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1. 57 lead d XER N PIN 1 Ls PING PIN 9 PIN 5 AT 4 lead Figure 5 9 Sync Pulse cable CONFIGURING FOR SYNC PULSE TRANSMIT RECEIVE To configure the unit to transmit or receive 1 Remove all input power from the transmit and receive units 2 Using the soft keys on the Active Front Panel or Remote Active Front Panel select SUPPLY PULSE TX RX 3 Set the unit to TRANSMITTER or RECEIVER Note One unit must be set to transmit all other units must be set to receive 4 Repeat steps 1 and 2 for the rest of the units Note Units can not be hot plugged for Sync Pulse to operate Sync Pulse Configuration Examples PIN 5 PIN 1 PIN 1 ofereo D OO o9 PINS mes PIN 9 PIN 6 PIN 6 PIN 9 The following block diagrams provide a high level view of possible configurations for a Sync Pulse system SIMPLE SYNC PULSE SYSTEM The following configuration 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 5702285 B Installation 5 17 Advanced Energy Transmit Receive Receive In the Sync Pulse system all units pulse at the same frequency but may have their own unique output power set
2. 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 3 12 Specifications 5702285 B Pinnacle Plus 10 kW 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 5702285 B 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 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 75
3. Pin Pin Name Description 1 UNASSIGNED 2 TXD D RS 232 transmit data 3 RXD D RS 232 receive data 4 UNASSIGNED 5 COM D Data common 6 TR R RS 485 transmit receive data RS 422 received data 4 46 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 12 AE Bus Host Port Pin Descriptions Continued Pin Pin Name Description 7 TR RS 485 transmit receive data RS 422 received data 8 T RS 422 transmit data 9 T RS 422 transmit data Transmission Parameters Switch Settings 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 RS 232 1200 4800 9600 19 200 RS 422 RS 485 9600 19 200 38 400 57 600 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 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
4. Table 7 3 Help Code Troubleshooting Table Continued Help Help Code Problem Indicated Suggested Action Code Message Number H006 Analog Setpoint You have attempted to De assert the analog set Selected change the regulation mode point and retry the function or a set point when the For more information see power supply has been setto command 17 in the I O respond to an external Communication and analog source Control chapter H007 Faults Are You requested output On Clear fault and try again Active while fault was active H009 Data Byte The number of data bytes Check the command s Count Incorrect sent does not match the requirements and resend the number of data bytes command For more required by the command information see the I O Communication and Control chapter 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 target through another another target through interface select target 1 from another interface that is the User port through either a serial port or a panel Note When you have selected a target greater than 1 through the User port the User port s target setting has priority H012 Specified You have attempted switch Select another interface Interface Not to User control when your Local or Host For more Installed power s
5. a 5 14 Clearing Faults in a Master Slave System 5 14 Master Slave Input On Off Combinations iles 5 15 Sync Pulse Operation cse ehe dd bee KK KK KK KK RE SESE ER EEE REESE DS 5 15 X 5702285 B Pinnacle Plus 10 kW Sync Pulse Port Connector idus d be ES KAG EE Ec a KE KI KK Ri 5 16 Sync Pulse Port Pin Descriptions kK KK KK KK RR eee 5 16 Syne Pulse POLIT Cabl 26e arco dci one NAA BUKAKA PRA C e Ce 5 17 Configuring For Sync Pulse Transmit Receive 0 KK RR RR KK eee 5 17 Sync Pulse Configuration Examples cece eee eee 5 17 Simple Sync Pulse System 0 00 KK KK KK eee eens 5 17 Sync Pulse Master Slave System 00000 aa 5 18 Monitoring Your Sync Pulse System KK KK KK KK KE KK KK KK KK 5 19 Clearing Faults in a Sync Pulse System 0a 5 20 Rear Panel Illustration kk kK kK kK KK KK KK KK KK KK KK KK KK KK KK 5 21 Chapter 6 Operation Operating Overview oc vic en KG kk kk kk KK KK KK KK KK KK KK KK KK KK KK KK KK eRe ES 6 1 Understanding Pinnacle Plus Arc Handling llli 6 2 Voltage Arc Trip Level kk kk kk KK KK KK KK KK KK es 6 2 Frequency and Reverse Time Settings KK eee eee KK KK 6 3 Low Power Operation Versus High Power Operation 6 4 Low Power Operation d acc kk kk kK KK KK KK KK Rc KK K KK KK KK KK KK KK 6 4
