 127 arc suppression fe
201. for it and not for another unit in the network At this time the Pinnacle Plus unit also analyzes the checksum to verify that the message was received correctly If the address does not match the Pinnacle Plus unit does not respond to the host the Pinnacle Plus unit resets and resumes waiting for a message addressed to it If the address is correct but the exclusive or sum of the bytes in the packet including the checksum is not zero the Pinnacle Plus unit sends a NAK negative acknowledgment hex code 15h to the host If the address matches and the message is intact the Pinnacle Plus unit sends an ACK acknowledgment hex code 06h to the host 57000097 00B Communication Interfaces 4 169 Advanced Energy If the Pinnacle Plus unit receives a request for data or status information it gathers and sends the requested information Otherwise it evaluates the incoming command and sends a message packet that contains a 1 byte data value CSR code to the host see Understanding Command Status Response CSR Codes on page 4 170 CSR code 0 is sent when the command has been accepted If the host receives a NAK from the Pinnacle Plus unit the host either re transmits the packet or does whatever else it has been programmed to do in this situation If the host receives an ACK it waits for the requested data or status information or for the CSR code telling it whether or not the new parameter was accepted If the host recei
202. functions changing 4 146 target life counter User port 4 15 4 23 targets selection 4 37 termination procedure 4 73 theory of operation 2 2 functional diagram 2 2 timeout setting 4 139 setting for AE bus 4 160 timer watchdog 4 74 transmission parameters AE bus 4 160 standard serial port 4 158 transmission rates PROFIBUS 4 76 troubleshooting checking software revision 4 138 checking your ROM 4 138 checks if output does not turn on 6 9 checks with the unit on 6 2 clearing master slave faults 5 39 contacting customer support 6 26 debugging 4 136 help codes 6 9 LEDs 6 7 passive front panel help codes 6 7 two line display 4 129 type files PROFIBUS 4 73 U UHF output connector 5 20 interlock 5 21 military spec number 5 20 unit icons and symbols used 1 3 unpacking 5 5 unpacking 5 5 upload packet PROFIBUS specific 4 77 refresh rates 4 80 upload status bytes 4 79 profibus upload status bytes 4 78 user manual symbols and icons used 1 2 User port 4 2 4 16 4 24 4 36 4 39 cathode switch 4 15 connecting 5 9 connector 4 17 4 26 EMI 4 36 installation 4 3 4 36 4 40 pin description table 4 5 4 19 4 27 pin descriptions 4 37 4 42 rear panel switch description 4 26 rear panel switch settings 4 33 regulation mode 4 16 4 24 4 49 signals 4 3 4 18 4 26 4 37 4 41 target life counter 4 15 4 23 vi Index 57000097 00B Pinnacle Plus 10 kW Power Supply target selection 4 37 see also DeviceNet V viewin
203. g arc density 4 150 voltage arc trip level 5 37 voltage arc trip level setting 4 149 VOLTAGE switch 4 129 W watch dog timer disabling 4 74 watchdog timer 4 74 work around command sequences 4 75 57000097 00B Index vii Advanced Energy viii Index 57000097 00B
204. g in multiple cathode applications Additionally the Sync Pulse feature 57000097 00B Installation and Operation 5 25 Advanced Energy offers a broadcast mode in which a unit transmits hard arc detection signals to other units The units receiving the hard arc signal will control its output in sync with all other units receiving the signal Note The synchronized pulsing function is only available on units specially configured for Sync Pulse operation at the factory The Sync Pulse feature may be available even if your unit is not configured with a master slave Host card CONFIGURING FOR SYNC PULSE OPERATION To Configure a Unit for Sync Pulse Transmit or Receive 1 Using the soft keys on the Active Front Panel or Remote Active Panel of a power supply select SUPPLY PULSE TX RX 2 Set the unit to TRANSMITTER or RECEIVER Note Ina Sync Pulse configuration you must set one power supply to transmit and set all other units to receive 3 Repeat steps 2 and 3 for the rest of the units Note You cannot hot plug units for synchronized pulsing operation To Enable Disable Broadcast Hard Arc Detection You can disable the broadcast hard arc detection feature from the active front panel or from a remote active panel of a power supply by using the Process menu Press SUPPLY PULSE B CAST SYNC PULSE CONFIGURATION EXAMPLES You can configure your power supplies as a simple Sync Pulse system or as a Sync Pulse
205. gulated output parameter over 20 C to 40 C ambient temperature range Output Ripple Voltage The component of output voltage ripple as related 360 Hz 300 Hz to input line frequency is less than 2 rms Accuracy of All Analog 1 of the actual value V kW or A or 0 2 of Signals the full scale value whichever is greater Power Factor gt 0 95 for 10 kW Standard Output Range 10 kW over the 325 to 800 Vdc range in DC full power mode with a maximum current of 30 8 A Note Output is measured at the DC inverter output Figure 2 1 on page 2 2 Note Do not use an output cable longer than 32 8 feet 10 m Usable Output Range See Figure 3 4 on page 3 17 Impedance Range See Figure 3 5 on page 3 17 Accuracy of User defined Limits Current 0 to 5 over the limit from 10 to 100 of full rated output Voltage 0 to 5 over the limit from 10 to 100 of full rated output Power 0 to 10 over the limit from 2 kW to 10 kW 57000097 00B Product Specifications 3 7 Advanced Energy Table 3 3 Electrical Specifications Continued Description Specification Ignition Capability Ignition cycle runs at 1350 VDC for 100 ms then at the user selected maximum output voltage limit for 900 ms Analog Interface Scaling Depending on the choice and configuration of your User port the analog input and output signals are either 0 to 5 V or 0 to 10 V full scale If your suppl
206. guration example 0 005 5 25 Figure 5 15 Sync Pulse system kk kk kk KK KK KK KK eee 5 27 Figure 5 16 Sync Pulse master slave configuration 0 ce eee eee 5 28 Figure 5 17 Rear view cc kk kk kk kk kK kK KK KK Beene bet eee KOK KK KK KK KK KK Ke 5 29 Figure 5 18 Pulsing begins after a 300 ms filter time if below threshold 5 33 Figure 5 19 Ignition cycle if unit remains above threshold 5 33 Figure 5 20 Pulsing behavior when using voltage threshold 5 34 Figure 6 1 Equipment setup for Pinnacle Plus basic functionality test 6 5 xvi List of Figures 57000097 00B Pinnacle Plus 10 kW Power Supply List of Tables Table 3 1 Functional Specifications kk kk kk kK KK KK KK KK eee 3 1 Table 3 2 Physical Specifications lk kk kK KK KK KK eee 3 3 Table 3 3 Electrical Specifications kk kk kk kK kK KK KK KK KK KK KK KK KK KK k 3 6 Table 3 4 Reverse Time Given a Self Run Frequency hk RR RR KK KK 3 9 Table 3 5 Reverse Time as a Function of Voltage Limit V Limit 3 13 Table 3 6 Climatic Specifications per EN50178 KK KK KK RR RR eee 3 18 Table 3 7 Environmental standard specifications 00000005 3 18 Table 3 8 Coolant Specifications kk kk kk kk KK KK KK KK KK KK KI KIR KK KK KK k 3 19 Table 4 1 Identifying the User port kK KK KK KK KK KK KK K KK
207. h arc handling parameters for normal process runs In addition the PROCESS menu lets you view arc density statistics SETTING THE MICRO ARC TRIP LEVEL PROCESS ARC MORE gt LEVEL This function lets you set the micro arc trip level that is the output voltage level as measured at the output of the unit at which the unit determines an arc is occurring If the voltage level is changing below the specified trip level the Pinnacle Plus supply reacts by shutting down the output 57000097 00B Communication Interfaces 4 149 Advanced Energy To set the arc trip level 1 PROCESS gt ARC gt MORE gt LEVEL 2 Rotate the MODIFY knob to select a micro arc trip level 3 Press ENTER to accept and exit SETTING THE ARC COUNT LIMIT PROCESS gt ARC gt COUNT This function lets you set a maximum limit of hard arcs that can occur during a run If the limit is exceeded the ARCLIM message appears in the warning field of the display and the ARC LED lights and the 4RC_D digital output line on the user card is toggled low for a predetermined time when output power is shut off if applicable To set the hard arc count limit 1 Press PROCESS ARC gt COUNT 2 Rotate the MODIFY knob to select a hard arc count limit Note To enable the arc count limit feature you must enter a value greater than 0 If you set the limit to 0 the ARC LED lights for a predetermined time each time a hard arc is seen
208. h to select the MAC ID s least significant digit Switch settings greater than 63 or in the PGM region of the MSD switch let you configure the MAC ID via DeviceNet Note If your Pinnacle Plus unit is a dual output unit and if it has DeviceNet cards one for each side it is important that you set the NODE ADDRESS of the first card to a different setting than the NODE ADDRESS of the second card If you do not one side will fault when the network boots up Operation You may operate your Pinnacle Plus unit either through the 15 pin User port user control mode or through the DeviceNet port host control mode To operate your Pinnacle Plus unit through the DeviceNet port you must also close the interlock on User port pins 11 and 12 For best results during DeviceNet operation do not create a connection between pins 4 and 9 on the 15 pin User port Closing and opening a connection between these two pins overrides output on and off signals from DeviceNet When the Pinnacle Plus unit powers up it defaults to user control mode Engaging DeviceNet places the unit in host control mode and power regulation mode 57000097 00B Communication Interfaces 4 55 Advanced Energy Before operating your Pinnacle Plus unit through the DeviceNet port ensure that your system controls the interlock on User port pins 11 and 12 as well as with the DeviceNet port But ensure that no connection exists between pins 4 and 9 on the User po
209. he Header field contain a value of 7 Under those circumstances the Optional field contains a value only when the length bits in the Header field contain a value of 7 A value of 7 indicates that the Data field contains more than 6 bytes of data Under those circumstances the Optional field contains a one byte value between 0 and 255 indicating the number of data bytes DATA DATA BYTES The Data field can contain from 0 to 255 bytes of binary data which are interpreted in various ways depending on the value that appears in the Command field The Data field typically contains data or a CSR see Creating an Ideal AE Bus Communications Transaction on page 4 168 depending on what was requested Since some commands do not require data sometimes the Data field is not present 57000097 00B Communication Interfaces 4 167 Advanced Energy If the value specified in the length bits of the Header field is 0 to 6 the Pinnacle Plus unit expects 0 to 6 bytes of data However if the value in the Header field is 7 the Pinnacle Plus unit looks for an additional eight bit byte after the Command field the Optional field and uses this value for the data byte count CHECKSUM This one byte field is the last one in the packet The content depends on the value of each of the preceding fields The transmitting unit determines this value by accumulating the XOR exclusive or of all bytes of the packet up to but not including the che
210. he Message structure are based on binary representation of analog voltages Thus they have analog scaling associated with them The scaling for power output is 0 to 10 V where 10 V the full rated output power capability of the Pinnacle Plus power system master and slave units The read back is limited to 10 V OxOFFF even in those cases where output may temporarily exceed the maximum output capability of the power system The scaling for voltage output is 0 to 10 V Depending on the DeviceNet configuration 10 V equals 1000 V or the maximum output voltage capability of the unit The read back is limited to 10 V OxOFFF even in those cases where output may temporarily exceed 1000 V or the maximum output voltage capability The scaling for current output is 0 to 10 V Depending on the DeviceNet configuration 10 V equals the maximum output current capability of the unit or the maximum output current capability of the transducers The read back is limited to 10 V OxOFFF even in those cases where output may temporarily exceed the maximum output current capability 4 62 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply EXPLICIT MESSAGING The DeviceNet interface provides a vendor specific Application Object so that you can receive information about the power system parameters Depending on the DeviceNet configuration you must use Class Code 100 0x64 Instance 1 attributes to send the explicit mes
211. he Pinnacle Plus unit runs at set point for the specified step Note To enable this function set the number of steps to 1 2 3 4 5 6 7 or 8 To disable this function set the number of steps to 0 To set the recipe type 1 From the RECIPE menu options press TYPE 2 A screen displays TYPE Rotate the MODIFY knob to show TIMED JOULE CONTINOUS or JOULE DISCRETE 3 Press ENTER to save your selection To set the number of recipe steps 1 Press PROCESS CONTROL RECIPE 2 Rotate the MODIFY knob to select a value from 1 through 8 3 Press ENTER The display progresses to a series of screens Screen content depends on the recipe TYPE you set Ifyou set TIME the screens allow you to set ramp time set point and run timer for each step Ifyou set JOULE CONTINUOUS or JOULE DISCRETE the screen allows you to set the number of joules and a set point To set the ramp time set point and run timer value for each step 1 If you set the TYPE as TIME after you have set the number of recipe steps a screen that requests a RAMP TIME value displays 2 Rotate the MODIFY knob to select a value from 0 to 600 s in 0 01 s increments 3 Press ENTER the display progresses to a screen requesting a SETPOINT value 4 Set the set point a Choose the regulation mode by using the REGULATION key to toggle between power current and voltage b Use the MODIFY knob to select a value between 0 and the full rated output of
212. he voltage level at 0 1 which the unit indicates an arc is occurring For request a list of the voltage levels indicated by the voltage arc index values see command 10 text The trip level returning packet contains 1 data byte indicating the trip level index This value is set with command 10 172 Requests how many joules remain during a 0 4 run the returning packet contains 4 data bytes request 32 bit value indicating the number of joules joules remaining 4 206 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 173 Requests the joules set point the returning 0 4 packet contains 4 data bytes 32 bit value request indicating the set point level in joules joules set i point This value is set with command 4 174 Requests the over voltage timer value the 0 2 returning packet contains 2 data bytes 16 bit request over value indicating the value voltage timer i i value This value is set with command 34 175 Requests how much time has elapsed since 0 3 output power was turned on the returning request time packet contains 3 data bytes output on i First byte Number of hours Second byte Number of minutes Third byte Number of seconds 178 Requests the hard arc count limit the returning 0 4 packet conta
213. hese status bits for units with a standard configuration Table 4 33 defines the status bits for units configured to run joule recipes In general if the bit is set 1 the condition is true 57000097 00B Communication Interfaces 4 77 Advanced Energy Table 4 32 Upload Status Bytes First Status Byte 0 Control mode with bit 9 1 Control mode 00 User 01 Local 10 PROFIBUS 2 Set point status OK 3 Unused 4 End of Target Life EOTL 5 Active toggle bit 6 Bus fault high or low 7 Inverter low Second Status Byte 0 Fault active 1 fault exists 1 Overtemperature condition 2 Interlock mechanism open 3 Momentary power failure 4 Joule mode enabled 5 Contactor open 6 Joules reached 7 Output is on 4 78 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 33 Upload status bytes joule recipe configuration Status Byte Status Bit Definitions Byte 0 Bit 0 Plasma ignited see explanation below for more information e Bits 1 2 and 3 Joule recipe active step read the binary bit pattern and interpret as follows 000b step 1 while the recipe step is running 001b step 2 while the recipe step is running 010b step 3 while the recipe step is running gt 011b step 4 while the recipe step is running 100b step 5 while the recipe step is running gt 101b step 6 while the recip
214. ill stay on in seconds if this feature is enabled If the length of time since the last output on event exceeds this setting the unit will turn output off The timer is reset at each output on event You can set a time in whole seconds from 0 to 65535 A value of zero disables this feature Not all units have this feature available Returns 2 data bytes 16 bit value indicating the timer value in seconds This value is set with command 87 4 120 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Example Command Sequences The following examples describe how specific values for selected parameters appear in the download outbyte packet from the PROFIBUS master to the Pinnacle Plus power supply See Download Packet on page 4 76 for more information Additionally the examples if executed in order presented are a recommended startup sequence for users of the PROFIBUS interface Note Entries are given as hex numbers with decimal equivalents in parenthesis immediately after EXAMPLE 1 Change control mode to HOST Note PROFIBUS commands 2 through 128 are only accepted if the control mode is HOST Thus at startup it is good to force the unit to HOST control mode e Byte 0 Eh 14 e Byte 1 02h 2 HOST control mode e Byte 2 not applicable values are ignored e Byte 3 n a EXAMPLE 2 Explicit clear reset clears any pre existing faults that may be pres
215. ime in seconds Or if joule recipe is enabled returns 4 data bytes 32 bit value indicating the joule set point With timed recipes two decimal places are implied For example a value of 5 would indicate 0 05 s This value is set with command 23 Command Description Number Number of Sent of Data Response Bytes Data Bytes 181 Requests the amount of ramp time you have 1 2 set for a specific recipe step M request recipe d ME U eine en Send 1 data byte 8 bit value indicating the CSR code 4 recipe step The returning packet contains 2 data bytes 16 bit value indicating the time in seconds Two decimal places are implied For example a value of 5 would indicate 0 05 s This value is set with command 21 182 Requests the set point level you have set for a 1 3 specific recipe step M a request recipe Saa bia point kes Send 1 data byte 8 bit value indicating the CSR code 4 imode The returning packet contains 3 data bytes First and second bytes Value of set point in the mode indicated e Third byte Regulation mode e 6 Power e 7 Voltage e 8 Current This value is set with command 22 183 Requests the run time you set for a specific 1 2 or 4 recipe step or if joule recipe is enabled this request recipe command requests the joule set point May return CSR code 4 4 114 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 25
216. in Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 32 9 REF A analog This signal provides an output accurate 5 V or 10 V reference 10 V at 10 mV The P2 jumper controls the level of this pin s reference signal To set the reference to 10 V place the jumper across pins and 2 To reference to 5 V place the jumper across pins 2 and 3 33 nla unassigned n a n a 34 36 TARGET2 D digital This signal is used with input TARGETO D pin 4 and TARGETI D pin 35 to select the active target life counter See Setting the Active Target Life Counter on page 4 15 for more information 35 36 TARGETI D digital This signal is used with input TARGETO D pin 4 and TARGET2 D pin 34 to select the active target life counter See Setting the Active Target Life Counter on page 4 15 for more information 57000097 00B Communication Interfaces 4 13 Advanced Energy Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Continued Signal Pin 36 Return Pin n a Pin Name INCOM D Signal Type n a Description Dedicated return for digital inputs Pins 4 5 6 7 14 34 and 35 should be referenced to this pin 37 n a OUTCOM D Dedicated return for digital outputs Pins 1 2 3 20 21 and 22 should be referenced to this pin USER PORT OUTPUT ENABLE DISABLE BEHAVIOR AND SIGN
217. in Descriptions Continued Signal Pin Return Pin Pin Name Signal Type Description 4 9 OUTPUT ENABLE D Input This signal is used to turn on output power from the 15 pin User port Closure between OUTPUT ENABLE D and OUT ENABLE COM D pin 9 will turn on output power XPROG A Input This signal is the 0 to 10 V analog set point input which is sent through the custom CMR buffer 1 to 10 V 0 to full scale for each regulation mode n a COM A n a This signal is used as a remote ground VOUT A pin 2 POUTA pin 3 and XPROGA pin 5 should be referenced to this pin PWRON D digital output When output power is enabled a contact closure between pin 7 and pin 8 occurs Use 0 5 A maximum for this readback n a PWRON COM D n a This signal is the return for pin 7 n a OUT ENABLE COM D n a This signal is the return reference for SETPOINT D OUTPUT ENABLE D and OUTPUT D pins 1 4 and 13 10 n a MOD GREEN Output This pin is the emitter side of an opto coupler for MOD LED 11 INTERLOCK D Input This digital signal provides a safety interlock Closure between pins 11 and 12 enables the ac input power contactor 12 INTLK COM D This signal is the return reference for the interlock signal on pin 11 4 38 Communication Interfaces 57000097 00B Pinnacle Plus
218. ing 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 A CAUTION This equipment is intended for use with a single source of three phase power with all phases vectored at 120 angles 5 If the equipment is used with an uninterruptable power supply UPS or other type of power conditioner the user is responsible to guarantee the safety and EMC performance of the entire system Unpacking the Unit Unpack and inspect the unit carefully looking for obvious physical damage If no damage is apparent proceed with the unit installation and setup If you do see signs of shipping damage contact Advanced Energy Industries Inc and the carrier immediately Save the shipping container for submitting necessary claims to the carrier INSTALLING THE UNIT The following sections explain how to install the unit 57000097 00B Installation and Operation 5 5 Advanced Energy e Grounding on page 5 6 Connecting the Contactor Intlk Port on page 5 7 e Connecting a Remote Passive Panel on page 5 8 e Connecting a Pinnacle Remote Active Panel on page 5 8 e Connecting to the Standard Serial Port on page 5 8 Connecting for Serial Host Port Control on page 5 8 Connecting for DeviceNet Control on page 5 9 Connect
219. ing for User Port Control on page 5 9 Connecting Input Power on page 5 9 e Connecting Output Power on page 5 10 Connecting for Master Slave Operation on page 5 21 Connecting for Sync Pulse Operation on page 5 25 Grounding WARNING Before making any other connection you must connect the secondary Protective Earth ground stud to the system ground terminal This connection is a mandatory connection The rear panel of the Pinnacle Plus power supply features two Protective Earth ground studs and one equi potential ground stud two M5 studs and a 10 32 stud These are indicated on the rear panel by a ground symbol See Rear view on page 5 29 You must ground the power supply as specified by the conditions of use See Conditions of Use on page 1 7 for more information Note For optimal performance ground the equi potential ground stud to the system ground If connecting a master slave system see Connecting for Master Slave Operation on page 5 21 for the optimal grounding connection of the master and slave units 5 6 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Connecting the Contactor Intlk Port A DANGER RISK OF DEATH OR BODILY INJURY Disconnect and lockout tagout all sources of input power before working on this unit or anything connected to it A CAUTION Turn off power to the system before connecting a cable to
220. ing keys to turn output power on and off Table 4 39 Output Power Keys ON Turns on output power if the control panel has control of the on off function and all interlock conditions are satisfied OFF Turns off output power no matter which interface is currently controlling the unit Control Key To control your Pinnacle Plus supply from the panel select local mode by pressing the CONTROL key on the panel until the Local LED lights Placing the unit in local mode gives you full access to the front panel menu 4 128 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply To control the Pinnacle Plus supply from a serial interface or the DeviceNet port press the CONTROL key until the Host LED lights To control the Pinnacle Plus supply from the User port press the CONTROL key until the User LED lights When the Pinnacle Plus unit is in host or user control mode you can view all the menu items but you cannot modify parameters or lock the display Note You can not change control modes while output power is energized on Table 4 40 Control Key LEDs LOCAL Specifies that control of the Pinnacle Plus power supply has been assigned to the control panel HOST Specifies that control of the Pinnacle Plus power supply has been assigned to a serial interface that is Host port DeviceNet port or standard serial port USER Specifies that control of the Pinnacle Plus po
221. innacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 84 redefine PROFIBUS status bits Redefines the PROFIBUS status bits Send 1 data byte e 0 Normal format e Non zero Joule recipe definition Read back this setting with command 163 CSR only 85 change configuration option bit Changes the configuration option bit Requires 2 data bytes 1st data byte Bit setting e 0 Clear bit Non zero Set bit 2nd data byte Configuration option bit number valid entries 0 31 e 7 RAMP RESOLUTION bit clear 10ms ramp resolution bit set 100ms ramp resolution 8 JOULE RECIPE STATUS bit clear Normal PROFIBUS status bytes bit set Joule recipe definition PROFIBUS status bytes e 18 USER PORT EOTL DEFINED AS READY SIGNAL bit clear User Port EOTL defined as EOTL bit set User Port EOTL defined as Ready Signal e 19 HIGH SPEED AEBUS bit clear Standard AE Bus baud rates bit set High Speed AE Bus baud rates e 25 EXPLICIT FAULT CLEARING bit clear enables OFF or reset command clears faults bit set disables requires power cycle to recover from fault CSR only 57000097 00B Communication Interfaces 4 99 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number of Sen
222. ins 4 data bytes a 32 bit value request hard indicating the limit arc count limit This value is set with command 9 57000097 00B Communication Interfaces 4 207 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 179 request active recipe step ramp run status and ramp run time remaining Requests the active recipe step number the ramp run status and the ramp run time remaining the returning packet contains 4 or 6 data bytes depending on the recipe type First byte Active recipe step number Second byte Ramp run or recipe type status 1 ramp 2 run 4 continuous recipe 5 discrete recipe e Third and fourth bytes Ramp run time remaining in tens of milliseconds or 0 if a ramp or recipe has run to completion if timed recipe is running OR Third fourth fifth and sixth bytes Joules remaining if discrete or continuous joule recipe is running Note If output is shut off either through a fault or an off command the active recipe step number ramp run status and ramp run time remaining will all maintain their last value A subsequent off command will set recipe step number to 1 or 0 if recipes are not active and set ramp run time remaining to 65535 if the time is nonzero If the run segment of the last recipe step is 0 ramp run time remaining is set to 655
223. is seen before the last pulse is complete the pulse width will be refreshed to the full width These conditions will also be indicated through the ARC LED on a Passive Display Panel 22 37 EOTL D output This signal goes high when the active target life counter reaches zero thus indicating that target life has ended 57000097 00B Communication Interfaces 4 21 Advanced Energy Table 4 7 Single 24 V 37 pin User Port Pin Description Continued Signal Return Name Signal Description Pin Pin Type 23 9 VOUT A output This signal represents output voltage Full scale 10V represents 1500 V output voltage 24 9 POUT A output This signal represents output power Full scale 10 V represents the maximum output of the supply see the Specifications chapter of this manual for information specific to your unit 25 9 IOUT A output This signal represents output current e 5kW units Full scale 10V represents 20 A output current 10kW units Full scale 10V represents 40 A output current Master Slave systems 40 A x number of units Total output current 26 n a unassigned n a n a 27 10 LEVELIN A input This signal programs the output level Full scale 10 V represents the rating of the supply see the Specifications chapter of this manual for more information 28 n a unassigned n a n a 29 n a unassign
224. ital outputs are as follows e Logical 0 3 V maximum with 1 0 mA maximum leakage e Logical 1 Vpos less 1 5 V minimum Vpos refers to the 24 V supply output current may range from 0 5 mA to 0 5 A The signal levels for digital inputs are as follows e Logical 0 30 V to 5 V with 0 5 mA maximum leakage e Logical 1 13 V to 30 V and 8 5 mA typical All digital input lines incorporate a low pass filter that rejects signals less than 10 ms Pin Descriptions The following table list the pin descriptions for the User port Table 4 7 Single 24 V 37 pin User Port Pin Description Signal Return Name Signal Description Pin Pin Type 1 37 CS1 D output This signal along with pin 20 CS2 D tells an external device such as a cathode switch box which of the Pinnacle Plus supply s target life counters is active See Table 4 9 on page 4 23 for a list of signal conditions relative to target life counters 2 37 OUTPUT D output When high this signal indicates that the contactor is closed and output power is on 3 37 SETPOINT D output When high this signal indicates that the output is equal to the requested set point 4 36 TARGETO D input This signal is used with TARGETI D pin 35 and TARGET2 D pin 34 to select the active target life counter Table 4 9 on page 4 23 for a list of the signal conditions for each target selection 57000097 00B Communication Interfa
225. ith command 163 65 Enables pulsing at the current threshold 1 CSR codes default setting always or use voltage 0 1 2 4 9 ulsin Sae Note Frequency is limited to 150 kHz when mode the pulse mode is set to be enabled always Send one data byte 8 bit value 0 Pulsing enabled at current threshold e Pulsing enabled always e 2 Pulsing enabled using voltage Ifyou choose to set pulsing to use voltage you must also set the voltage threshold for this pulsing function with command 82 For more information about the pulsing modes see Understanding Pulsing Modes on page 5 32 Read back this setting with command 163 57000097 00B Communication Interfaces 4 189 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 66 Enable or disable the hard arc broadcast 1 CSR codes feature 0 1 2 9 enable or disable Send 1 data byte hard arc hah broadcast se e Non zero Enable Read back this setting with command 163 72 Set a joule value to indicate the joule down 2 CSR only near end counter is near expiration joule Ph zer 2 Send 2 data bytes 16 bit value Read back this setting with command 232 73 Resets the joules remaining counter to its initial 0 CSR only joule count value while the output is on reset 74 Enable or disable the joule countdown hold 1 CSR only
226. k a lk kk kk ak ak a ceded kk a kale l l l 4 161 Setting the Pinnacle Plus Unit s AE BUS Address 4 164 Setting Baud Rates and Communication Mode 4 165 AE Bus Communications i kk kk kk kk kK kK kK KK kK KK kK KK kK kk kk kk k 4 166 AE Bus Protocol sa lt sa G k mek Al dn Gel d dr Kid n ok HA Mel c AD di ekl 4 166 Header npaka a oN e EA iE A ee ee 4 167 Command lt 5 x 3 dad ee E baa a EE R An dr d n Eg 4 167 57000097 00B Table of Contents xi Advanced Energy Optional Length Byte 222i de kk kk kk KK KK KK KK KK KK KI KIRI KK K KI KIK IK 4 167 Data Data Bytes i kk kk kk kk kK KK KK eG KK KI nce hearth ns eee 4 167 CHECKSUM A cy sayeca nena xena yak Sekna Seta Kani 2 lb wh ae tae 4 168 Creating an Ideal AE Bus Communications Transaction 4 168 Understanding Command Status Response CSR Codes 4 170 AE Bus Commands Jk kk kk kk kK kk kk KK kK KK KK kK kK kk kk kk kk kk ka 4 172 Chapter 5 Installation and Operation Preparing to Install the Unit 0 kk kK KK KK KK KK KK ees 5 1 Meeting Spacing Requirements 0 0000 cece eee KK KI KK ees 5 1 Cooling Requirements kk kk kk kk kK KK KK KK KK KK KK KK KK KK KK KK KK KK 5 1 Cabinet Design kk kk kk kk kk kK KK KK KK KK KI K KI KK KI K KK KI KI KOK KK KK KK KH 5 2 Installation Requirements kk kk kk kK kK KK KK KK KK KI teens 5 5 Unpacking the
227. k kK KK KK KK KK eee 6 16 Contacting AE Global Services J K kk kK KK KK KK KK KK KK KI KIRI KK KK KK 6 26 Advanced Energy World Headquarters 24 x 7 Technical Support 6 27 Returning Units for Repair Ak kk kk KK KK KK KK KK KI KI K K ees 6 27 57000097 00B 1 xiii Advanced Energy 1 xiv 57000097 00B Pinnacle Plus 10 kW Power Supply Figure 2 1 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure 4 14 Figure 4 15 Figure 4 16 Figure 4 17 Figure 4 18 Figure 4 19 Figure 4 20 Figure 4 21 Figure 4 22 Figure 4 23 Figure 4 24 162 Figure 4 25 Figure 4 26 Figure 4 27 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 5 7 Figure 5 8 List of Figures Pinnacle Plus functional block diagram 00 00 eee K3 2 2 Dimensional drawing 00 0c KK KK KK KK K K K KIR KK es 3 5 Pulse reversal times and self run frequencies XWAR KK 3 9 Pulse reversal time as a function of voltage limit V Limit 3 13 Operating range fcc cece ceed cak hades Rehnaa Rae HERE KK KK KK eS 3 17 Impedance range kk kk kk Oh bee kk be eek be ak a kak ka ak oe a kk aM 3 17 37 pin subminiature D female connector 0 0000 cece eee 4 2 37 pin subminiature D male and
228. k kk kk kk kk kk kK KK KIR KK KK eee 4 70 Module Status LED JJ kk kk kk kk kk KK KK KI KK KI K KI KI KOK KI KOK KK KK KK ka 4 70 Network Status LED Jk kk kk kk kk kK KK KI KI KI KI KK KK KK KI KK KK KK KK ke 4 71 AE PROFIBUS Protocols sa ay Au da rene beans Reb bade Ros dae Kea nd ged 4 72 Type Files GSD Files kk ka kk kk kK kk kk kk ieee OER ERA kk kk ES 4 73 Setting the Pinnacle Plus Unit s Network Address 4 73 Termination 2 kk kk kk kk kk KK kK KK KK KI eens 4 73 Bad Rate sad tintin dade Gad Rahs AD ad d nS le AE n ew dick 06 4 73 Master Reset Command kk kk kk k kK KK KK KK KIR KK eee 4 74 Watch Dog Tim sumas suiii aia la db betsy esd A ado eee eens 4 74 PROFIBUS Specific Errors 0 0 0 00000 eee 4 74 Data Consistency oi xis Ko kk kk tn eM ese WRG he wea boa KK KK K kamen xe 4 75 PROFIBUS Software Commands kk KK KK KK KK KIR KI KK KK KK KK 4 75 Transmission Rates and the Handshake Feature 0 4 76 Download Packet LL lk kk kk kk kk kK kK kK kK KK kk kk kk eee 4 76 Upload Packet s sx 4 koka Alk kal alan ask 41814 4 n 4 dl ay di Ak r kck G L A 8 d allkl 4 77 Status Flag Byles a i deossen reinn ka da etude eee 4 aya dl a d ea 4 77 Output Readback Bytes Bytes 2 Through 7 04 4 80 Response Data Bytes i kk kk kk kK KK KK KI KK KK be KIR KK KK KK KK KK 4 80 Refresh Rates in the Upload Packet WAK KK
229. kW Power Supply See below for more information about the MODIFY knob SOFT KEYS The five unlabeled soft keys directly below the vacuum fluorescent display let you select menu choices Menu choices appear on the second line of the display Since different selections different menu levels are displayed at different times this manual refers to the soft keys by whichever terms are displayed above them For example you are instructed to press the ARC soft key when ARC is the menu choice directly above that particular key See Figure 4 14 on page 4 128 and Figure 4 16 on page 4 132 MODIFY KNOB Use the MODIFY knob to change values and move back through the menus When the display screen shows a flashing value you can change it by turning the MODIFY knob In addition you can use the MODIFY knob to move quickly through the menus Pressing the MODIFY knob once moves you up one level in the menu Pressing it twice quickly moves you all the way out of the menu to the output display screen REGULATION KEY At the top menu level choose one of three methods of output regulation power current or voltage by pressing the REGULATION key until the desired LED lights Note You cannot change regulation modes when output is on ON OFF BUTTONS amp LEDS The ON and OFF keys on the control panel turn on and off the output power The relevant LED lights to indicate output is on or off ARC LED After the output has been turned off this L
230. l Services 57000097 00B Pinnacle Plus 10 kW Power Supply 6 Repeat the previous two steps with the set point set to 25 50 and 100 of full rated output power 7 Change the following settings then repeat the previous three steps Reduce the set point to 10 Change the frequency to 350 kHz gt Change the reverse time to 1 1 ps 8 Turn off the output and set the set point to 0 Passive Front Panel Help Codes When only a Passive Front Panel PFP is available the Pinnacle Plus unit displays 4 character strings on start up to identify personality cards installed in the unit A code flashes once for each card installed The following table describes the strings Table 6 1 Passive Front Panel Help Codes PFP Display String Personality Card P 0 No Cards P 01 or P 17 Dual User Card P 03 or P 26 PROFIBUS Card P 04 Host Protocol Translator Card P 05 or P 21 Single User Card P 18 or P 28 AE Bus Card P 22 or P 29 Master Slave Card with AE Bus P 23 or P 30 DeviceNet Card P 32 Master Slave Card with PROFIBUS Troubleshooting LEDs Use the following information to troubleshoot the unit based on the status of the unit LEDs The table shows whether an LED state indicates normal status or indicates a problem 57000097 00B Troubleshooting and Global Services 6 7 Advanced Energy Table 6 2 Troubleshooting LEDs for LED On Off Status POWER X Nor
231. life is left as the counter decreases When the end of target life is reached the output display screen flashes EOTL and the Pinnacle Plus unit continues running until a normal off command is received Note The Pinnacle Plus unit cannot turn back on until the target life is reset or until the target status is disabled or a new active target is selected Setting Process Limits PROCESS LIMITS This menu lets you control user selectable operating limits for the Pinnacle Plus unit strike voltage and maximum output voltage current and power Some considerations when setting limits are Before entering a maximum output limit consider your system s output impedance and consider how your selected power limits will interact The unit will limit output when output reaches the first applicable limit You cannot set a set point greater than the corresponding limit in that regulation mode e Ifamaster slave card is installed in the unit the system sets the power and current limits to default each time power is cycled SETTING A STRIKE VOLTAGE LIMIT PROCESS LIMITS STRIKE This function lets you set a strike voltage limit 57000097 00B Communication Interfaces 4 147 Advanced Energy To set the strike voltage limit 1 Press PROCESS gt LIMITS gt STRIKE 2 Rotate the MODIFY knob to select a value low medium or high 3 Press ENTER to accept and exit SETTING A MAXIMUM LIMIT FOR OUTPUT VO
232. ling feature returns to enabled Note You can disable micro arc handling if your process allows it You should disable arc handling only if your system includes special post process equipment that provides arc interruption You cannot disable hard arc handling A CAUTION Disabling the unit s arc handling ability without providing external arc interruption could cause severe target damage VOLTAGE ARC V ARC TRIP LEVEL To set the V arc trip level use the ARC menu on an active front panel or the Pinnacle Remote Active Panel or AE Bus PROFIBUS Command 10 See Chapter 4 for more information By setting the voltage arc V arc trip level you are indicating the voltage threshold as measured at the output of the unit at which the Pinnacle Plus power supply recognizes an arc The best value for a voltage arc trip level is somewhere between your process s normal operating voltage and the typical low voltage that occurs when your system experiences a hard arc The latter depends on your target type but typical low voltages for hard arcs are between 10 and 30 V Thus a reasonable voltage arc trip level might be 50 V Note Some target types experience hard arcs at 100 V so do not assume that 50 V is right for all processes The recommeded V arc trip level for low impedance metal targets is the default value of 70 V For sputter applications the V arc trip level should be set above 60 V For bias applications the V arc trip level can b
233. log This signal is used as a remote analog common common VOUT pin 2 POUTA pin 1 and JOUT A pin 3 should be referenced to this pin This pin is switch connectable to COM D for previously wired systems Refer to Table 4 12 on page 4 34 Switch 8 description for more information Note This pin is internally connected to User port pins 5 8 15 and 16 15 COM A Analog This signal is used as a remote analog common common VOUT A pin 2 POUT A pin 1 and JOUT A pin 3 should be referenced to this pin This pin is switch connectable to COM D for previously wired systems Refer to Table 4 12 on page 4 34 Switch 8 description for more information Note This pin is internally connected to User port pins 5 8 14 and 16 16 COM A Analog This signal is used as a remote analog common common VOUT A pin 2 POUT A pin 1 and JOUTA pin 3 should be referenced to this pin This pin is switch connectable to COM D for previously wired systems Refer to Table 4 12 on page 4 34 Switch 8 description for more information Note This pin is internally connected to User port pins 5 8 14 and 15 57000097 00B Communication Interfaces 4 31 Advanced Energy Table 4 11 Single 15 V 25 Pin User Port Pin Description Continued Signal Name Signal Description Pin Type 17 COM D Digital This signal is used as a remote digital common common FLT D pin 9 OUTPUT D pin 10 ON D pin 11 PULSEON
234. lus power supply must be especially configured for master slave operation at the factory and equipped with a master slave Host card interface a Master Slave Pulse port and a Syne Pulse port MASTER SLAVE HOST CARD INTERFACE The master slave Host card is located near the top left side of the unit s rear panel see Figure 5 13 The master slave Host card includes the following ports e A 9 pin female subminiature D serial communications port for external serial control See Chapter 4 Communication Interfaces for more information Two modular ports P1 and P2 for connecting master and slave units with the master slave cable The P1 and P2 molded plug ports connect daisy chain a master unit to a slave unit and a slave unit to another slave unit The master slave Host card also includes a master slave MSTR SLV switch This switch indicates whether the power supply is functioning as a master stand alone or slave unit When you connect your units for master slave operation you must connect 5 22 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply the Master Slave Pulse port between master and slave units in addition to the ports on your Host card interface see Chapter 4 of the Pinnacle Plus power supply user manual for more information P1 P2 Da PORTS Figure 5 13 Master slave Host card interface P1 P2
235. lus supply has experienced a non recoverable explicit clear fault that is a configuration fault or a PROFIBUS error fault We recommend sending this command upon the startup of PROFIBUS communications so that any existing fault indications will be cleared Watch Dog Timer As a safety feature the PROFIBUS maintains a watch dog timer that shuts off the Pinnacle Plus supply s output if the PROFIBUS master stops communicating The watch dog timer maintains a value for time between 10ms and 10 minutes that the Pinnacle Plus supply waits between commands from the master The timer counts down this time in 10 ms increments If your PROFIBUS system does not calculate the watch dog timer value for you or if you want to modify the existing watch dog timer value then you may enter a timer value by using the PROFIBUS Set Prm function call see DIN 19245 PROFIBUS Standard Part III To get the actual wait time value the Pinnacle microprocessor uses the numbers you enter to octet 2 and 3 of the Set_Prm multiplies them together and then multiplies the result by 10 ms Therefore when using the Set_Prm function call calculate the numbers for octet 2 and 3 accordingly Remember the values for octet 2 and 3 must not be equal or be zero Note You can disable the watch dog timer via the PROFIBUS master Note Commands 0 1 and 119 will also turn off the power supply s output PROFIBUS Specific Errors With AE s PROFIBUS interface