6. 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 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 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 Options on page 4 20 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 with the soft keys to change selections and modify values that appear on the two line display 5702285 B O Communication and Control 4 19 Advanced Energy CONTROL PANEL CONTROLS Use the MODIFY knob and the five unlabeled soft keys that are directly below the display to select parameters and modify values To changes 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
7. 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 7 12 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW Error Code Troubleshooting Table Table 7 4 Error Code Troubleshooting Table Error Code Message Problem Indicated Suggested Action E000 DSP Init Control Fault The DSP failed to respond to the processor Power the unit off and then back on If the error code reappears contact AE Global Customer Support 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 Bus Fault The DC bus has failed probably due to an AC input power problem 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 See the Specifications chapter for AC input power specifications E004 Heat Sink Over Temperature The unit is overheating Inspect the unit s cooling system and review cooling specifications ensure that th
8. 00 00 eae 4 44 Transmission Parameters kk kk KK KK KK KK KK es 4 45 5702285 B ix Advanced Energy AE Bus Hest POIL 22225 S QI eire d te poo pedes BAKA AE 4 46 Pin Descriptions face in oe waned dt de esee KK KK KK kK KK kK KK kk M aU 4 46 Transmission Parameters kk kk kk kK KK KK KK KK KK KK eee KK KS 4 47 Switch Settings access ese kk kk kK kK kK KK KK KK KK ees KIR KK IK KK LEE RE REDE 4 47 Setting the Pinnacle Plus Unit s AE BUS Address 4 50 Setting Baud Rates and Communication Mode 4 52 AE Bus Communications 00 kk kk kK KK KK KK ees 4 52 AE Bus Protocol s y xao NAKA OY ERG SES ERR Y EWE AOS 4 53 Header asic sexe b rok ERU Ae ee wee A ae AG 4 53 Comnal d imate 2 Ga 2002 2 d w l eb hess ASAN 4 54 Optional Length Byte WR KK KK KK KK eee 4 54 Data Data Bytes kk kk kK KK KK KK KK KK KK E KK KK KK KK KI 4 54 NECKSUIN PI 4 55 Creating an Ideal AE Bus Communications Transaction 4 55 Understanding Command Status Response CSR Codes 4 56 AE Bus Commands 05542344540 kk kk RR REOR eee Shan deen een en AG 4 58 Front Panel Illustrations kk kk kk kK KK KK KK KK KK KK KK KK KK KK KK KK k 4 97 Chapter 5 Installation UNPACKING exact ba dial la W ku ERA d ai sees RESQUE RE a W la XA RO de hus 5 1 Meeting Spacing Requirements KK KK KK KK KK KK KK KK KK KK KK KK KK 5
9. I O Communication and Control chapter Ensure that all system interlocks have been satisfied Power the unit back on 5702285 B Troubleshooting and Global Customer Support 7 15 Advanced Energy Table 7 4 Error Code Troubleshooting Table Continued Error Code Message Problem Indicated Suggested Action E021 Interlock Open Cable The ribbon cable between the logic card and the inverter board has come loose Call AE Global Customer Support E022 Interlock Open Contactor The unit s Contactor Interlock has not been satisfied Power off the Pinnacle Plus unit Ensure that the Contactor Interlock is properly connected Ensure that all system interlocks have been satisfied 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 See I O Communication and Control chapter for additional information E033 Message Queue The microprocessor has fallen behind and cannot keep up with events De energize the Pinnacle Plus unit and then restart Overflow E051 The PROFIBUS master Have the master reestablish
10. 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 MASTER SLAVE SYSTEM FAULTS SERVICE DEBUG SYSTEM Use this option to check for faults in your master slave system Select FAULTS to determine fault type select UNITS to determine which units have faults Note Master Slave options are only available if your unit has a master slave Host card installed 5702285 B O Communication and Control 4 25 Advanced Energy 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 COMMUNICATIONS CARD SERVICE DEBUG CARD Use this option to find out specific communications debug information 1 Press SERVICE gt DEBUG CARD Note Not all cards support this feature CHECKING YOUR SOFTWARE LOGIC SERVICE DEBUG LOGIC Use this option to find out what software logic options are installed 1 Press SERVICE gt DEBUG LOGIC The configuration options display one at a time Arrows above the first two soft keys allow you to move forward or backward Selections that can be changed will appear with CHANGE on th
11. 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 e First byte Recipe step value must be greater than 0 but no greater than 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 1 through 8 the MSW is cleared To set joule set points greater than 65535 first send command 23 with steps 1 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 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 5702285 B O Communication and Control 4 67 Advanced Energy