236. mal POWER The Pinnacle Plus unit is not receiving AC input power Power the unit off Using all applicable safety precautions inspect your AC input power source to ensure that it is properly connected and that the specified voltage is being applied to the Pinnacle Plus unit If the unit is damaged the internal main fuses may be opened Note These fuses should only be accessed by AE personnel See Returning Units for Repair on page 6 27 for information concerning the return of units for repair OUTPUT Normal OUTPUT The Pinnacle Plus unit is not producing output See Checks if the Output Does Not Turn On on page 6 9 SETPOINT Normal SETPOINT The Pinnacle Plus unit is not operating within set point Note the error code on the display and see Error Code Troubleshooting on page 6 16 INTERLOCK Normal INTERLOCK An interlock fault condition exists Note the error code on the display and see Error Code Troubleshooting on page 6 16 BUS FAULT A bus fault condition exists Note the error code on the display and see Error Code Troubleshooting on page 6 16 BUS FAULT Normal OVERTEMP An over temperature fault condition exists Note the error code on the display and see Error Code Troubleshooting on page 6 16 OVERTEMP Normal 6 8 Troubleshooting and Global Services 57000097 00B Pinnacle Plus
237. may cause the power supply to turn off because of excessive reflected power For Pinnacle Plus 5 kW and 5x5 kW units with UHF connectors we recommend you use RG8U cable For Pinnacle Plus 10 kW units with UHF connectors we recommend you use RG393 cable For two pin pluggable connectors we recommend you use twisted pair cable with an external shield or RG393 for use with PG 11 style strain relief connectors A CAUTION Never use an output power cable longer than 10 m 33 or you may cause damage to your power supply 57000097 00B Installation and Operation 5 11 Advanced Energy TWO TERMINAL MULTICONTACT OUTPUT CONNECTOR ATTENTION Before making your output power connection see Connecting Output Power on page 5 10 for safety information and requirements Strain Relief Fitting The two terminal multi contact output connector for your Pinnacle Plus power supply includes a liquid tight grounded strain relief fitting The fitting is either an M32 style fitting or a PG style fitting that can vary in its dimensions depending on your power supply s configuration Figure 5 3 and Figure 5 4 show the dimensions of the different styles of PG fittings While the dimensions are slightly different all fittings function similarly 1380 Figure 5 3 Actual size of PG 11 style strain relief fitting 28 mm diameter 1381 Figure 5 4 Actual size PG 16 style strain relief fitting 34 mm diameter Note If y
238. me 04 0 4 us 05 0 5 us 06 to 49 follow the same format 50 5 0 us 152 Requests the ramp start set point percentage 0 1 request ramp Returning packet contains 1 data byte 8 bit start set point between 0 and 95 percentage Note This setting only applies to regular ramp mode It does not apply to ramp mode in a timed recipe This value is set with command 32 153 Requests joule mode status the returning 0 1 packet contains byte request joules i status e 0 Inactive e Non zero value Active See also command 163 154 Requests the output regulation mode set by 0 1 command 3 the returning packet contains 1 request data byte 8 bit value regulation mode e 6 Power e 7 Voltage 8 Current See also command 164 155 Requests control mode The returning packet 0 1 contains 1 data byte 8 bit value request control i mode e 2 Serial Host port 4 104 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number Number of Sent of Data Response Bytes Data Bytes 156 Requests an indication of the active target 0 1 The returning packet contains 1 data byte request active indicating target 1 2 3 4 5 6 7 or 8 target number i i This value is set with command 11 157 Requests the amount of target life time 1 4 remaining for the target you specify ii reques
239. mentary power failure e 1 Unassigned 2 Near end joule value setting has been reached e 3 Joule Threshold achieved e 4 Side A inverter low 5 Side B inverter low 6 Unassigned interrupt event e 7 PROFIBUS error Continued on next page 57000097 00B Communication Interfaces 4 201 Advanced Energy Table 4 48 AE Bus Commands Continued continued 3 Fatal fault active 4 Out of set point timer expired 5 Ground fault detected if your Pinnacle Plus supports this feature 6 Short circuit fault active 7 Fatal short circuit active Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 162 4th status byte 0 4 request 0 Hard bus fault process 1 Fault active status 2 Joules reached 4 202 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 163 Requests the system configuration status the 0 4 returning packet contains 4 data bytes request config status 1st status byte e 0 Host program source 0 internal 1 external e 1 Local program source 0 internal 1 external e 2 Analog program source 0 internal 1 external e 3 Master e 4 Slave e 5 Unassigned e 6 Program source 0 internal 1 external e 7 Target life
240. mize over voltage conditions When the unit detects an over voltage condition it triggers an algorithm that controls the user voltage limit in order to minimize and eliminate over voltage events To view the over voltage density 57000097 00B Communication Interfaces 4 143 Advanced Energy 1 Press PROCESS gt MONITOR gt OVER_V Note When you see the counter increment or OV flashing in the top level menu of the output display screen the algorithm is active or has just run For an illustration of the output display screen see Two Line Output Display Screen on page 4 129 RESETTING THE OVER VOLTAGE DENSITY PROCESS MONITOR gt OVER_V gt RESET Use this option to reset the over voltage density counter to zero You can use this feature to characterize a process by recording the over voltage counter over the same time period for every parameter change in the process To use the over voltage counter in this way reset both the counter and the period timing at the start of a parameter change Record the counter at the end of the timed period and repeat To reset the over voltage density counter 1 Press PROCESS MONITOR gt OVER_V gt RESET SETTING THE OVER VOLTAGE TIMER PROCESS gt MONITOR gt OVER_V gt TIMER Use this option to enable and set the over voltage timer This function lets you indicate how long you want the power supply to tolerate an over voltage condition before it sh
241. nd other troubleshooting materials see the Troubleshooting chapter LEDs Table 4 37 Display Panel LEDs POWER ON Lights green when input power is on OUTPUT Lights green if output power is on SETPOINT Lights green if the Pinnacle Plus supply is operating within set point accuracy is within 0 4 of full scale or 2 of set point whichever is greater INTERLOCK Lights green if all interlock conditions have been met BUS FAULT Lights green when a bus fault occurs OVERTEMP Lights green if the Pinnacle Plus supply has exceeded the maximum operating temperature ARC After the output has been turned off this LED lights green for a predetermined time if the hard arc count limit was reached during the previous run You define this limit The ARC LED will be activated under two different conditions 1 Ifthe hard arc count limit is non zero and the number of hard arcs seen exceeded this limit during the last run the pulse will occur when the output is turned off 2 Ifthe hard arc count limit is set to zero this signal will pulse for a predetermined time for every hard arc seen by the unit If another hard arc is seen before the last pulse is complete the pulse width will be refreshed to the full width 4 124 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply ACTIVE FRONT PANEL PINNACLE REMOTE PANEL The Pinnacle Plus supply presents a broad array of featur
242. ndicating the limit in kilowatts The value implies 3 decimal places for a non master slave unit and 2 decimal places for a master slave system This value is set with command 49 Command Description Number Number of Sent of Data Response Bytes Data Bytes 128 Requests the power supply type the returning 0 4 packet contains 4 ASCII characters PLUS request supply type 129 Requests the output capacity of the power 0 5 supply the returning packet contains 5 ASCII request supply characters indicating capacity in kilowatts H The data string implies 3 decimal places for a stand alone unit 10000 10 000 kW and implies 2 decimal places for a master slave system 2000 20 00 kW 130 Requests the maximum voltage and current 0 4 levels The returning packet contains four request data bytes two 16 bit values maximum voltage and e Bytes 0 and 1 Voltage level in volts current e Bytes 2 and 3 Current level in hundredths of amps 136 Requests the output power level that needs to 0 2 be met before the Joule output energy request joule calculation begins threshold This value is set with command 26 The joule threshold type power voltage or current is set with command 64 141 Requests the output power limit 0 2 4 102 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Desc
243. ndition for Overcurrent longer than was set on the overcurrent timer E088 One of the following short 1 Power the unit off and then back on 2 If the error code reappears contact AE Global Services E089 Fatal Short Circuit Fault A fatal short circuit fault occurs when 10 or more short circuit faults have occurred within a 40 second timeframe Cycle AC power to the unit 6 22 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Table 6 4 Error Code Troubleshooting Table Error Code Problem Indicated Suggested Action Message E090 More than one unit is Reconfigure units so only one unit is the configured as atransmitter transmitter Multiple Sync in your sync pulse system Pulse Transmitters Detected E091 Sync pulse receivers are 1 Check the sync pulse cable to ensure No Sync Pulse Transmitter not receiving a transmitter synchronization signal that it is plugged in 2 Reconfigure one unit so that it operates as a sync pulse transmitter Detected E092 No master system is Verify a unit is set as the master unit or detected At least one unit that the link to the master unit has not No Master must be set as the master been broken Detected unit E093 An invalid frequency has Reset the frequency value been set to properly Invalid operate the unit Frequency E094 A unit on the sync pulse 1 Check that all units ha
244. ne PROFIBUS status bits Redefines the PROFIBUS status bits Send 1 data byte e 0 Normal format e Non zero Joule recipe definition Read back this setting with command 163 CSR only 57000097 00B Communication Interfaces 4 191 Advanced Energy Table 4 48 AE Bus Commands Continued 0 Clear bit Non zero Set bit 2nd data byte Configuration option bit number valid entries 0 31 e 7 RAMP RESOLUTION bit clear 10ms ramp resolution bit set 100ms ramp resolution 8 JOULE RECIPE STATUS bit clear Normal PROFIBUS status bytes bit set Joule recipe definition PROFIBUS status bytes e 18 USER PORT EOTL DEFINED AS READY SIGNAL bit clear User Port EOTL defined as EOTL bit set User Port EOTL defined as Ready Signal e 19 HIGH SPEED AEBUS bit clear Standard AE Bus baud rates bit set High Speed AE Bus baud rates e 25 EXPLICIT FAULT CLEARING bit clear enables OFF or reset command clears faults bit set disables requires power cycle to recover from faults Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 85 Changes the configuration option bit Requires 2 CSR only change 2 data bytes configuration option bit 1st data byte Bit setting 4 192 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued
245. nerally pressing a soft key causes another level of menu choices to display for example MONITOR LIMITS ARC and CONTROL display if you press the PROCESS soft key SERVICE SUPPLY PROCESS Figure 4 16 Control panel main menu functions As you press soft keys and move through the menu levels the top line of the output display screen displays the path of the menu in the upper left hand corner of the display screen A parameter flashes if it can be modified make such modifications with the MODIFY knob Pressing the ENTER soft key enters the modification into nonvolatile memory You can press the MODIFY knob at any time to cancel what you are doing leave the parameter s unchanged and return to the output display screen If a fault exists or the panel is locked the soft keys are locked out until you clear the fault See Troubleshooting and Global Services on page 6 1 for a list of fault messages UNDERSTANDING THE MENU OPTIONS Pressing the rightmost soft key will bring up the main menu tree When at the top level you have three menu options Service Supply e Process From the Service menu you can access diagnostic information From the Supply menu you can modify supply specific parameters and from the Process menu you can access options that affect your process or monitor your process To select a menu option press the soft key below the menu option See the menu maps for a graphical representation of the m
246. nergized to switch between regulation modes 7 Enter a set point value 8 If necessary enter the following parameters Enter a pulse frequency and reverse time Enable joule mode and select a set point in joules available only through the serial port the active front panel or the Pinnacle Remote Panel Enable target life counters and select a target life for each applicable target available only through the serial port the active front panel or the Pinnacle Remote Panel Enable arc handling and enter appropriate arc handling parameters available only through the serial port active front panel or the Pinnacle Remote Panel Create a ramping recipe available only through the serial port active front panel or Pinnacle Remote Panel Set the out of setpoint timer to a value other than 0 available only through the serial port active front panel or Pinnacle Remote Panel 9 If necessary set limits for output power output voltage output current and or process voltage available only through the serial port active front panel or Pinnacle Remote Panel 10 Verify all output power load conditions and connections and when the system is ready enable the output The output information on the output display screen should equal your requested set point 11 Verify the status of the power supply LEDs If you are using a passive front panel verify that the OUTPUT and SETPOINT LEDs light If these L
247. nfig status continued from previous page 3rd status byte 0 Transmitter Receiver mode 0 Receiver 1 Transmitter e 1 Over voltage timer active e 2 Over current timer active e 3 Constant duty cycle active e 4 Micro arc handling 0 disabled 1 enabled 5 Pulsing mode also see 4th status byte bit 2 the setting on that bit overrides this bit 0 at current threshold 1 always e 6 and 7 Joule threshold type Type Bit 7 Bit 6 Power 0 0 Voltage 0 1 Current 1 0 4th status byte 0 Hard arc broadcast 0 disabled 1 enabled 1 Joule countdown hold 0 disabled 1 enabled 2 Pulsing mode also see 3rd status byte bit 5 the setting on this bit overrides that bit 0 uses setting on 3rd status byte bit 5 1 voltage pulsing type 3 Sync Pulse standalone unit 4 through 7 Unassigned 4 57000097 00B Communication Interfaces 4 111 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued request joules set point command 4 the returning packet contains 4 data bytes 32 bit value indicating the set point level in joules Command Description Number Number of Sent of Data Response Bytes Data Bytes 164 Requests the set point level by whichever 0 3 method of output regulation has been selected request set set by command 3 the returning packet
248. nnacle Plus unit has powered up this bit s continuous change indicates that the PROFIBUS interface is ready During operation a cessation of this change indicates that a communication problem exists OUTPUT READBACK BYTES BYTES 2 THROUGH 7 Upload bytes 2 through 7 give readback information for output levels in power voltage and current RESPONSE DATA BYTES Upload bytes 8 through 13 represent the response for all commands Byte 13 always echoes the last command sent to the Pinnacle Plus supply Depending on the command number data bytes 8 through 13 are used in two different ways e For commands 0 through 127 the response is a Command Status Response CSR code contained in byte 8 Bytes 9 through 12 are not applicable For commands 128 through 230 the response is usually data Data lengths vary from one byte to five bytes depending on the type of data requested When the data extends over more than on byte the PROFIBUS sends the least significant byte LSB before the most significant byte MSB If one of these commands is not accepted it may return a CSR code REFRESH RATES IN THE UPLOAD PACKET Due to the speed with which data is exchanged attempting to refresh all the data in any given upload packet would consume too much of the Pinnacle Plus processing resources Therefore data is refreshed and returned in the upload packet at timed intervals These intervals vary depending on the relative importance of the data The
249. ns 2 data bytes 16 bit request out value indicating the timer value in seconds of set point One decimal place is implied For example a timer value of 999 would indicate a timer value of 99 9 s This value is set with command 31 188 Requests the arc density that occurred in the 0 4 previous second returning packet contains 4 arc density data bytes per second f First second byte Micro arcs 16 bit value Third fourth bytes Hard arcs 16 bit value 189 Requests how many micro arcs occurred in the 0 4 previous run returning packet contains 4 data request micro bytes 32 bit value indicating the number of arc density micro arcs in the previous run Note The unit records a micro arc each time the output voltage goes below the voltage arc trip level set with command 10 All arc counters are updated every 100 ms or 10 times per second 4 210 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued e overcurrent events e 2 overvoltage events Returns 4 data bytes 32 bit value indicating the number of requested events Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 190 Requests how many hard arcs occurred in the 0 4 previous run returning packet contains 4 data request hard bytes 32 bit value indicating the number of arc density hard arcs in the previous
250. ns are 1 through 65535 Readback this value with command 233 61 Enables or disables micro arc handling 1 CSR only feature Hard arc handling is always enabled enable disable Send 1 data byte 8 bit value micro arc nani handling 0 Disable 4 96 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number Numberof of Sent Response Data Data Bytes Bytes 64 Sets the joule mode counter threshold type 1 CSR only threshold Send one data byte 8 bit value type e 0 Power e 1 Voltage e 2 Current Read back this setting with command 163 65 Enables pulsing at the current threshold 1 CSR only default setting or enables pulsing always pulsing a hae enabled Note Frequency is limited to 150 kHz when mode the pulse mode is set to be enabled always Send one data byte 8 bit value e 0 Pulsing enabled at current threshold e 1 Pulsing enabled always Read back this setting with command 163 66 Enable or disable the hard arc broadcast 1 CSR only feature enable or disable Send 1 data byte hard arc s D broadcast ees e Non zero Enable Read back this setting with command 163 72 Set a joule value to indicate the joule down 2 CSR only near end counter is near expiration joule inen Send 2 data bytes 16 bit value Read back this setting with command 232 73 Resets the
251. nt the returning packet contains 2 request data bytes 16 bit value indicating the voltage actual voltage level For example a value of 800 would indicate 800 V no implied decimal 167 Requests a snapshot of the output current level 0 2 at that instant the returning packet contains 2 request data bytes 16 bit value Two decimal places 57000097 00B Communication Interfaces 4 205 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 168 Requests a snapshot of the output power 0 6 voltage and current at that instant the request returning packet contains 6 data bytes actual power voltage e First second byte Power level current e Third fourth byte Voltage level e Fifth sixth byte Current level See commands 165 166 and 167 for the format of the reported output values 169 Requests the set point levels for power 0 6 voltage and current the returning packet request set contains 6 data bytes three 16 bit values points power See commands 165 166 and 167 for the voltage and format of the reported set point values current 170 Requests the arc shutdown time The returning 0 2 request arc packet contains 2 data bytes shutdown e Byte 1 Unused e Byte 2 Index value set with command 8 refer to command 8 for the shutdown index values 171 Requests the index for t
252. nt within the specified accuracy 10 24 VSUPPLY input Connect your system s 24 V power supply to this pin 4 44 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 14 Dual 24 V 37 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 11 29 B_SETPOINT D digital A high on this signal output indicates that the output is equal to the requested set point within the specified accuracy 12 29 B_ARC D output A pulse of a predetermined width normally 100 ms will be seen on this pin under two different conditions Note Both conditions can be active during the same run 1 If the hard arc count limit is non zero and the number of hard arcs seen exceeded this limit during the last run the pulse will occur when the output is turned off 2 If your unit has been configured for signaling on every hard arc this signal will pulse for a predetermined time for every hard arc seen by the unit If another hard arc is seen before the last pulse is complete the pulse width will be refreshed to the full width 13 15 B_PREG D digital This pin is used with input B_IREG D pin 32 to set the regulation mode for Side B See Table 4 16 on page 4 49 for more information 57000097 00B Communication Interfaces 4 45 Advanced Energy Table 4 14 Dual 24 V 37