12. Read back this setting with command 146 5702285 B O Communication and Control 4 75 Advanced Energy Table 4 17 AE Bus Commands Continued scratch pad Retrieve this information with command 131 Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 93 Sets pulse reverse time from 0 4 usto 5 0 us in 1 CSR codes 0 1 us increments 0 1 4 9 33 pulse reverse time e 04 04 us e 05 0 5 us e 06 0 6 us 07 to 49 follow the established pattern e 50 5 0 us Read back this setting with command 147 119 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 128 Requests the power supply type the returning 0 4 packet contains 4 ASCII characters PLUS request supply type 4 76 O Communication and
13. 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 5702285 B Pinnacle Plus 10 kW Chapter 3 Specifications FUNCTIONAL SPECIFICATIONS Table 3 1 Functional Specifications 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 Regulation 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 s
14. 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 1 Verify that the joules mode is disabled or has a valid set point value For more information read about the Energy function in the I O Communication and Control chapter Verify that the target life counter is disabled or has a valid value For more information read about the Target function in the I O Communication and Control chapter For dual models verify that both units are enabled For more information consult the descriptions for E020 in the table in the following section Verify that the user definable power voltage and current limits are set to values reasonable for the process application Check for interlock bus fault or over temperature faults 5702285 B Troubleshooting and Global Customer Support 7 5 Advanced Energy 6 From the front panel main menu press SUPPLY DEFAULTS and reset the unit default settings Or send command 119 through the Host port to reset all defaults 7 Try again to turn on output power Help Code Troubleshooting Table Table 7 3 Help Code Troubleshooting Table If the output does not turn on your unit may display one of the following help codes Help Help Code Problem Indic
15. L User Powe O Oo O O Power Oc QO Voltag Control Regulation E AERE pinn4cle O O Figure 4 19 Remote panel front view 5702285 B O Communication and Control 4 99 Advanced Energy 1547 Remote Display Connector 00000 SSS O O Figure 4 20 Remote panel rear view 4 100 O Communication and Control 5702285 B Pinnacle Plus 10 kW eo t O O To E 2 2 3 E 3 5 ir PH 5535 5335 000 000 z 2 t S t 8 gL E E QE E NO C 28 N e eo i I 2 lt e amp 2 zo IL a afs o amp 0 Y z E C co bE Im N 6 apan oo Tio o 9 o co t o Figure 4 21 Remote panel dimensions 5702285 B O Communication and Control 4 101 Advanced Energy 4 102 O Communication and Control 5702285 B Pinnacle Plus 10 kW Chapter 5 Installation UNPACKING Unpack and inspect your power supply carefully Check for obvious physical damage If no damage is apparent proceed with the unit connections 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 MEETING SPACING REQUIREMENTS See Figure 5 2 on page 5 3 for a graphical representation of the spacing require
16. Pinnacle Plus 10 kW List of Tables Table 1 1 Electromagnetic Compatibility EMC Directives 1 5 Table 1 2 Electromagnetic Compatibility EMC Standards 1 5 Table 1 3 Safety Directives kk kk kk Rene kK KK KK KK KK KK KK KK KK KK beds 1 6 Table 1 4 Safety Standards kk kK kK KK KK KK eee 1 6 Table 3 1 Functional Specifications KK KK KK KK KK eee 3 1 Table 3 2 Physical Specifications 00 c KK KK KK KK KK KK KK KK KK KK 3 3 Table 3 3 Electrical Specifications liliis 3 4 Table 3 4 Reverse Time Given a Self Run Frequency KK KK KK 3 7 Table 3 5 Reverse Time as a Function of Voltage Limit V Limit 3 11 Table 3 6 Climatic Specifications 00 2 ce eee 3 16 Table 3 7 Coolant Specifications kk kk kk kk kK KK KK teens 3 17 Table 4 1 User Port Pin Descriptions kk kk KK KK KK KK KK KK es 4 4 Table 4 2 Cathode Switch pin 20 and pin 1 KK KK KK RR KK 4 11 Table 4 3 Target Life Counter pin 34 35 and 4 KK KK RR 4 11 Table 4 4 Regulation Mode pin 5 and pin 6 KK KK KK KK KK 4 11 Table 4 5 Display Panel LEDs kk kk kk kK KK KK KK KK ee 4 12 Table 4 6 Remote Panel Pin Descriptions liliis 4 14 Table 4 11 Serial Port Pin Descriptions KK KK KK KK KK eee 4 45 Table 4 12 AE Bus Host Port Pin Descriptions a
17. 1 Press SUPPLY PULSE gt ENABLE 2 Rotate the MODIFY knob to display PULSING ENABLED AT CURRENT THRESHOLD or PULSING ENABLED ALWAYS 3 Press ENTER to accept and exit SETTING SYNC PULSE HARD ARC DETECTION BROADCAST SUPPLY PULSE B CAST Note This feature is only available if your Pinnacle Plus unit was specifically configured 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 B CAST 2 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 5702285 B O Communication and Control 4 29 Advanced Energy SETTING THE UNIT AS A SYNC PULSE TRANSMITTER OR RECEIVER 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 or receiver e Press SUPPLY PULSE TX RX Select TRANSMIT or RECEIVE Note One unit must be set to transmit all other units must be set to receive If your unit