253. ntity of the unit s personality 0 2 cards request B Un ality Returns 2 data bytes card First byte Identity of card in slot 1 e 0 Card not present 01 or 17 Dual User port 03 or 26 PROFIBUS 05 or 21 Single User port 18 or 28 AE Bus e 23 or 30 DeviceNet Second byte Identity of card in slot 2 e 0 Not present 03 or 26 PROFIBUS e 04 Host Protocol Translator 05 or 21 Single User port 18 or 28 AE Bus e 22 or 29 Master slave with AE Bus 196 Requests the recipe type Returns data byte 0 1 request recipe a type e Timed e 2 Joule continuous e 3 Joule discrete This value is set with command 33 197 Requests the revision of the unit s flash 0 5 configuration The returning packet contains request flash the last five characters of the revision name configuration 198 Requests the revision of the unit s flash 0 5 mainframe software the returning packet request flash contains the last five characters of the mainframe revision name software 57000097 00B Communication Interfaces 4 117 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 211 Requests revision number of FPGA request FPGA Returns 4 ASCII characters revision 4 220 Allows AE Customer Service to access unit statistics request i esi Send 1 data byte 8 bit value service Stalistics e 0 Tot
254. o select the active target number 3 Press ENTER to accept and exit Note The User port has priority in selecting targets Thus if your unit has a user card installed you must set the target to 1 at the User port if you want to select targets from the serial port active front panel or Pinnacle Remote Active Panel that is when the Pinnacle Plus unit is in host or local control mode Leaving the target bits open or leaving the User port pins unconnected causes the target selection at the User port to default to 1 When the User port is set to a target other than 1 the User port selection 4 146 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply has priority If a change to the target is attempted on the front panel User Port Has PRIORITY displays and you must depress the MODIFY knob to exit ENTER is no longer displayed PROCESS MONITOR TARGET gt LIFE To set the target life in 0 01 kWh increments 1 Press PROCESS MONITOR TARGET gt LIFE 2 Rotate the MODIFY knob to select a target life between 0 and 99999 99 kWh The default is 0 If you are rotating the MODIFY knob slowly press the appropriate soft key to indicate how quickly you want the display to increment the value x 1000 x100 x10 or x1 Note If you turn the MODIFY knob quickly the counts per click setting takes effect 3 Press ENTER to accept and exit This function will also display how much target
255. ol and regulation settings If the unit had been in LOCAL mode with a Pinnacle Remote Panel but the Remote Panel is removed the unit will boot up in Host control mode If there is no Host card the unit will boot up in User control mode An active DeviceNet card will act as a Host card if applicable but if the DeviceNet card is not active the unit will boot up in User control mode 3 If the display screen shows no message and or if no control or regulation LEDs light ensure that the unit is properly installed and is receiving AC input power 4 Verify which power supply LEDs are not lit If you are using the passive panel verify that the BUS FAULT and OVERTEMP LEDs are not lit If either or both is lit power down the Pinnacle Plus power supply clear the fault and return to Step 1 Refer to Chapter 6 for error code explanations and troubleshooting suggestions 5 30 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply If you are using an active front panel or the Pinnacle Remote Panel verify that the output display screen information shows on the display screen See Chapter 4 for details If the display screen shows an error code and message note the error code number Refer to Chapter 6 5 Select a method of control Host serial port User port or Local panel control 6 Select a regulation mode power current or voltage Output power must be off that is output must be de e
256. olated AE bus 4 159 J joule mode setting 4 155 L labels on unit 1 3 LEDs ARC 4 127 DeviceNet 4 70 passive display panel 4 124 troubleshooting 6 7 verifying 5 30 local control setting 4 142 LOCAL switch 4 129 low power operation 5 34 M marking CE 1 5 master reset PROFIBUS 4 74 master slave card 5 22 clearing faults 5 39 connecting 5 22 drawing of interface 5 23 master unit configuring 5 23 monitoring 5 39 on off combinations 5 39 slave units configuring 5 24 master slave termination 4 73 57000097 00B Index iii Advanced Energy menu menu map 4 134 message packet method control microprocessor 2 2 control panel options 4 132 control panel selections 4 132 functions selecting control panel functions 4 131 AE bus 4 166 selecting 5 31 military spec number UHF 5 20 P mode regulation 5 31 MODIFY knob 4 127 4 131 monitoring master slave system 5 39 monitoring your process 4 143 N strain relief connector 5 12 UHF connector 5 20 output display screen 4 129 output readback bytes PROFIBUS 4 80 output signal scaling incorrect scaling 4 34 output strain relief 5 17 over current timer setting 4 145 over voltage timer setting 4 144 overvoltage specifications 3 18 parameters setting for the supply 4 139 passive display panel 4 123 help codes 6 7 LEDs 4 124 physical specifications 3 3 pin descriptions network address AE bus 4 164
257. ommunication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply e STATS supply statistics DEBUG debug screens MEMORY ROM CRC checksums e SW_ REV software revision numbers Checking Service type Statistics SERVICE STATS Use this option to check the service type statistics CHECKING THE TOTAL ENERGY OUTPUT SERVICE STATS gt ENERGY To check the total energy output e Press SERVICE gt STATS gt ENERGY The total energy output for the unit appears CHECKING THE AMOUNT OF IDLE RUN TIME SERVICE gt STATS gt TIME To check the amount of time idle and the amount of time running 1 Press SERVICE gt STATS TIME 2 To display the amount of time idle press the IDLE soft key The amount of time idle appears 3 To display the amount of time running press the RUN soft key The amount of time running appears CHECKING THE NUMBER OF FAULTS SERVICE gt STATS gt EVENTS To check the number of faults 1 Press SERVICE STATS gt EVENTS FAULTS and CYCLES options appear 2 Press the FAULTS soft key 3 MORE INTRLOCK IRQS MONITOR and DSP options appear 4 If you press MORE you can check the following faults POWER displays the number of line power faults 57000097 00B Communication Interfaces 4 135 Advanced Energy gt OVRTMP displays the number of over temperature faults BUS displays the number of bus faults INVRTR displays the number
258. on method Send 1 data byte 8 bit value 6 Power e 7 Voltage e 8 Current Read back this value with command 154 4 Specifies the number of joules to be delivered 3 CSR only joule set Send a 3 byte 24 bit value the value must point be between 0 and 9 999 999 Read back this value with command 173 5 Enables or disables joule mode 1 CSR only joule mode Note If a timed recipe is active the timed enable recipe overrides the joule feature Send 1 data byte 8 bit value e 0 Disable Non zero value Enable Read back this value with command 153 57000097 00B Communication Interfaces 4 83 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued Send 2 data bytes 16 bit value An output power value should imply 3 decimal places for a stand alone unit and 2 decimal places for a master slave system An output current value should imply 2 decimal places and an output voltage value should imply 0 decimal places For example for a 6 kW standard Z stand alone supply send a value between 0 and 6000 6 000 kW decimal is implied or 0 and 1500 15 00 A decimal is implied or 0 and 800 maximum output voltage Note Please refer to the Specifications chapter of this manual for your unit s capabilities Read back this value with command 164 Command Description Number Numberof of Sent Response Data Data Bytes Bytes 6 Specifies the output set point level for 2 CSR only whicheve
259. onnector pins Note Some pin signals require specific switch settings on the rear panel switch to produce certain results See Table 4 12 on page 4 34 for more information on these switch settings 57000097 00B Communication Interfaces 4 27 Advanced Energy Table 4 11 Single 15 V 25 Pin User Port Pin Description Signal Name Signal Description Pin Type 1 POUT A Analog This signal represents output power output Full scale 10 V represents the maximum output of the supply see the Specifications chapter of this manual for information specific to your unit Note Pins 5 8 14 15 and 16 are the dedicated returns for this pin 2 VOUT A Analog This signal represents output voltage output Be at The scaling of this pin is switch selectable To set the analog output signal refer to Table 4 12 on page 4 34 Switch 1 and 2 descriptions Note Pins 5 8 14 15 and 16 are the dedicated returns for this pin 3 IOUT A Analog This signal represents output current output See the Specifications chapter of this manual for information specific to your unit The scaling of this pin is switch selectable To set the analog output signal refer to Table 4 12 on page 4 34 Switch 3 description Note Pins 5 8 14 15 and 16 are the dedicated returns for this pin 4 unassigned n a n a 4 28 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply
260. ons on page 4 132 explains how to perform these operations from the Pinnacle control panel Note If you re at the top level press the MENU soft key to make the menus appear MODIFY Knob Use the MODIFY knob to change values and move back through the menus When the display screen shows a flashing value you can change it by turning the MODIFY knob In addition you can use the MODIFY knob to move quickly through the menus Pressing the MODIFY knob once moves you up one level in the menu Pressing it twice quickly moves you all the way out of the menu to the output display screen CONTROL PANEL CONTROLS Use the MODIFY knob and the five unlabeled soft keys that are directly below the display to select a parameter and modify its value To change parameters using the menu the Pinnacle Plus unit must be in local control mode the Local LED will be illuminated Note When the Pinnacle Plus unit is in User or serial Host mode you can view the value of all the menu items but you cannot modify any of the items or lock the unit If you switch the Pinnacle Plus unit to User mode while you are viewing an item in the menu you are returned to the output display screen immediately 57000097 00B Communication Interfaces 4 131 Advanced Energy Press the MENU soft key when the top level display screen is displayed to cause the main menu to appear The main menu contains three menu selections which are shown in the figure below Ge
261. oot error codes Table 6 4 Error Code Troubleshooting Table DSP Init Control Fault to the processor Error Code Problem Indicated Suggested Action Message E000 The DSP failed to respond 1 Power the unit off and then back on If the error code reappears contact AE Global Services E001 Out of Setpoint Timer Expired The out of set point timer has expired Increase the set point timer value or disable the timer by setting it equal to 0 If the problem persists check your process parameters for limiting factors That is ensure that your load impedance matches the impedance of the Pinnacle Plus unit E002 The DC bus has failed Using all applicable safety precautions probably due to an AC inspect your AC input power source to Bus Fault input power problem ensure that it is properly connected and that the specified voltage is being applied to the Pinnacle Plus unit See the Specifications chapter for AC input power specifications E004 The unit is overheating Inspect the unit s cooling system and review cooling specifications Ensure Heat Sink that Over i i i Temperature The input air temperature is correct The Pinnacle Plus unit s fans are functioning properly The cabinet allows for adequate ventilation for all the units in the cabinet For more information see the Installation chapter 6 16 Troubleshooting and Global Services 570
262. op of the hole see Figure 5 6 on page 5 14 6 Tighten the strain relief The strain relief needs to contact the outer shield 7 Replace the output box and cover THREE TERMINAL MULTICONTACT OUTPUT CONNECTOR ATTENTION Before making your output power connection see Connecting Output Power on page 5 10 for safety information and requirements Strain Relief Fitting The three terminal multi contact output connector for your Pinnacle Plus power supply includes a liquid tight PG 36 style grounded strain relief fitting see Figure 5 8 If your Pinnacle Plus unit is a dual unit it will have two strain relief fittings of the same size Use the following dimensions for working with the strain relief e Wrenching Flats for Fitting 50mm 1 970 57000097 00B Installation and Operation 5 17 Advanced Energy Wrenching Flats for Locking Nut 51 mm 2 01 1531 Figure 5 8 PG 36 style strain relief fitting Connecting Output To Connect the Output Port 1 2 wa Disconnect all sources of input power to the Pinnacle Plus unit Prepare the appropriate output cable We recommend triaxial cable The cable should be between 22 mm and 32 mm 0 86 Remove the output box see Figure 5 9 negative and ground see Figure 5 9 place with the seal ring output negative or positive and 1 26 Lock the strain relief fitting in place with the lo
263. or the Pinnacle Remote Panel For a complete list of available functions refer to the list of commands later in this chapter Note To obtain a diskette containing sample software as well as an executable version of the AE Bus Host software please call AE Customer Support Note The flash port is not available for serial communications on Pinnacle Plus supplies with AE Bus cards installed Standard Serial Port Description The Standard Serial port or flash port lets AE personnel program the internal flash function of the Pinnacle Plus unit If the unit does not have an AE Bus card installed the flash port also lets you use a type of AE Bus protocol to communicate with the Pinnacle Plus supply see Transmission Parameters on page 4 158 Located on the rear panel the Standard Serial port is a shielded modular jack illustrated on page 4 158 See also the rear panel illustration at the end of the Installation chapter 57000097 00B Communication Interfaces 4 157 Advanced Energy Ti TI Figure 4 20 Standard Serial port STANDARD SERIAL PORT PIN DESCRIPTIONS The pin descriptions for this port are as follows Table 4 42 Serial Port Pin Descriptions Pin Description 1 Do not connect 2 Power supply transmit 3 Power supply receive 4 Ground Note We recommend that for optimal performance you use only shielded modular cable between
264. ormation Connecting a Pinnacle Remote Active Panel Connect the AE Pinnacle Remote Active Panel at the 9 pin male subminiature D connector labeled REMOTE on the rear panel of the Pinnacle Plus power supply See Chapter 4 for more information Note To reduce EMI interference we recommend using shielded cable to connect to the Remote Active Panel port Connecting to the Standard Serial Port This interface lets you use most parameters of the AE Bus communications protocol during serial communications with a host computer See Chapter 4 for more information Note To reduce EMI interference we recommend using shielded cable to connect to the serial port Connecting for Serial Host Port Control See Chapter 4 for instructions on connecting your serial communications Host port Note Any time you remove one Host card and replace it with another you must restore all system defaults Restoring defaults resets the User port limits and the front panel display Additionally restoring defaults will ensure the Pinnacle Plus power supply recognizes the new Host card or lack of Host card Note To reduce EMI interference we recommend using shielded cable to connect to the serial Host port 5 8 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Connecting for DeviceNet Control If you have a DeviceNet interface please reference the DeviceNet section in Chapter 4 in the Pinnacle Plus po
265. ote controller The connector is a 15 pin subminiature D female connector see the following illustration Pin 8 Pin 15 Pin 1 666600 Pin 9 1061 Figure 4 5 15 pin User port You may operate the Pinnacle unit solely through the 15 pin User port User port operation does not require connection to a DeviceNet network Installation A DANGER Disconnect all sources of input power before working on this unit or anything connected to it Note Signals at the User port can be sensitive to environmental noise We recommend that you take standard preventative measures against electro magnetic interference EMI including using shielded cabling on the User port Note Grounding the User port at the power supply reduces noise interference To avoid ground loop problems you should typically ground only one end Refer to the pin descriptions on the following pages when connecting your remote controller to the User port Use shielded cabling to avoid EMI problems If you have a Pinnacle Active Remote Panel and you want to operate the Pinnacle supply from the User port you must set the control mode for USER on the control panel 4 36 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Signals The User port is primarily an analog interface Signal descriptions appear in the following table Note that a A suffix appended to a pin name indicates an analog signal a
266. ough the Remote Active Panel the Active Front Panel or the serial interface Host port INTERLOCK REQUIREMENTS A CAUTION Turn off the 24 V supply before making connections to the User port To satisfy the User port interlock Your system s 24 V supply must be connected to pin 18 on the Pinnacle Plus supply s User port see below for power requirements e Pin 18 must be connected to pin 11 AUX D INTLK Note A pull up resistor is not necessary USER SUPPLIED POWER REQUIREMENTS Your 24 V supply must meet the following requirements Voltage nominal 24 V dc e Ripple 3 6 Vac maximum Permissible voltage range 20 V to 30 V e V surge t lt 0 5 s 35 V Current depends on loading of outputs 5 0 A maximum 1 0 A minimum Figure 4 7 on page 4 19 provides information about each pin The following paragraphs give general information about the analog and digital signals ANALOG SIGNALS A A suffix appended to a pin name indicates an analog signal Analog common lines are denoted by the COM A suffix Analog outputs can source or sink up to 3 0 mA The input impedance of the analog inputs is 200 KQ 4 18 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply DIGITAL SIGNALS A D appended to a pin name indicates a digital signal Digital commons are denoted by the COM D suffix Digital outputs are short circuit protected The signal levels for dig
267. our Pinnacle Plus power supply is a dual unit it will have two strain relief fittings of the same size 5 12 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Output Box and Connector Figure 5 5 shows the output box and connector for the PG style strain relief fitting and Figure 5 6 shows the output box and connector for the M32 style strain relief fitting Note For the M32 output connector in order to maintain CE certification you must fill each output terminal block mounting screw hole with RTV adhesive to the top of the hole see Figure 5 6 on page 5 14 Lock Nut N A CD 16 PG11 or PG 16 Strain Relief Figure 5 5 PG style output box and connector 57000097 00B Installation and Operation 5 13 Advanced Energy Cover Lock Nut M32 Strain Relief 2245 Output Box Fill each output terminal block mounting screw hole with RTV adhesive to the top of the hole Figure 5 6 M32 style output box and connector Negative Output Configuration The most common output configuration for sputtering applications is negative output negative voltage with respect to ground To achieve negative output connect the Pinnacle Plus power supply s negative terminal on the output connector to the chamber s cathode Connect the positive terminal on the power supply s output connector to the chamber s anode or ground Connect the negative ou
268. pins 10 26 31 to this return 6 5 A_ON D digital When operating in analog input control mode a low to high transition on this pin turns on the output a high to low transition shuts off the output 7 5 A_PREG D digital This pin is used with input A_JREG D pin 25 to set the regulation mode for Side A See Table 4 16 on page 4 49 for more information 57000097 00B Communication Interfaces 4 43 Advanced Energy Table 4 14 Dual 24 V 37 Pin User Port Pin Descriptions Continued Signal Pin 8 Return Pin 28 Pin Name A_ARC D Signal Type output Description A pulse of a predetermined width normally 100 ms will be seen on this pin under 2 different conditions Note Both conditions can be active during the same run 1 If the hard arc count limit is non zero and the number of hard arcs seen exceeded this limit during the last run the pulse will occur when the output is turned off 2 If you set the hard arc count limit to zero this signal will pulse for a predetermined time for every hard arc seen by the unit If another hard arc is seen before the last pulse is complete the pulse width will be refreshed to the full width These conditions will also be indicated through the ARC LED on a Passive Display Panel 28 A_SETPOINT D digital output A high on this signal indicates that the output is equal to the requested set poi
269. ponse CSR Codes Code Meaning 0 Command accepted The following CSR codes are sent in response to a command that was not accepted and provide an indication of why the command was not accepted Control mode is incorrect Output is on change not allowed Output is off change not allowed Data is out of range Invalid parameter Program source is incorrect Active fault s exist OINI oO O AJ N Data byte count is incorrect User port has priority _ _ Bus is not ready N This feature is not available on your unit __ 9 Target life has been consumed _ Output OFF timer active minimum off time is 50 ms o Recipe is active change not allowed 57000097 00B Communication Interfaces 4 81 Advanced Energy Table 4 34 Command Status Response CSR Codes Continued 21 Joule set point has not been reached 25 Unit is configured as a slave 28 Set point exceeds user limit 29 Regulation mode is locked you cannot switch between regulation modes while output power is on 31 The User port reset is active you must de assert the reset line on the User port 33 Pulsing disabled frequency 0 34 Unit is a Sync Pulse receiver 36 User set point out of range 99 Command not accepted there is no such command Commands 0 through 127 Commands