18. 10 kW HOST LOCAL and USER options appear Press one of these buttons to toggle between internal and external for that types 2 Press EXIT Note A user card must be installed in order to alter these settings 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 knob clicks SELECTING REMOTE OR LOCAL MODE SUPPLY PANEL gt 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 PANEL gt LOCK p 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 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 CLICKS 5702285 B O Communication and Control 4 31 Advanced Energy The clicks feature specifies the number of high speed
19. 1350 V and is held until the current is detected flowing above 0 5 A At this time pulsing is started Should 100 ms expire before pulsing begins a duty cycle is imposed on the unit s voltage limit to prevent the unit from being damaged This duty cycle is 100 ms at maximum voltage and 900 ms at the user voltage limit This cycle will repeat until the current is detected flowing above 2 0 A at which time pulsing is started Note If the regulation mode is Voltage the output on voltage will jump to a maximum of the set point plus 12 5 and no duty is imposed Hard Arc Shutdown Following the shutdown should the unit detect the current has dropped below 0 5 A which is a good indication the plasma has extinguished the unit will return to ignition state otherwise the unit continues to pulse Open Load Circuit Should the unit detect an open circuit condition the unit will return to ignition state otherwise the unit continues to pulse 5702285 B Operation 6 5 Advanced Energy CABLE RECOMMENDATIONS Choosing the appropriate cable solution for your Pinnacle Plus supply will produce the best process results For UHF connectors RG393 cable is recommended For two pin pluggable connectors twisted pair cable with an external shield is recommended or RG393 for use with PG 11 style strain relief connectors In general the shortest cable will give you the widest process window and the best resul
20. master slave system 5 14 Installation 5702285 B Pinnacle Plus 10 kW Table 5 2 Errors Associated With The Pinnacle Plus 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 Detected The master slave cables or switches set incorrectly Slave reports The master slave pulse cable has been removed No Master Slave Transmitter Detected Any unit reports e One of the units in the system is not energized that System Input Power is does not have input power Fault Note For more information about error codes please refer to the Troubleshooting chapter 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 on and off sequences the master unit re scales the total output that is its I O signals adjust to accommodate the most recent change in output capability of the combined units SYNC PULSE OPERATION Note This function is only available on units specially configured for Sync Pulse operation at the factory A unique feature of the Pinnacle Plus power supply is that up to six units can be synchronized to operate at the same frequency with independent set points and On Off control This Sync Pulse feature is very useful for red
21. the Pinnacle Plus unit sends an ACK acknowledgment hex code 06h to the host 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 56 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 receives 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 c
22. unit is in User or serial Host mode you can view 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 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 Generally 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 5 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 Customer Support on page 1 for a list of fault messages UNDERSTANDING THE MENU OPTIONS Pressing the right
23. 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 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 4 62 l O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 11 Specifies which target will be active 1 CSR codes 0 1 2 4 9 10 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 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 12 Sets the life in kilowatt hours of the target 5 CSR codes you specify 0 1 2 4 9 target life Send 1 data byte 8 bit value plus 4 data bytes 32 bit value arranged as follows First byte Target n