270. power supply E059 indicates an error in the PROFIBUS card located in the left I O slot of the unit if applicable For more information about troubleshooting this error see E059 E160 AE BusCommand Buffer Overflow E160 is the same error documented for E060 E160 indicates an error in the AE Bus card located in the right I O slot located on the back panel of the power supply E060 indicates an error in the AE Bus card located in the left I O slot of the unit if applicable For more information about troubleshooting this error see E060 E181 Initializing Master Slave This error occurs at startup in units that are configured with a master slave Host interface card Once the master slave Host card has been successfully initialized the fault self clears Ordinarily if this fault does not clear automatically there is a hardware problem Check your master slave cabling 57000097 00B Troubleshooting and Global Services 6 25 Advanced Energy Table 6 4 Error Code Troubleshooting Table Error Code Problem Indicated Suggested Action Message E182 A fault has occurred in the Check your master slave cabling master slave system Master Slave Fault E183 No master unit detected Verify a unit is set as the master unit or At least one unit must be that the link to the master unit has not No Master set as the master unit been broken see Configuring
271. r method of regulation mode has set point been selected 4 84 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number of Sent Data Bytes Number of Response Data Bytes 8 arc shutdown time Send 2 data bytes to set the arc shutdown time e Byte 1 Unused e Byte 2 Send the index value that represents the arc shutdown time in us The list below shows standard index values Your unit may be configured with different values For information about a specific unit contact AE Global Services 0 200 gt 1 500 gt 2 1000 gt 3 1500 4 2000 5 2500 6 3000 7 4000 8 5000 Readback this value with command 170 CSR only 9 hard arc count limit Sets the number of hard arcs required for the power supply to provide an arc indication If the limit is reached during a process cycle then after output shuts off the ARC LED lights and if applicable a signal is sent to the User port Send 3 data bytes a 24 bit value indicating the number of arcs the value must be at least 0 but no greater than the maximum set for your unit Note If you set the hard arc count limit to 0 the ARC LED lights for a predetermined time and if applicable a signal is sent to the User port for every hard arc seen by the unit Read back this value with command 178
272. rd arc handling To disable micro arc handling 1 Press PROCESS ARC gt ENABLE 2 Rotate the MODIFY knob to select YES or NO to enable or disable micro arc handling 3 Press ENTER to accept and exit Note As an inherent safety feature cycling power to the unit resets micro arc handling to enabled Note Hard arc handling is always enabled Setting Control Parameters PROCESS gt CONTROL Use this menu option to set up Pinnacle parameters that directly control the output of your process The menu options are e RECIPE e JOULES e RAMP Setting Recipes PROCESS CONTROL RECIPE Note If you are using recipes you cannot use the standard joule mode You can set up both recipes and joules however running recipes does not trigger the Joule mode To use joules in recipes you must use the JOULE CONTINUOUS or JOULE DISCRETE recipe types Use the RECIPE menu to implement a ramping recipe or joule recipe This function lets you program the Pinnacle Plus in incremental steps 1 to 8 steps are possible For each step you must set one of the following sequences 4 152 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Ramp time set point and run timer e Number of joules and set point Ramp time is the amount of time in seconds that the Pinnacle Plus takes to ramp up to the set point for the specified step Run timer is the amount of time in seconds for which t
273. rder these parts separately through Advanced Energy using AE part number 3052078 We do not provide the cable and you cannot purchase it through Advanced Energy Military Spec Number The military specification number for this connector is SO 239 Select cables and tools appropriate for this mil spec and assemble connecting materials according to specifications Also note that the connector housing may provide interlock capability see UHF Connection Interlock Capability on page 5 21 for more information 5 20 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply UHF Connection Interlock Capability Figure 5 11 illustrates an UHF connector without interlock capability A lop Figure 5 11 Rear view of UHF housing without interlock back plate removed Figure 5 12 illustrates a UHF connector with interlock capability The interlock is closed when the connector housing s back plate with its three interlock pins is properly attached When you remove the back plate the interlock is open and output from your Pinnacle Plus power supply is turned off SSS 1420 Figure 5 12 Rear view of UHF housing with interlock back plate removed Connecting for Master Slave Operation The following se
274. re internally pulled up to 15 V through a 10 kQ resistor and have an output impedance of 100 Q When low each digital output line will sink up to 35 mA Digital inputs are also 0 to 15 V with a low input being less than 0 5 V An open input defaults high via a 4 32 kQ pull up to 15 V A low input will source up to 3 3 mA All digital lines incorporate a low pass filter that rejects signals less than 1 ms Pin Description Table The User port has priority for selecting targets even when the unit is in local or host control Thus to select targets from the active front panel the Pinnacle Active Remote Panel or a host computer connected to the host port you must set the target to 1 at the User port Leaving the target bits open or leaving the User port pins unconnected causes the target selection at the User port to default to 1 Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Signal Return Pin Name Signal Description Pin Pin Type 1 37 CS1 D digital This signal with pin 20 output CS2 D tells an external device such as a cathode switch box which of the Pinnacle Plus supply s target life counters is active See Table 4 4 on page 4 15 for more information 2 37 OUTPUT D digital This signal indicates that the output contactor is closed and output power is on 3 37 SETPOINT D digital This signal indicates that the output output is within specified tolerance of the requested set point
275. reases from 25 C to 30 C note 3 Maximum absolute humidity when the unit temperature directly decreases from 70 C to 15 C Table 3 7 Environmental standard specifications Description Overvoltage Specification Category II Pollution degree 2 3 18 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply COOLANT SPECIFICATIONS Table 3 8 Coolant Specifications Description Specification Coolant Temperature Air gas minimum 0 C maximum 40 C Note See Cooling Requirements on page 5 1 for more information Pollution Degree CE Marked devices install and operate this device 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 condensation causes temporary conductivity when the device is not operating EMI EMC Tested for electromagnetic compatibility Note See Safety Guidelines on page 1 2 and the declaring letter for specific standards Acoustic Noise Noise generated by this unit is 75 6 dB A ata 1m distance from the front of the unit 57000097 00B Product Specifications 3 19 Advanced Energy 3 20 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply Chapter 4 Communication Interfaces This chapter provides information on a variet
276. recipe step the unit will switch to continuous output when it reaches set point for this step In this situation to turn off output you must send an off command using the OFF button or the appropriate User port signal or serial port command or you must have already enabled joule mode and programmed a joule set point Read back these values with command 183 CSR only 57000097 00B Communication Interfaces 4 91 Advanced Energy Table 4 35 PROFIBUS Commands 0 to 127 Continued current is set with command 64 If the threshold type is set in Watts send 2 bytes 16 bit value between 10 and maximum power divided by 8 This value represents watts in a stand alone system and decawatts in a master slave system For threshold types set in Volts or Amps send 2 bytes 16 bit value between 0 and the maximum output limit Note The Joule energy calculation begins after n mS regardless of the output power level The time value n mS is set in the configuration and cannot be changed If the output power level meets the joule energy threshold prior to the time expiration the joule energy calculation will begin Read back this value with command 136 Command Description Number Numberof of Sent Response Data Data Bytes Bytes 24 Requests the Pinnacle Plus supply to 0 CSR only calculate its logic CRC This request is always calculate honored regardless of which interface has
277. rent will exist You must connect the primary and supplemental Protective Earth ground wires 208 VAC Input Current 32 A nominal per phase at least 90 EFF 50 A circuit breaker 400 VAC Input Voltage wye connection only 360 to 440 VAC 3 phase 4 wire 50 to 60 Hz no neutral required Leakage current less than 3 5 mA Maximum phase to phase voltage 400 V 10 Maximum phase to ground chassis voltage 230 V 10 400 VAC Input Current 17 A nominal per phase at least 90 EFF 20 A circuit breaker 480 VAC Input Voltage wye connection only Not available for this configuration 480 VAC Input Current Not available for this configuration 3 6 Product Specifications 57000097 00B Pinnacle Plus 10 kW Power Supply Table 3 3 Electrical Specifications Continued Description Specification Output Accuracy Accuracy of actual output value to set point at 25 C is 1 of the actual value V kW or A or 0 2 of the full rated output whichever is greater for the full input voltage range and within the output impedance range Load Regulation 1 for 4 1 load change Line Regulation 1 for 10 line voltage change or 2 frequency change Repeatability Output power repeatability from run to run at a constant set point is 0 1 from 10 to 100 of rated power Temperature Coefficient lt 0 05 C lt 150 ppm C variation in the re
278. rfaces 4 195 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 142 Requests the output voltage limit Accuracy is 0 2 0 3 of the full rated output voltage for the request user supply voltage limit f The returning packet contains 2 data bytes 16 bit value indicating the limit in voltage This value is set with command 50 143 Requests the output current limit Accuracy is 0 2 0 3 of the full rated output current for the request user supply current limit f The returning packet contains 2 data bytes 16 bit value indicating the limit in amperes Assume 2 decimal places 5000 50 00 A This value is set with command 51 144 Requests the strike voltage limit The returning 0 1 packet contains 1 data byte indicating a strike request user voltage strike voltage limit O low e 1 medium e 2 high This value is set with command 52 146 Requests pulse frequency index read in 5 kHz 0 1 increments the returning packet contains 1 request pulse byte frequency i i index e 0 0 kHz pulsing disabled e 1 5kHz e 2 10kHz e 3 15 kHz 4 to 69 follow the established pattern e 70 350 kHz This value is set with command 92 4 196 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued
279. rieve this information with command 131 Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 119 Send this command to clear fault indication 0 CSR codes when the Pinnacle Plus supply has 0 9 master reset experienced a non recoverable fault Note Output will be turned off This request is always honored regardless of which interface has control 126 Resets all user defined values to their factory 1 CSR codes defaults and stores them in non volatile 0 1 2 9 reset default memory settings Send one data byte with a value of 0 127 Lets you write up to 40 ASCII characters to a 0 to 40 CSR codes scratch pad memory non volatile 0 9 write to Commands 128 through 255 request a value to be read from the Pinnacle Plus unit Some of these commands may return CSR codes The data string implies 3 decimal places for a stand alone unit 10000 10 000 kW and implies 2 decimal places for a master slave system 120000 1200 00 kW 128 Requests the power supply type the returning 0 4 packet contains 4 ASCII characters PLUS request supply type 129 Requests the output capacity of the power 0 6 supply the returning packet contains 6 request characters indicating capacity in kilowatts supply size 4 194 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued
280. ription Number Number of Sent of Data Response Bytes Data Bytes 142 Requests the output voltage limit 0 2 request user Accuracy is 0 3 of the full rated output voltage limit voltage for the supply The returning packet contains 2 data bytes 16 bit value indicating the limit in voltage This value is set with command 50 143 Requests the output current limit 0 2 request user Accuracy is 0 3 of the full rated output current limit current for the supply The returning packet contains 2 data bytes 16 bit value indicating the limit in amperes This value implies 2 decimal places This value is set with command 51 144 Requests the strike voltage limit The 0 1 returning packet contains 1 data byte request user indicating a strike voltage strike voltage limit e 0 low e 1 medium e 2 high This value set with command 52 146 Requests pulse frequency index the returning 0 1 packet contains byte request pulse e yed e 0 0 kHz pulsing disabled index e 1 5kHz e 2 10kHz 3 to 69 follow the same format e 70 350 kHz 57000097 00B Communication Interfaces 4 103 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued e 3 A control panel e 4 User port This value is set with command 14 Command Description Number Number of Sent of Data Response Bytes Data Bytes 147 Requests pulse reverse time the returning 0 1 packet contains 1 byte request pulse B reverse ti
281. rol for the Pinnacle 1 CSR only Plus supply This request is always honored control mode regardless of which interface has control Send 1 data byte e 2 Serial Host port 4 User port e 6 A control panel Read back this value with command 155 15 Enables or disables the ramp feature 1 CSR only ramp enable Send 1 data byte 8 bit value e 0 Disable e Non zero Enable Read back this value with command 163 16 Sets the ramp time in 10 ms increments 2 CSR only Range is 50 ms to 600 00 s ramp time 4 88 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0 to 127 Continued Command Description Number Numberof of Sent Response Data Data Bytes Bytes 17 Tells the Pinnacle Plus supply whether the 3 CSR only source of information for regulation mode and program set points is internal or external the source source can be set independently for each of the three control modes Send 3 data bytes arranged as follows e First byte Program source if the serial Host port is active e Second byte Program source if a control panel is the active interface e Third byte Program source if the User port is active For each mode send an 8 bit value as follows e 0 Program source is internal Non zero value Program source is external that is the program source for the regulation mode and the set point is an analog signal from the
282. rs PROFIBUS specific 4 74 example command sequences PROFIBUS 4 121 F faults clearing in a master slave system 5 39 floating output configuration safety warning 5 15 Index 57000097 00B Pinnacle Plus 10 kW Power Supply frequency setting 4 131 frequency time settings 5 37 functional specifications 3 1 G general description 2 1 grounding 5 6 GSD see type files 4 73 guidelines safety 1 2 H handshaking PROFIBUS 4 76 help codes passive front panel 6 7 troubleshooting 6 9 high power operation 5 34 Host AE bus isolated cards 4 159 Host connectors AE bus 4 159 Host port connecting 5 8 see also AE bus Host see also DeviceNet HOST switch 4 129 l icons in user manual 1 2 on unit 1 3 illustrations rear view 5 29 impedance range output 3 17 inbytes 4 77 installation cabinet design 5 2 Contactor Intlk port 5 7 cooling requirements 5 1 DeviceNet 5 9 dimensional drawing 3 5 grounding the unit 5 6 input power 5 9 master slave 5 22 preparing to install 5 1 remote active panel 5 8 remote passive panel 5 8 requirements 5 5 safety guidelines 1 2 serial Host port 5 8 spacing requirements 5 1 standard serial port 5 8 unpacking 5 5 User port 4 3 4 40 5 9 installing DeviceNet 4 54 User port 4 36 interfaces control panel 4 128 general description 2 1 types 2 4 interlock UHF connector without 5 21 internal microprocessor 2 2 IOUT A signal incorrect output signal scaling 4 34 is
283. rsion level of the unit s flash 0 32 memory returning packet contains 32 data request flash bytes configuration 198 Requests the revision level of the mainframe 0 11 software the returning packet contains 11 request s w ASCII characters rev level mainframe 4 212 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 208 Returns a list of fault codes representing active 1 Variable request fault faults affecting the unit list Send 1 data byte e 0 Returns all active fault codes The returning packet contains a variable amount of data bytes A two byte value represents each error code If a single fault is active the data length will be 2 data bytes If two faults are active the data length is 4 data bytes and so on If no faults are active the data length is 0 Ifa CSR is returned the data length is 1 211 Requests the revision of the FPGA software 0 4 Returns 4 ASCII characters FPGA software revision 57000097 00B Communication Interfaces 4 213 Advanced Energy Table 4 48 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 220 Requests unit statistics returning packet contains 4 data bytes 32 bit value request
284. rt Note If you have an isolated AE Bus card your card provides isolation of more than 500 Vrms from the Pinnacle Plus unit s SELV logic and control circuitry to all nine pins on the connector Make connections for the serial port through its 9 pin female subminiature D connector on the rear panel of the unit Figure 4 21 AE Bus port connector Pin Descriptions Refer to the following table for pin descriptions Table 4 43 AE Bus Host Port Pin Descriptions Pin Pin Name Description 1 UNASSIGNED 2 TXD D RS 232 transmit data 57000097 00B Communication Interfaces 4 159 Advanced Energy Table 4 43 AE Bus Host Port Pin Descriptions Continued Pin Pin Name Description 3 AXD D RS 232 receive data 4 UNASSIGNED 5 COM D Data common 6 TR R RS 485 transmit receive data RS 422 received data 7 TR RS 485 transmit receive data RS 422 received data T RS 422 transmit data T RS 422 transmit data Transmission Parameters The communications capability of the serial AE Bus port is limited to the following parameters RS 232 RS 422 or RS 485 transmission standard Four baud rates selected by the DIP switch The unit is set for either standard or high speed baud rates which define the baud rates that can be selected You can use host command 85 to change between standard and high speed baud rates Standard baud rates
285. rt Also ensure that you have selected an appropriate MAC ID and baud rate Finally ensure that you have read the following information about command and respond messages and the DeviceNet LEDs When setting parameters in the Pinnacle unit via the DeviceNet controller send the Set_attribute_single command and then send the Get_attribute_single command to ensure the data was received To maintain proper timing of the application code the DeviceNet interface is given a low priority Therefore if you do not verify the receipt of the data by the Pinnacle Plus unit you may be required to wait up to 500 ms before sending the next explicit command to ensure proper receipt of each explicit set command A CAUTION The DeviceNet controller should be set to monitor the status of the unit and DeviceNet communications If the DeviceNet communication fails or the power to the power supply fails the DeviceNet controller must go into a safe mode If the DeviceNet controller is only reading and sending the poll commands it is possible for the power supply to restart immediately and output power when communication is reestablished or power is restored to the Pinnacle Plus unit POLL COMMAND MESSAGE The Pinnacle Plus DeviceNet interface operates as a slave on the DeviceNet network The interface supports the Explicit Messages and Polled I O Messges of the predefined master slave connection set The DeviceNet interface responds to poll r
286. s 243 Reports the maximum amount of time that 0 2 request output will stay on in seconds if this feature maximum on is enabled If the length of time since the last timer output on event exceeds this setting the unit will turn output off The timer is reset at each output on event You can set a time in whole seconds from 0 to 65535 A value of zero disables this feature Not all units have this feature available Returns 2 data bytes 16 bit value indicating the timer value in seconds This value is set with command 87 4 216 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 251 Requests the full scale power for DeviceNet 0 4 special 32 bit value DeviceNet 252 Requests the full scale current for DeviceNet 0 4 special 32 bit value DeviceNet 253 DeviceNet poll commands The returning 0 8 special packet contains 8 data bytes DeviceNet 57000097 00B Communication Interfaces 4 217 Advanced Energy 4 218 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Chapter 5 Installation and Operation PREPARING TO INSTALL THE UNIT These sections provide information that you need to understand before installing the Pinnacle Plus Meeting Spacing Requirements See
287. s master slave system procedure see Master Slave System Operation on page 5 38 H028 Setpoint Out of You have attempted to seta Retry setting the set point Range set point to a value outside using an acceptable value the allowable range H031 User Port Reset The User port reset is De assert the User port reset is Active asserted function 6 14 Troubleshooting and Global Services 57000097 00B Pinnacle Plus 10 kW Power Supply Table 6 3 Help Code Troubleshooting Table Help Help Code Problem Indicated Suggested Action Code Message Number H034 Unit Configured You have attempted to De assert the receiver status as Sync Pulse initiate a unit function that is of the unit and retry the Receiver not allowed while the power function For information supply is configured as a regarding this procedure see sync pulse receiver Sync Pulse Operation on page 5 40 H099 Command Not The Pinnacle Plus unit Review the list of Implemented does not support the commands command most recently sent by the computer host If by following the information in these checklists and this table you fail to identify the problem please call AE Global Services If the unit s front panel or Pinnacle Plus Remote Panel displays an error code please consult the following error codes table for further troubleshooting ideas You can reset the unit s user selectable parameters to the factory defaults using
288. s a synopsis of the principles to follow when designing a cabinet containing a stack of Pinnacle Plus power supplies Coolant air must be drawn easily into the cabinet exhaust air must be able to pass unrestricted out of the cabinet If some physical constraint restricts the flow of exhaust air out of the cabinet we recommend mounting the fans or blowers so that the hot air is removed from the cabinet as quickly as possible Each Pinnacle Plus power supply dissipates up to 10 of its maximum power at full rated output Table 5 1 shows the minimum air flow in cubic feet per minute CFM required by individual Pinnacle Plus power supplies The static pressure inches of water of the empty cabinet should not exceed 0 1 inches of water at the CFM level obtained by adding together the minimum CFM values for all the power supplies that will be placed in the cabinet 5 2 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply For example if three Pinnacle Plus power supplies are mounted in a cabinet the minimum CFM requirement would be three times the CFM of cabinet air volume compared to an individual supply Table 5 2 shows the approximate cooling requirements for three Pinnacle Plus power supplies mounted in a cabinet Table 5 1 Minimum CFM Required for a Pinnacle Plus Power Supply Power Supply CFM Required 5 kW 100 CFM 47 2 liters second 5x5 kW 200 CFM 94 4 liters second 10 kW 200
289. s not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 4 68 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 26 Instance 1 attributes Attribute Access Name Type Value 97 Set Get Arc Shutdown UDINT Get or set the arc shutdown Time time Send returns an index value identifying the shutdown time in us The times may vary depending on your unit configuration If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal Index Shutdown Time ps 0 10 1 20 2 30 3 40 4 50 3 100 6 200 7 500 8 1000 9 2500 100 Get Max Voltage UINT The Max Voltage attribute returns a value in volts Depending on your DeviceNet configuration this value is 1000 V or the maximum output voltage capability of the unit This value is the scale used in the poll message Note If the attribute is not supported the unit responds with the DeviceNet Attribute Not Supported error code 14 hexadecimal 57000097 00B Communication Interfaces 4 69 Advanced Energy For more information about this type of messaging refer to section 4 2 of the DeviceNet Specification version 2 0 or later Table 4 27 Common services codes Service Code Class Instance Service Name
290. sages in Table 4 26 Note Table 4 26 shows the Class Code 100 0x64 Instance 1 attributes used to retrieve this information ATTENTION Depending on your DeviceNet configuration some features may not be available in the Pinnacle Plus power supply For ordering information contact AE Global Services Table 4 26 Instance 1 attributes Attribute Access Name Type Value 1 Get Power UINT Power output expressed in 12 bit A D units with upper 4 bits equaling 0 2 Get Voltage UINT Voltage output expressed in 12 bit A D units with upper 4 bits equaling 0 3 Get Current UINT Current output expressed in 12 bit A D units with upper 4 bits equaling 0 4 Set Get Ramp Rate Set UINT Ramp rate set point expressed in Point 12 bit A D units with upper 4 bits equaling 0 57000097 00B Communication Interfaces 4 63 Advanced Energy Table 4 26 Instance 1 attributes Attribute 5 Access Get Name Status Type USINT Value Returns 1 8 bit data byte Bit 0 POS 0 Power Off 1 Power On e Bit 1 SPS 0 Not At Set Point 1 At Set Point e Bit 2 TS 0 Temp Not OK 1 Temp OK e Bit3 ARCD 0 No Arc Detected 1 Arc Detected e Bit4 INTS 0 Interlock Not Satisfied 1 Interlock Satisfied Bit 5 is not used e Bit 6 Control Mode 0 Unit not in host mode 1 Unit in host mode Bit 7 Ramping State not all units support this fe
291. scriptions for the User port Table 4 14 Dual 24 V 37 Pin User Port Pin Descriptions Signal Pin 1 Return Pin 20 Pin Name 4_INTLK D Signal Type digital input Description A low on this pin inhibits the main contactor from closing or opens the main contactor if it is already closed The pin needs to be pulled up to 24 V by between 100 Q and 5 KQO The fault condition is shown on the front panel n a A_INCOM A This line is a dedicated return for analog inputs Reference A LEVELIN A pin 21 to this pin 23 A POUTA analog output This 0 to 10 V signal represents output power Full scale 10 V represents the rating of the supply see the Specifications chapter of this manual for more information 23 A IOUTA analog output This 0 to 10 V signal represents output current Full scale 10 V represents the rating of the supply see the Specifications chapter of this manual for more information 4 42 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 14 Dual 24 V 37 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 5 n a A_INCOM D n a This line is a dedicated return for digital inputs Reference A_ON D pin 6 A_PREG D pin7 A_RESET D pin 24 and A_IREG D pin 25 to this pin You also may reference the 24 V supply
292. slave unit To Configure a Master Unit as a Stand Alone Unit 1 Set the MSTR SLV switch in the up MSTR position 57000097 00B Installation and Operation 5 23 Advanced Energy 2 Remove all master slave interface cables from the master unit Configuring the Slave Units To Configure a Power Supply as a Slave Unit 1 2 Remove all input power from the power supplies in the master slave system If the Pinnacle Plus power supply includes a User card ensure that the interlock inputs are satisfied Refer to Chapter 4 in the Pinnacle Plus power supply user manual for specific User port pin descriptions and required voltage levels Set the MSTR SLV switch in the down SLV position Connect the master slave interface cable with the modular plug ends between port P1 on the first slave unit and port P2 on the next slave unit Continue cabling slave units together in this daisy chain manner The master slave interface cables are included with the power supplies Note The last slave unit in the master slave system will not have an interface cable connected to port P1 Connect the included master slave pulse interface cable with the 15 pin subminiature D plug ends between the Master Slave Pulse port labeled on the master unit and the Master Slave Pulse port on the associated slave units Use a grounding strap to connect an equi potential ground stud on the first slave unit to an equi potential gro
293. ss for each Pinnacle Plus supply in a multi drop configuration The DIP switch is located on the rear panel of the Pinnacle Plus supply next to the AE Bus port There are two types of DIP switches on AE Bus interfaces rocker DIPs and slide DIPs see Figure 4 22 on page 4 161 and Figure 4 23 on page 4 162 Your supply will have one of these types While the switches on these DIPs are slightly different they serve the same function Both DIPs contain eight miniature switches here called min switches In all units setting a switch to the up position means setting it toward the numbers on the DIP and setting a switch to the down position means setting it away from the numbers On rocker DIPs up means that the side of the switch toward the numbers is depressed On slide DIPs up means that the slide is pushed toward the numbers lt A tr co T CON Of lt lt lt lt mm 23456 e Unit Address Baud Rate Communication Mode Dip switch shown 2 1 2 times actual size 1683 Figure 4 22 Rocker DIP switch 57000097 00B Communication Interfaces 4 161 Advanced Energy Unit Address Baud Rate PONE Mode Dip switch shown 2 1 2 times actual size 1684 Figure 4 23 Slide DIP switch On units where the DIP switch is located externally on the rear panel it can be difficult to see the n
294. ssage packet combines chunks of information in such a way that much information can be sent over communication lines at one time Five types of information or Fields make up message packets Figure 4 25 e Header address and length of data field e Command see the command list later in this chapter Optional length byte Data Checksum error checking Figure 4 25 shows the organization of these fields in the AE Bus message packet The subsequent paragraphs describe each field Note The message packet features this structure whether the message originates at the host computer master node or the Pinnacle Plus unit Command Data 0 255 bytes 0 FFh e o Header Optional Checksum 5 bit address 3 bit length 1138 Figure 4 25 Graphic representation of an AE Bus message packet 4 166 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply HEADER The first byte in each packet contains two pieces of information five bits contain the packet address and three bits contain the data byte count If the message packet originates with the host computer master the address specifies the packet s destination to a Pinnacle Plus unit for example If the packet is going to the hos
295. status 0 inactive 1 active 2nd status byte 0 Profibus Status Bit Definition 0 normal 1 Joule Recipe e 1 Active control panel access 0 unlocked 1 locked e 2 Joule mode 0 disabled 1 enabled e 3 Contactor status 0 open 1 closed 4 Unassigned 5 Ramp mode 0 disabled 1 enabled 6 Unassigned e 7 Pulsing enabled 0 disabled 1 enabled Continued on next page 57000097 00B Communication Interfaces 4 203 Advanced Energy Table 4 48 AE Bus Commands Continued config status continued from previous page 0 Receiver 1 Transmitter 1 Over voltage timer active e 2 Over current timer active 3 Constant duty cycle active e 4 Micro arc handling 0 disabled 1 enabled e 5 Pulsing mode also see 4th status byte bit 2 the setting on that bit overrides this bit 0 at current threshold 1 always e 6 and 7 Joule threshold type Type Bit 7 Bit 6 Power 0 0 Voltage 0 1 Current 1 0 4th status byte e 0 Hard arc broadcast 0 disabled 1 enabled e 1 Joule countdown hold 0 disabled 1 enabled 2 Pulsing mode also see 3rd status byte bit 5 the setting on this bit overrides that bit 0 uses setting on 3rd status byte bit 5 1 voltage pulsing type e 3 Sync Pulse standalone unit 4 through 7 Unassigned Command Description N
296. stem After a power cycle the system returns the power and current limits to the default settings 4 148 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply To set the user power limit 1 Press PROCESS gt LIMITS POWER 2 Rotate the MODIFY knob to select a value between 0 and the maximum rated output power 3 Press ENTER to accept and exit SETTING THE GROSS SHORT CIRCUIT CURRENT LIMIT This menu option sets the gross short circuit current limit This value is used in the gross short circuit algorithm This algorithm starts if the following condition exists Output readback is less than the out of set point lower limit The unit has detected no hard arcs e The current A is greater than the gross short circuit current limit This condition has existed for the detection time If the algorithm determines that a gross short circuit exists SC flashes on the front panel and then error E088 Short Circuit Fault or E089 Fatal Short Circuit Fault appears on the front panel PROCESS LIMITS gt SC_LIM To set the gross short circuit current limit 1 Press PROCESS LIMITS gt SC_LIM 2 Rotate the MODIFY knob to select the desired value in hundredths of amps 3 Press ENTER to accept and exit Setting Arc Handling PROCESS ARC Use the ARC menu to implement arc handling during your normal process cycle or during standby Selections in the ARC menu let you establis
297. t Note The 16 bit Power Output value AI AO is shifted right four bits and the remaining four bits are filled with 0s This changes the 16 bit AO to a 12 bit AO with a value of 10 V OxOFFF Note Reserved Write Reserved bits with a 0 for future compatibility 57000097 00B Communication Interfaces 4 57 Advanced Energy Table 4 21 Assembly object data poll optional instance 1 and instance 101 Byte Bit7 Bit 6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit 0 0 Power Output Setpoint AO LSB 1 0 0 0 0 Power Output Setpoint AO MSB 2 Ramp Rate AO LSB 3 0 0 0 0 Ramp Rate AO MSB 4 n uz k Clear Clear PO Run Run Micro Hard Arcs Arcs Note In Bit 0 of Byte 4 PO refers to Power On In this bit 1 turns on the unit s Note Note output 0 turns off the unit s output The 16 bit Power Output value AI AO is shifted right four bits and the remaining four bits are filled with 0s This changes the 16 bit AO to a 12 bit AO with a value of 10 V OxOFFF Reserved Write Reserved bits with a 0 for future compatibility Table 4 22 Assembly object data poll legacy instance 1 Byte Bit7 Bit6 BitS Bit4 Bit3 Bit2 Bit1 Bit 0 0 Power Output Setpoint AO LSB 1 0 0 0 0 Power Output Setpoint AO MSB 2 Ramp Rate AO LSB 3 0 0 0 0 Ramp Rate AO MSB Note In
298. t the address specifies the packet s origin from the Pinnacle Plus unit The address section of the Header field is five bits long which allows a total of 32 distinct addresses Address 0 zero is reserved for the AE Bus broadcast address when this address is used in a host originated packet all units execute the packet but do not respond back to the host For more information on setting the unit address see Setting the Pinnacle Plus Unit s AE BUS Address on page 4 164 The remaining three bits tell the receiving unit how long the Data field is so that the unit can determine when the entire message has been received Note The value in these bits should refer only to the number of actual data bytes Do not include the checksum byte when calculating the value for these bits The Header field address and length must be at the beginning of the message packet so that the receiving unit can compute the length of the packet after receiving the first byte COMMAND This field contains a one byte value 00h to FFh 0 to 255 If the message packet originates with the host computer this value specifies the purpose of the message packet If the message originates with the Pinnacle Plus unit the value specifies the command to which it is responding See AE Bus Commands on page 4 172 for a complete list of AE Bus commands OPTIONAL LENGTH BYTE This field supplements the Header field and exists only when the length bits in t
299. t Data Bytes Number of Response Data Bytes 87 set maximum on timer Sets the maximum amount of time that output will stay on in seconds if this feature is enabled If the length of time since the last output on event exceeds this setting the unit will turn output off The timer is reset at each output on event You can set a time in whole seconds from 0 to 65535 A value of zero disables this feature Not all units have this feature available Send 2 data bytes 16 bit value indicating the timer value in seconds Read back this setting with command 243 CSR codes 0 1 4 9 12 92 pulse frequency index Sets pulse frequency between 0 and 350 kHz in 5 KHZ increments Note Frequency is limited to 150 kHz when the pulse mode is set to be enabled always Send 1 data byte an 8 bit value e 0 Pulsing disabled e 1 5kHz e 2 10kHz e 3to69 15 kHZ to 345 kHZ in 5 kHZ increments e 70 350 kHz Read back this value with command 146 CSR only 93 pulse reverse time Sets pulse reverse time in 0 1 us intervals Send 1 data byte an 8 bit value e 04 0 4 us 05 to 49 follow the same format e 50 5 0 us Note You cannot set a reverse time that is greater than a 45 duty cycle Read back this value with command 147 CSR only 4 100 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 35 PROFIBUS Commands 0
300. t PGM_SRC HOST LOCAL and USER options appear Press one of these buttons to toggle between internal and external for the selected type 2 Press EXIT Note A user card must be installed in order for EXT to function correctly Setting the Panel Mode SUPPLY PANEL Use this option to select between a remote and local control panel lock the control panel set the lock code or set the encoder rate for the MODIFY knob clicks SELECTING REMOTE OR LOCAL MODE SUPPLY PANEL SELECT To switch between the remote active panel and the local active panel 1 Press SUPPLY PANEL SELECT 2 Rotate the MODIFY knob to display YES or NO depending on whether or not you want to switch to a remote local active panel 3 Press ENTER to accept and exit 4 Wait several seconds for verification of switch before using the other control panel SELECTING A LOCK CODE SUPPLY PANEL LOCK To enter a lock code for locking the active control panel 1 Press SUPPLY gt PANEL gt LOCK SET CODE and LOCK UNIT options appear 2 To set a lock code press the SET CODE soft key If a code is already entered press LOCK UNIT gt Any further menu accesses will require entry of the code Note Cycling power on the supply resets the lock status to UNLOCKED SELECTING THE NUMBER OF CLICKS SUPPLY PANEL gt CLICKS 4 142 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply The clicks
301. t both the counter and the period timing at the start of a parameter change Record the counter at the end of the timed period and repeat To reset the over current density counter 1 Press PROCESS MONITOR OVER I gt RESET SETTING THE OVER CURRENT TIMER PROCESS gt MONITOR gt OVER_I gt TIMER Use this option to enable and set an over current timer This function lets you indicate how long you want the power supply to tolerate an over current condition before it shuts off output When the timer expires the unit shuts off output and displays error code E087 see Error Code Troubleshooting on page 6 16 or passive front panel help code H027 see Help Code Troubleshooting Table on page 6 9 To enable the over current timer follow these steps to select a value in 0 1 s increments To disable the timer follow these steps and select a value of 0 1 Press PROCESS MONITOR gt OVER I1I gt TIMER 2 Rotate the MODIFY knob to adjust the value 3 Press ENTER to accept and exit SETTING THE OUT OF SET POINT TIMER PROCESS MONITOR gt SETPT Use this option to enable and set an out of set point timer This function lets you indicate how long you want the power supply to tolerate an out of set point condition before it shuts off output An out of set point condition occurs whenever output moves out of a range determined by your selected set point see page 4 152 57000097 00B Communication Interfa
302. t panel or remote passive panel attached to any unit in the system you can view the output for the individual unit Ifyou have an active front panel or remote active panel attached to any unit in the system you can monitor the output power current or voltage and set point of the individual unit Ifyou have a host computer connected to a serial port on any unit in the system you can monitor the output power current or voltage and set point of the individual unit 5 40 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply For more information on the above devices see Chapter 4 in the Pinnacle Plus power supply user manual Clearing Faults in a Sync Pulse System Table 5 6 describes some of the errors you might encounter with a Pinnacle Plus sync pulse system Table 5 6 Errors Associated With The Pinnacle Plus Sync Pulse System Condition Possible Cause s Transmit unit reports Two or more units have been designated as Multiple Sync Pulse transmitters Transmitters Detected Note Multiple transmitter errors are detected only at power up or when changing port directions Receive unit reports The sync pulse cable has been removed No Syne Pulse All units in the system are designated as receivers Transmitter Detected Note No transmitter errors are detected any time the unit is powered up Any unit reports One of the units in the system is not energiz
303. t target yS NE a life Send 1 data byte indicating which target the CSR code 4 returning packet contains 4 data bytes 32 bit value indicating the time remaining in kilowatt hours Two decimal places are implied For example a value of 100 indicates 1 kWh This value is set with command 12 158 Requests ramp time Returns a 2 byte value 0 2 16 bits indicating a ramp time of 5 50ms request ramp to 60 000 600 00 s time Note If your unit has 100 ms ramp feature enabled one decimal is implied The range is 0 5 s to 6000 0 s This value is set with command 16 159 Requests how much ramp time is remaining 0 2 Returning packet contains 2 data bytes 16 ramp time bits indicating how many 10 ms intervals remaining remain Note If your unit has 100 ms ramp feature enabled the data indicates how many 100 ms intervals remain 57000097 00B Communication Interfaces 4 105 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued information in the returning packet is used by request status AE Global Services The returning packet contains 6 data bytes Ist and 2nd bytes SW_OPTS1 16 bit value e Bit 0 Single Inverter Unit read only Bit 5 500 ns Gate Drive Unit read only Bit 7 100 ms ramp bit clear 10 ms ramp e Bit8 Joule recipe definition bit clear normal e Bit 12 Measurement balance bit set feature enabled 3rd and 4th bytes SW_OPTS2 16 bit value e Bit 1
304. t to the User port ARC D output signal For more information Communication Interfaces on page 4 1 Send 4 data bytes a 32 bit value indicating the number of arcs the value must be at least 0 but no greater than the maximum set for your unit Note If you set the hard arc count limit to 0 each time a hard arc occurs the ARC LED lights for a predetermined time and if applicable a signal is sent to the User port Read back this value with command 178 Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 9 Sets the number of hard arcs required for the 4 CSR codes power supply to provide an arc indication If 0 1 4 9 hard arc the limit is reached during a process cycle then 4 176 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 10 Specifies the voltage level at which the unit 1 CSR codes indicates an arc is occurring Sixteen discrete 0 1 4 9 voltage arc levels are available These levels are trip level represented by the index numbers in the following table Send one data byte 8 bit value identifying the appropriate index value for the desired trip level The table below shows standard index values Your
305. tactor is open due to a fault condition e 44 The Pinnacle Plus has not received a request to turn output on since power up Note See Understanding Command Status Response CSR Codes on page 4 170 for more information on CSR codes Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 161 Reports the status of the most recent output on 0 1 request since the last power up event on the request unit The returning packet contains data byte output on 8 bit value status 4 200 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 162 Requests a report on process status the 0 4 returning packet contains 4 data bytes request 1 i process st status byte status e 0 Unassigned e 1 Ramp active e 2 Run active 3 Output power 0 off 1 on e 4 TIllegal regulation mode e 5 Cable interlock open e 6 End of target life event e 7 Set point status 0 within tolerance 1 out of tolerance 2nd status byte e 0 Over voltage condition exists e Over current condition exists e 2 Unassigned e 3 Control circuit fault e 4 Heat sink over temperature event 5 User interlock open e 6 User port reset active e 7 Main contactor interlock open 3rd status byte 0 Mo
306. tage category II or better installation only 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 nonconductive pollution occurs during operation Occasionally condensation causes temporary conductivity when the device is not operating Note To maintain CE certification for units with the M32 output connector the output terminal block mounting screws must be filled with RTV adhesive to the top of the hole If this device does not have a circuit breaker install and operate it with an AE approved circuit breaker on the AC input to provide the required overcurrent protection In addition you must provide the primary circuit protection such as the branch circuit backup fuse Advanced Energy Industries Inc may provide a supplementary protection circuit breaker in the power supply You must provide a branch circuit backup fuse with a UL LISTED Type K5 or RKS fuse or equivalent that is rated 15 A minimum and no more than four times full load amps not to exceed 125 A for 50 A or less rated breaker and not to exceed 175 A for 51 to 100 A rated breaker 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 57000097 00B Safety and Product Compliance Guidelines 1 7 Advanced Energy 1 8 Safety and Product
307. te If your unit has 100 ms ramp feature enabled the range is 0 5 s to 6000 0 s The out of set point timer is disabled while output is ramping PROCESS CONTROL RAMP To enable ramp mode 1 2 3 Press PROCESS CONTROL gt RAMP gt ENABLE Rotate the MODIFY knob to select Yes or No to enable or disable ramp mode Press ENTER to accept and exit 4 156 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply To select the ramp starting point a percentage of the set point to begin ramping Note This setting only applies to regular ramp mode It does not apply to ramp mode in a timed recipe 1 Press PROCESS gt CONTROL gt RAMP gt START PT 2 Rotate the MODIFY knob to select a percent 3 Press ENTER to accept and exit To select the ramp time 1 Press PROCESS gt CONTROL RAMP gt TIME 2 Rotate the MODIFY knob to select a time 3 Press ENTER to accept and exit Note Under Host control one can generate multiple ramps between set points by sending new set points while the output is on STANDARD SERIAL FLASH PORT Your Pinnacle Plus supply contains a modified AE Bus serial Host communications interface accessible through the Standard Serial port This allows the Pinnacle Plus unit to interface with a host computer You can do everything from the host computer interfaced with the Pinnacle Plus supply that you can do from the active front panel
308. te polarity terminal to ground indirectly through a passive component or a second power source DANGER For safety compliance when configuring for floating output do not allow the maximum voltage at either connection of the output connector terminals to exceed 1700 V with respect to ground Optimal Output Connection To comply with EMI RFI you must meet the following conditions when connecting the Pinnacle Plus power supply to your chamber You should use RG393 or RG 8U type cable Belden 8237 to connect the output to the chamber You should use a good high quality cable with a minimum of 97 shield coverage You can also use other types of cable for example RG 213 as long as they provide the same or higher density shielding and sufficient copper area Note Triax cable is recommended only if the output is floating The outer shield in this case acts as the safety ground 57000097 00B Installation and Operation 5 15 Advanced Energy e RG393 is preferred in high temperature environments and for output currents above 15 A e Inside the output connector shell connect the center conductor to the negative terminal labeled and connect the shield to the positive terminal labeled Keep the loop area inside the shell You should also make a low inductance connection from the shield of the cable to the connector shell Atthe chamber side the center should go to the cathode while the shield connects to the
309. the Pinnacle Plus unit s Standard Serial port and your host computer Transmission Parameters The communications capability of the Standard Serial port is limited to the following parameters Note These transmission parameters do not apply for units with AE Bus cards installed If your unit has an AE Bus card installed see the AE Bus section of this manual for more information on transmission parameters e RS 232 protocol e Baud rate of 19 2 kbps e Pinnacle Plus unit address of 1 Odd parity e 1 start bit 8 data bits one stop bit e Low order bytes are transmitted before high order bytes 4 158 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Please note that the time out period for the Pinnacle Plus is factory set at 0 02 s that is no more than 20 ms can elapse between bytes or the unit will reset and begin looking for a new message packet This can be changed using command 40 or from the active front panel AE BUS HOST PORT Your Pinnacle Plus supply features an AE Bus card with a 9 pin female subminiature D connector for interfacing with a host computer You can do everything from a host computer interfaced with the Pinnacle Plus supply that you can do from the active front panel or Pinnacle Plus Remote Active Panel To obtain a diskette containing sample software with a limited command set as well as an executable version of the AE Bus software please call AE Customer Suppo
310. the last run time is lt 1 minute the seconds will display in hundredths precision That is 12 1 2 s will display as 12 50 s The following information appears in the bottom line of the display left to right e Reverse time Frequency of pulsing Set Point Regulation mode W Power A Current V Volts Warning field flashes the following codes ARCLIM arc limit reached Note ARCLIM is only active when the Hard Arc Counting feature is enabled EOTL end of target life OC over current condition 4 130 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply OV over voltage condition gt SC short circuit MENU soft key which gives you direct access to the menu SETTING THE REVERSE TIME FREQUENCY AND SET POINT To change the reverse time frequency or set point press the soft key under the display The units will flash indicating that you can rotate the MODIFY knob to change the value Once you select a value it s only active for editing changing You need to press the soft key again to enter the value If you press another key before you press the soft key to enter the value the new edited value will not be accepted The one exception is the set point The set point changes as you rotate the MODIFY knob Soft Keys Use the soft keys to select whichever menu functions are shown immediately above them on the two line display Understanding the Menu Opti
311. ther control mode reset the control mode to the User port before attempting to send User port signals 4 40 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Signals The table on the next page provides information about each pin The following paragraphs give general information about the analog and digital signals Note that signals that have the prefix A_ control Side A and signals that have the prefix B_ control Side B ANALOG SIGNALS A A suffix appended to a pin name indicates an analog signal Analog common lines are denoted by the COM A suffix Analog outputs can source or sink up to 3 0 mA The input impedance of the analog inputs is 200 kQ DIGITAL SIGNALS A D suffix appended to a pin name indicates a digital signal Digital commons are denoted by the COM D suffix Digital outputs are short circuit protected The signal levels for digital outputs are as follows Logical 0 V maximum with 1 0 mA maximum leakage e Logical 1 Vpos less 1 5 V minimum Vpos refers to the 24 V supply Output current may range from 0 5 mA to 0 5 A The signal levels for digital inputs are as follows e Logical 0 35 V to 5 V with 0 5 mA maximum leakage e Logical 1 13 V to 30 V and 8 5 mA typical 57000097 00B Communication Interfaces 4 41 Advanced Energy Pin Description Table The following table provides pin and signal de
312. time the output voltage goes below the voltage arc trip level set with command 10 All arc counters are updated every 100 ms or 10 times per second 57000097 00B Communication Interfaces 4 115 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number Number of Sent of Data Response Bytes Data Bytes 190 Requests how many hard arcs occurred in the 0 4 previous run returning packet contains 4 data request hard bytes 32 bit value indicating the total of arc density per hard arcs run Note The unit records a hard arc every time the output voltage goes below the voltage arc trip level for longer than the arc detect time The unit then shuts down for the arc shutdown time period All arc counters are updated every 100 ms or 10 times per second 191 Reports the number of overvoltage or 1 4 report overcurrent events that occurred since the overvoltage counter was last reset AR e NA Send 1 data byte 8 bit value indicating the events desired report e 1 overcurrent events e 2 overvoltage events Returns 4 data bytes 32 bit value indicating the number of requested events 4 116 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 36 PROFIBUS Commands 128 to 255 Continued Command Description Number Number of Sent of Data Response Bytes Data Bytes 195 Requests the ide
313. tion constant when the Pinnacle Plus is producing output it can be power or current or voltage Select one of these regulation modes from the optional Pinnacle Remote Active Panel the active front panel the User port or the serial Host port Note Output power must be off that is output must be deenergized to switch between regulation modes Programmable Set You can program an output level from low values Points up to the unit s maximum rate of output for power current or voltage You can also program the chopper output frequency and reverse time Select these values from the optional Pinnacle Remote Active Panel the active front panel the User port or the serial Host port Note The User port does not have access to the chopper Output Limits You may set maximum output limits for power voltage and current Select these values from the optional Pinnacle Remote Active Panel the active front panel or the serial Host port 57000097 00B Product Specifications 3 1 Advanced Energy Table 3 1 Functional Specifications Continued Description Specification Process Control You can control the process with the following features joule mode ramping and recipes Process Monitoring You can monitor process values for the following target life timer out of set point timer over voltage timer and over current timer Sync Pulse You can control the synchronization of multipl
314. to 127 Continued Command Description Number Numberof of Sent Response Data Data Bytes Bytes 119 Send this command to clear the fault 0 CSR only indication when the Pinnacle Plus supply has master reset experienced a non recoverable explicit clear fault This request is always honored regardless of which interface has control 126 Sets all user definable values to their defaults 1 CSR only reset default settings and stores them in non volatile memory User definable limits are always set to their maximum values Send 1 data byte with a value of zero Commands 128 through 255 Commands 128 through 255 request a value to be read from the Pinnacle Plus unit None of these commands require the unit to be in host control mode Some of these commands for example command 220 require you to include data in the download packet In this case the Number of Transmit Data Bytes column in the following list indicates how many data bytes of the download packet are needed to support the command Response bytes will appear in upload bytes 8 through 12 when ready see Upload Packet in this chapter 57000097 00B Communication Interfaces 4 101 Advanced Energy Table 4 36 PROFIBUS Commands 128 to 255 request user power limit Accuracy is 0 3 of the full rated output power for the supply The returning packet contains 2 data bytes 16 bit value i
315. tput to the center conductor of the coax cable RG8U RG393 If you do not connect the anode to ground use a triax cable and connect the inner shield to the anode The outer shield is connected to the chamber and the shell of the two terminal conductor 5 14 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply Positive Output Configuration For special applications that require a positive output voltage positive with respect to ground connect the Pinnacle Plus power supply s positive terminal on the output connector to the load Connect the negative terminal on the power supply s output connector to the load s common or ground Use the ground terminal on the Pinnacle Plus power supply s output connector to terminate the output cable s shield only Neither the terminal nor the outer shield of the output cable should carry load current Do not use the power supply s ground terminal as a system ground Do not connect a current carrying conductor to the terminal even if the conductor is a shield element of the cable Floating Output Configuration You can configure the Pinnacle Plus power supply s output such that neither the positive output terminal nor the negative output terminal have a direct connection to ground floating output To achieve the floating output configuration connect either the positive or the negative terminal of the power supply s output connector to the load and connect the opposi
316. ture is only available on Pinnacle Plus 10 kW units This feature is not available on Pinnacle Plus 5 kW or dual units Connector The Master Slave Pulse port is a 15 pin subminiature D connector that is used for master slave operations Pin 8 Pin 15 Pin 1 Pin 9 OOOOOOOO POOOOO 1061 Figure 4 7 Master Slave Pulse port connector 4 50 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Pin Descriptions Table 4 17 provides pin and signal descriptions for the Master Slave Pulse port Table 4 17 Master Slave Pulse Port Pin and Signal Descriptions Pin Associated Pin Name Description Pin 1 n a unassigned unassigned 2 n a unassigned unassigned 3 n a unassigned unassigned 4 5 POFF MSP Pulse Off signal 5 4 POFF MSP Return Pulse Off signal return 6 7 PON MSP Pulse On signal 7 6 PON MSP Return Pulse On signal return 8 Cable shield SYNC POWER SENSE Verifies all units have logic control power 9 n a unassigned unassigned 10 n a unassigned unassigned 11 12 OC MSP Overcurrent signal 12 11 OC MSP Return Overcurrent signal return 13 14 OV MSP Overvoltage signal 14 13 OV MSP return Overvoltage signal return 15 n a unassigned unassigned 57000097 00B Communication Interfaces 4 51 Advanced Energy Cable Configuration Figure 4 8 illustrates the Master Slave Pulse port cable configuration EJ o
317. ty 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 NEVER DEFEAT INTERLOCKS OR GROUNDS iv 57000097 00B Pinnacle Plus 10 kW Power Supply TRADEMARKS Ac ADVANCED isa registered trademark of Advanced Energy Industries DL ENERGY Inc Bird is a registered trademark of Bird Electronic Corporation Pinnacle is a registered 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 e tech writing aei com To order a manual please contact Technical Support e technical support aei com 57000097 00B Advanced Energy vi 57000097 00B Pinnacle Plus 10 kW Power Supply Table of Contents Chapter 1 Safety and Product
318. ued Signal Name Signal Description Pin Type 9 FLT D Digital This signal provides fault indication A output low logic level on this pin indicates a fault with the Pinnacle Plus unit See the Troubleshooting and Global Support chapter for information regarding error recovery Note Pins 17 18 20 21 and 24 are the dedicated returns for this pin 10 OUTPUT D Digital This signal provides an indication of the output status of output power A low logic level on this pin indicates the contactor is closed and output is on Note Pins 17 18 20 21 and 24 are the dedicated returns for this pin 11 ON D Digital A low logic level on this pin sets DC input output on Note Pins 17 18 20 21 and 24 are the dedicated returns for this pin 12 PULSEON D Digital This signal provides control of the pulse input mode A high logic level on this pin sets pulse mode on A low logic level on this pin sets pulse mode off This pin is switch selectable to reverse sense to PULSEON D active low See Table 4 12 on page 4 34 Switch 6 description for more information Note Pins 17 18 20 21 and 24 are the dedicated returns for this pin 13 unassigned n a n a 4 30 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 11 Single 15 V 25 Pin User Port Pin Description Continued Signal Name Signal Description Pin Type 14 COM A Ana
319. ulation mode e User reference signals for voltage current and power 0 Vdc tol0 Vdc Fault status digital output e Flexible grounding selection for noise source separation Pulsing on off control input Selectable analog output scaling Compatibility with Allen Bradley Siemens and Mitsubishi PLCs If you are using a Pinnacle Remote Active Panel or an active front panel you need to set the control mode to USER to operate the Pinnacle Plus unit from the User port See Control Key in the Understanding the Control Panel section of this chapter for more information Note Advanced Energy recommends taking standard preventative measures against electro static discharge ESD around all Pinnacle Plus units Note Grounding the user port at the power supply reduces noise interference To avoid ground loop problems you should typically ground only one end Note You need to set the pulse frequency and reverse time through the Remote Active Panel the Active Front Panel or the serial interface Host port Interlock Requirements No user interlock is provided Cabling Requirements The cable used to connect the Pinnacle Plus 25 pin User port to the system controller must be a shielded 25 wire 22 AWG jacketed cable type UL 2343 or equivalent Twisted pair wiring may be used but is not mandatory To minimize signal losses keep the cable length as short as possible The maximum recommended cable length between the
320. ull scale represents the rating of the supply see the Specifications chapter of this manual for more information 57000097 00B Communication Interfaces 4 11 Advanced Energy Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 24 9 POUT A analog This signal represents output output power Full scale represents the rating of the supply see the Specifications chapter of this manual for more information 25 9 IOUT A analog This signal represents output output current Full scale represents the rating of the supply see the Specifications chapter of this manual for more information 26 nla unassigned n a n a 27 LEVELIN A This signal is used to program the output level Full scale represents the rating of the supply for the active regulation mode see the Specifications chapter of this manual for more information 28 nla unassigned n a n a 29 19 SPARE3 D digital Spare input input 30 n a unassigned n a n a 31 9 LEVELOUT A analog This signal represents the output programmed set point level Full scale represents the rating of the supply see the Specifications chapter of this manual for more information 4 12 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 2 Single 15 V 37 Pin User Port P
321. umber CSR of Codes or Transmit Number of Data Response Bytes Bytes 163 3rd status byte 0 4 request 0 Transmitter Receiver mode 4 204 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 48 AE Bus Commands Continued actual current are implied For example a value of 1500 indicates 15 00 A Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 164 Requests the set point level by whichever 0 3 method of output regulation has been selected request set the returning packet contains 3 data bytes point f regulation First second byte Set point level mode 16 bit value e Third data byte Regulation mode 8 bit value gt 6 Power 7 Voltage gt 8 Current Note Output power must be off that is output must be deenergized to switch between regulation modes These values are set with commands 3 and 6 165 Requests a snapshot of the output power level 0 2 at that instant the returning packet contains 2 request data bytes 16 bit value indicating power actual power level Assume three decimal places for a stand alone unit 6000 6 000 kW and two decimal places for a master slave unit 2000 20 00 kW Note Refer to the Specifications chapter of this manual for information regarding your unit s capabilities 166 Requests a snapshot of the output voltage level 0 2 at that insta
322. umbers and the orientation of the unit may change However the orientation of the DIP is always the same relative to the unit and when the unit is sitting right side up the numbers are at the top of the DIP The following illustration shows the orientation of the AE Bus port and DIP switch on the back panel of the Pinnacle supply AE Bus Port CO OROORO Q QZR Se ORO SREO LOO GORREBEOKN ss ss 0 SE ROROROROREROROROROROS Figure 4 24 Orientation of the AE Bus port and external DIP switch on the back panel 4 162 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply The first five min switches A4 to AO specify the address of a Pinnacle Plus unit see Table 4 44 on page 4 164 which a host computer must include in the message packet it sends Each Pinnacle Plus supply in a network must have a unique address The next two min switches BR1 and BRO specify the baud rate for the AE Bus port see Table 4 44 on page 4 164 The last min switch allows you to choose between RS 232 or differential communication RS 485 or RS 422 RS 232 is selected when the switch is up Differential communication is selected when the switch is down A DANGER RISK OF DEATH OR BODILY INJURY Disconnect and locko
323. und stud of the next slave unit Continue connecting together subsequent slave unit chassis in this manner Note We recommend you connect the ground stud on the master unit to system ground MASTER SLAVE CONFIGURATION EXAMPLE Figure 5 14 illustrates how to configure your Pinnacle Plus power supplies for master slave operation Note The master slave feature is only available on Pinnacle Plus 10 kW units This feature is not available on Pinnacle Plus 5 kW or dual units 5 24 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply oO Master O To Rack Ground and Chamber Ground O Slave 1 O as O Slave 2 O O 3121 Figure 5 14 Master slave system configuration example Connecting for Sync Pulse Operation The following sections include information about connecting and configuring your Pinnacle Plus power supplies for synchronized pulsing Sync Pulse operation UNDERSTANDING SYNC PULSE OPERATION With the Sync Pulse or synchronized pulsing feature of the Pinnacle Plus power supply you can synchronize up to six units to operate at the same frequency with independent set points and On Off control The Sync Pulse feature is useful for reducing arcin
324. unication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 47 Command Status Response CSR Codes Continued 5 Invalid parameter 6 Program source is incorrect 7 Active fault s exist 9 Data byte count is incorrect 10 User port has priority 11 Bus is not ready 12 This feature is not available on your unit 16 Target life has been consumed 17 Output OFF timer active minimum off time is 50 ms 19 Recipe is active change not allowed 21 Joule set point has not been reached 25 Unit is configured as a slave 28 Set point exceeds user limit 29 Regulation mode is locked you cannot switch between regulation modes while output power is on 31 The User port reset is active you must de assert the reset line on the User port 33 Pulsing disabled frequency 0 34 Unit is a Sync Pulse receiver 36 User set point out of range 99 Command not accepted there is no such command 57000097 00B Communication Interfaces 4 171 Advanced Energy OAh HOST PINNACLE PLUS 68h Header Cmd Data Chksum time 06h ACK 09h 06h OOh OFh Header Cmd CSR Chksum 2251 Figure 4 27 AE Bus communications transaction example AE Bus Commands To operate the power supply from a host computer you must first set the control mode to host command 14 AE Bus commands 1 through 127 change the value of a param
325. up down down 28 down down down up up 29 down down down up down 30 down down down down up 31 down down down down down SETTING BAUD RATES AND COMMUNICATION MODE Also use the DIP switch see Figure 4 22 on page 4 161 and Figure 4 23 on page 4 162 to set the baud rate for the AE Bus port The following tables show the DIP switch settings for BRO BR1 and Switch 8 Switch 8 sets the supply to either RS 232 or RS 485 422 Switches BRO and BR1 set the baud rates The unit is set for either standard or high speed baud rates which define the baud rates that can be be selected Host command 85 sets the unit for either standard or high speed baud rates Table 4 45 Setting Switch 8 Switch Position Communication Mode RS 232 Down RS 485 422 Table 4 46 Baud Rate Settings Standard Baud Rate High Speed BRO BR1 Baud Rate RS 232 RS 485 422 RS 232 RS 422 BRO BR1 RS 485 1200 9600 19 200 up up 4800 19 200 38 400 up down 9600 38 400 57 600 down up 19 200 57 600 115 200 down down 57000097 00B Communication Interfaces 4 165 Advanced Energy AE BUS COMMUNICATIONS The following sections describe communications between a host and the Pinnacle Plus supply AE Bus Protocol The AE Bus protocol uses pure binary data nothing is coded ASCII and is designed to facilitate direct communications between a host computer and the Pinnacle Plus power supply The AE Bus me
326. uring the last run the pulse will occur when the output is turned off 2 If you set the hard arc count limit to zero this signal will pulse for a predetermined time for every hard arc seen by the unit If another hard arc is seen before the last pulse is complete the pulse width will be refreshed to the full width These conditions will also be indicated through the ARC LED on a Passive Display Panel 4 10 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply Table 4 2 Single 15 V 37 Pin User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 22 37 EOTL D digital Normally this pin is output configured to signal the end idi of target life EOTL D but READY D if your unit was ordered and configured for use with an Advanced Energy Varian interface unit see READY D below e EOTL D This signal goes low when the active target life counter reaches zero thus indicating that target life has ended e READY D If your unit is configured for use with an Advanced Energy Varian Interface unit a high on this pin indicates faults are active ready bit is de asserted and the unit is not ready to output power A low on this pin indicates no faults are active and the unit is ready to output power provided all other necessary conditions have been met 23 9 VOUT A analog This signal represents output output voltage F
327. us 10 kW Power Supply Table 4 48 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 24 calculate logic CRC Tells the Pinnacle Plus supply to calculate its logic CRC Note During the approximately 2 seconds it takes to calculate the CRC the Pinnacle Plus unit will not respond to any other commands Read this value back with command 230 0 CSR codes 0 2 9 26 joule threshold Specifies the output level that needs to be met before the Joule output energy calculation begins the joule threshold The joule threshold type power voltage or current is set with command 64 If the threshold type is set in Watts send 2 bytes 16 bit value between 10 and maximum power divided by 8 This value represents watts in a stand alone system and decawatts in a master slave system For threshold types set in Volts or Amps send 2 bytes 16 bit value between 0 and the maximum output limit Note The Joule energy calculation begins after n mS regardless of the output level The time value n mS is set in the configuration and cannot be changed If the output level meets the joule energy threshold prior to the time expiration the joule energy calculation will begin Read back this value with command 136 0 1 2 4 9 57000097 00B Communication Interfaces 4 183 Advanced Energy T
328. ut tagout all sources of input power before working on this unit or anything connected to it A CAUTION Power down the Pinnacle Plus and take proper ESD precautions before removing the unit s top cover to position jumpers Failing to take proper ESD precautions in this case could result in damage to the unit ATTENTION If the product has a Warranty Void if Seal is Broken label you must receive prior approval from AE before you can remove the power supply box cover If you remove the box cover before receiving approval from AE the product warranty is no longer valid Contact AE Global Services for more information The mode of differential communication that is RS 485 or RS 422 is selected via the jumper labeled as such Place the jumper across pins 1 and 2 for RS 485 labeled 485 Place the jumper across pins 2 and 3 for RS 422 labeled 422 If you have selected RS 422 or RS 485 you also have to set two terminator jumpers according to the following Ifhave selected RS 422 or if your Pinnacle unit is the last device on an RS 485 multi drop chain place the jumpers across pins and 2 labeled Term This setting is the factory default Ifyou have selected RS 485 and your Pinnacle unit is not the last device on a multi drop chain place the jumpers across pins 2 and 3 for no termination If you have questions about setting these jumpers contact AE Global Services 57000097 00B Communication Interfaces 4 16
329. utput Power See the following sections for information on how to connect your output connector for the Pinnacle Plus power supply Each section contains a drawing of the output connector to help you determine your type of output connection Output Power Cable Recommendations on page 5 11 Two Terminal Multicontact Output Connector on page 5 12 Three Terminal Multicontact Output Connector on page 5 17 5 10 Installation and Operation 57000097 00B Pinnacle Plus 10 kW Power Supply e UHF Output Connector on page 5 19 A DANGER RISK OF DEATH OR BODILY INJURY Disconnect and lockout tagout all sources of input power before working on this unit or anything connected to it A WARNING 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 A WARNING This device must be installed so that the output power connection is inaccessible to the user OUTPUT POWER CABLE RECOMMENDATIONS Choosing the appropriate output power cable for your Pinnacle Plus power supply produces the best process results In general using the shortest possible cable gives you the widest process window and the best results Cables should be no longer than 10 m 33 ft Long cables
330. uts off output When the timer expires the unit shuts off output and displays error code E086 see Error Code Troubleshooting on page 6 16 or passive front panel help code H026 see Help Code Troubleshooting Table on page 6 9 To enable the over voltage timer follow these steps to select a value in 0 1 s increments To disable the timer follow these steps and select a value of 0 1 Press PROCESS gt MONITOR OVER_V gt TIMER 2 Rotate the MODIFY knob to adjust the value 3 Press ENTER to accept and exit VIEWING THE OVER CURRENT DENSITY PROCESS MONITOR gt OVER I Use this menu to view the density of unit over current responses per run To view the over current density 4 144 Communication Interfaces 57000097 00B Pinnacle Plus 10 kW Power Supply 1 Press PROCESS MONITOR gt OVER I Note When you see the counter increment or OC flashing in the top level menu of the output display screen an over current condition is active For an illustration of the output display screen see Two Line Output Display Screen on page 4 129 RESETTING THE OVER CURRENT DENSITY PROCESS MONITOR OVER_I RESET Use this option to reset the over current density counter to zero You can use this feature to characterize a process by recording the over current counter over the same time period for every parameter change in the process To use the over current counter in this way rese
331. ve input power System Input Power Fault cable has lost input power supplied and are in an on state 2 Check the sync pulse cable for damage E095 Reverse Time Limit Exceeded The pulsing transmitter unit has a higher reverse time than is allowed in the receiver unit This may be caused by a lower user voltage limit in the transmitter unit than in the receiver unit The reverse time is inversely proportional to the user voltage limit Reduce the reverse time set for the transmitter side or lower the voltage limit in the receiver side 57000097 00B Troubleshooting and Global Services 6 23 Advanced Energy Table 6 4 Error Code Troubleshooting Table PROFIBUS MAC Reset of Offline Error Code Problem Indicated Suggested Action Message E112 The closure of the This problem can be caused by rapid contactor has been cycling of any self clearing error that Contactor delayed for because it has opens the contactor Check for and Delayed received requests for more resolve these types of errors For than two closures within 6 example seconds The delay will i j last as long as it takes to Rapid cycling of the user interlock maintain the limit of no Noise on the Sync Pulse cable which more than 2 closures the unit interprets as a Sync Pulse within a six second System emor window E151 E151 is the same error For more information about documented for E051 trou
332. ves no response within a reasonable period it takes whatever action it has been programmed to take Meanwhile the Pinnacle Plus unit has prepared a message packet with the requested information or appropriate CSR code which it then transmits to the host The host determines by means of the checksum if the message is complete If the host detects an error in the transmission by using the Checksum it can request the packet be sent again by transmitting a NAK If the Pinnacle Plus unit receives an ACK it returns to the normal waiting state If the Pinnacle Plus unit receives a NAK it re transmits the message packet The Pinnacle Plus unit continues to re transmit in response to NAK transmissions until the host stops the cycle If the Pinnacle Plus unit receives no response it assumes an ACK and returns to the waiting state Understanding Command Status Response CSR Codes When the Pinnacle Plus unit sends a Command Status Response CSR code in response to a command interpret the CSR a one byte response code in the following way Table 4 47 Command Status Response CSR Codes Code Meaning 0 Command accepted The following CSR codes are sent in response to a command that was not accepted and provide an indication of why the command was not accepted 1 Control mode is incorrect 2 Output is on change not allowed 3 Output is off change not allowed 4 Data is out of range 4 170 Comm
333. w you to move forward or backward Selections that can be changed will appear with CHANGE on the 4th soft key ENTER is on the 5th soft key in all cases 2 Use the arrow keys to move to the selection you want 3 Press the 4th soft key CHANGE to select the change and then press the 5th soft key ENTER The change is accepted and you are returned to the Service Debug level Note Pressing the MODIFY knob once also returns you to the Service Debug level but the change is not saved The following are the available configuration options Note that certain configuration options are reset immediately while others require cycling power on the unit RAMP RESOLUTION 10ms to 100ms changes immediately JOULE RECIPE STATUS Redefine the Profibus upload status bits changes immediately USER PORT EOTL DEFINED AS Changes the definition form indicating End of Target Life EOTL or a ready signal changes immediately INVERTERS The number of inverters in the unit GATE DRIVE Inverter gate drive speed GROSS SHORT CIRCUIT DETECTION read only Enabled by default The factory set configuration file can disable the feature This feature operates only in power and voltage regulation modes The gross short circuit algorithm starts if the following condition exists Output readback is less than the out of set point lower limit The unit has detected no hard arcs The current A is greater than the gross short circuit current limit
334. wer supply has been assigned to the User port Note User control can only be selected when a User port interface card is installed in the unit Regulation Key Use this key to select the method of output regulation when the control panel has control local control Note You can not change regulation modes while output power is energized on Table 4 41 Regulation Key LEDs POWER Specifies that the method of output regulation is power CURRENT Specifies that the method of output regulation is current VOLTAGE Specifies that the method of output regulation is voltage Two Line Output Display Screen The display screen displays two lines of information When you first power up the display screen appears 57000097 00B Communication Interfaces 4 129 Advanced Energy Readbacks Clock I D Clock Y Y Y Reverse Time Frequency Setpoint Setpoint Warning Field Menu of Pulsing Source Access 1488 Figure 4 15 Two line output display screen The following information appears in the top line of the display left to right e Voltage readback e Current readback in amps Power readback in watts e Clock ID what the supply is doing RMP output is on and ramping RUN output is on and the clock shows the elapsed time gt OFF output is off and the clock shows the last run time gt IGN output is on voltage threshold has not been reached e Clock Note If
335. wer supply user manual for instructions on connecting to the port Note To reduce EMI interference we recommend using shielded cable to connect to the serial port Connecting for User Port Control See Chapter 4 for instructions on connecting your analog digital interface Note To reduce EMI interference we recommend using shielded cable to connect to the User port Grounding the User port at the power supply reduces noise interference To avoid ground loop problems you should typically ground only one end Connecting Input Power All power supplies leave the factory with their input voltages identified on the rear panel and on an enclosed test checklist The Pinnacle Plus power supply provides the following input voltages depending on your unit configuration e 208 VAC wye or delta connection 230 400 VAC wye connection only e 277 480 VAC wye connection only All input voltages are three phase 50 60 Hz The AC line input connection is a five terminal DIN terminal block on the rear panel On the terminal block connection labels on the input terminal shield and below each terminal position on the rear panel show line L3 L2 L1 neutral N and Protective Earth ground connections GND Note No neutral connection is required However if neutral is present connect it to the N terminal 57000097 00B Installation and Operation 5 9 Advanced Energy INPUT POWER CABLE REQUIREMENTS To connect your s
336. y does not contain a User port that emulates another supply full scale for set point input and readback output is as follows for power 0 to 10 kW for current 0 to 40 A for voltage 0 to 1500 V Output Polarities The two terminal connection allows a floating output The maximum voltage at either terminal relative to ground should not exceed 1700 V peak The UHF connector body is securely connected to chassis ground therefore the center connector is configured for negative output Output Frequency 5 kHz to 350 kHz 5 kHz increments self run When operating a master slave system in voltage regulation mode the maximum pulsing frequency is 250 kHz Note The PNCL PLUS self run frequency has a granularity of 50 ns Therefore the maximum difference from set point to actual is always lt 1 never exceeding 2 6 kHz maximum with an average difference across the frequency range of lt 0 1 Reverse Time 0 4 us to 10 0 us 0 1 us increments up to a 45 reverse duty cycle for a given frequency Some units are configured for a maximum of 5 0 us reverse time See Maximum Allowable Reverse Time For a Given Frequency on page 3 9 and Understanding Frequency and Reverse Time Settings on page 5 37 for more information Reverse Voltage Approximately 10 of the operating voltage voltage readback shown on the active front panel interface 3 8 Product Specifications 57000
337. y lethal voltages may cause serious personal injury or damage to equipment Ensure that proper safety precautions are taken First Check If you believe you are experiencing problems with a Pinnacle Plus power supply check for obvious signs of damage to the unit itself cables and connectors 57000097 00B Troubleshooting and Global Services 6 1 Advanced Energy If damage has occurred power off the unit and call AE Global Services If there are no obvious signs of damage proceed to Checks with the Unit Powered Off on page 6 2 and Checks with the Unit Powered On on page 6 2 Checks with the Unit Powered Off Perform the following checks with the unit powered OFF 1 Ensure the power to the unit is off 2 Check for visible damage to the unit cables and connectors 3 Ensure all unit connectors are installed correctly and are fastened tightly 4 Check to determine whether any system related circuit breakers have been tripped 5 Ensure all phases of the main input power are applied to the appropriate power supply terminals 6 Ensure there is input power to both the unit and the remote and ensure the input power meets specifications 7 Ensure ground connections are adequate and secure and comply with local safety codes 8 Check the position of the switches on the DIP for the serial Host port if your unit has a Host port against the addressing information in the user manual 9 Ensur
338. y of communication interfaces Not all of the information will apply to a given Pinnacle Plus unit If you are unsure about which interfaces are on a particular unit you can identify the interfaces by looking at the back panel of the unit The interfaces are labeled and most of the labels clearly identify the interface For User port identification please see the following section IDENTIFYING THE USER PORT ONA PINNACLE PLUS UNIT Pinnacle Plus units can come with a variety of User ports This manual covers several of those options Use the following table to find the information for the User port on a unit Table 4 1 Identifying the User port User Port Single 15 V 37 Pin The Unit Has This User Port If The User port is a 37 pin subminiature D port The User port label is either 15v User Port or 15v Sng Iso User Port For Information See This Section Single 15 V 37 Pin User Port on page 4 2 Single 24 V 37 Pin The User port is a 37 pin subminiature D port The User port label is User Port Iso Single 24 V 37 Pin User Port on page 4 16 Single 15 V 25 Pin The User port is a 25 pin subminiature D port Single 15 V 25 Pin User Port on page 4 24 57000097 00B Communication Interfaces 4 1 Advanced Energy Table 4 1 Identifying the User port Continued User Port The Unit Has This User Port If For Information See This Section
339. ystem to the power supply you need stranded wire of a gauge consistent with your application and applicable requirements and the input power specification See Conditions of Use on page 1 7 for more information on making the input power connection A CAUTION If your unit does not have a circuit breaker install and operate it with a circuit breaker on the AC input to provide over current protection The circuit breaker must have a trip value as specified in line current section of the electrical specifications of your unit The circuit breaker switch must be easily accessible and near the device Circuit breaker or disconnect device must lock out tag out all sources of input power FIVE TERMINAL INPUT CONNECTOR To Connect to the Five Terminal Input Power Connector 1 Strip approximately 60 mm 2 36 to 70 mm 2 760 of the insulation from the end of the power cord 2 Separate the five wires and strip approximately 10 mm 0 40 of the insulation from each wire 3 Ensure that the ground wire the yellow and green wire is approximately 7 mm 0 280 longer than the other wires Crimp a ferule of appropriate size on each lead Remove strain relief housing Pass the cable through the strain relief Connect each wire to the proper input terminal block according to the labels QO N A Nn A Replace the strain relief housing Tighten the strain relief Connecting O

Pinnacle® Plus+ 10 kW Power Supply 325 VDC – 800

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Pinnacle&reg; Plus+ 10 kW Power Supply 325 VDC &ndash; 800

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Pinnacle® Plus+ 10 kW Power Supply 325 VDC – 800