24. 155 Requests control mode the returning packet 0 1 contains data byte 8 bit value request control mode e 2 Serial Host port e 3 Active control panel Local 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 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 3 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 request ramp 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 4 80 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data
25. 4 17 AE Bus Commands Continued 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 04 0 4 us e 05 0 5 us e 06 0 6 us 07 to 49 follow the established pattern e 5025 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 percentage This value is set with command 32 153 Requests joule mode status the returning 0 1 packet contains 1 byte request joules status Oc Inactive Non zero value Active This value is set with command 5 154 Requests the output regulation mode the 0 1 returning packet contains 1 data byte 8 bit request value regulation mode 6 Power 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 5702285 B O Communication and Control 4 79 Advanced Energy Table 4 17 AE Bus Commands Continued remain Note If your unit has 100 ms ramp feature enabled the data indicates how many 100 ms intervals remain Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes
26. Byte 2 Send the appropriate value below indicating the arc shutdown time in us 0 200 1 500 2 1000 gt 3 1500 4 2000 5 2500 gt 6 3000 7 4000 8 5000 Readback this value with command 170 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 count limit after output shuts off the ARC LED on the passive panel or active control panel lights and if applicable a pulse is sent to the User port ARC D output signal For more information see I O Communication and Control on page 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 5702285 B O Communication and Control 4 61 Advanced Energy Table 4 17 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
27. Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 129 Requests the output capacity of the power 0 6 supply the returning packet contains 6 request characters indicating capacity in kilowatts supply size The data string implies 3 decimal places for a stand alone unit 10000 10 000 kWh and implies 2 decimal places for a master slave system 120000 1200 00 kWh 130 Reports the maximum limits for this unit the 0 6 request returning packet contains three 16 bit values maximum for power voltage and current limits unit limits 131 Displays most recent entry 40 characters to 0 40 scratch pad memory request 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 5702285 B O Communication and Control 4 77 Advanced Energy Table 4 17 AE Bus Commands Continued Co
28. KK 4 55 Figure 4 16 AE Bus communications transaction example 4 58 Figure 4 17 Passive front panel front view kK KK ee eee eee ee 4 98 Figure 4 18 Active front panel front view KK KK eee eee 4 98 Figure 4 19 Remote panel front view 0 000 e KK KK RR RR eee 4 99 Figure 4 20 Remote panel rear view eee 4 100 Figure 4 21 Remote panel dimensions KK KK KK KK KK RR RR KK 4 101 Figure 5 1 Dimensional drawing kK KK eee eee Kn 5 1 Figure 5 2 Clearances for Pinnacle Plus units stacked in a cabinet 5 3 Figure 5 3 Contactor interlock connector 0 a 5 6 Figure 5 4 Pinnacle Plus master slave interface Host card 5 9 Figure 5 5 Master Slave Pulse port connector RR KK K8 5 10 Figure 5 6 Master Slave Pulse port cable 2 0 c KK RR eee eee 5 11 Figure 5 7 Master Slave Pulse system diagram 0 0 KK RR RR RR KK 5 13 Figure 5 8 Sync Pulse connector 0 000 eee tes 5 16 Figure 5 9 Sync Pulse cable 32233 wee KK KK RE RET KK KK KK a Se KK KK IK KK KK KO 5 17 Figure 5 10 Simple Sync Pulse system kK KK KK KK KK KK KK KK KK KK KK 5 18 Figure 5 11 Sync Pulse master slave configuration llli eee eens 5 19 Figure 5 12 Rear view illustration kk kk kk KK KK KK ee 5 21 5702285 B xiii Advanced Energy xiv 5702285 B
29. Remove strain relief housing Slip the cable through the strain relief Connect each wire to the proper input terminal block according to the labels Replace the housing Tighten strain relief Connecting Output Power DANGER RISK OF DEATH OR BODILY INJURY Disconnect all sources of input power before working on this unit or anything connected to it 5702285 B Installation 5 7 Advanced Energy WARNING Operating and maintenance personnel must receive proper training before installing troubleshooting or maintaining high energy electrical equipment Potentially lethal voltages could cause death serious personal injury or damage to the equipment Ensure that all appropriate safety precautions are taken WARNING To meet EMI EMC requirements the shield of the output cable must be connected to the shell of the UHF connector or the shell of the two terminal connector A triax cable will allow a floating output of the power supply but the center connector has to carry the high voltage to ground potential No terminal should exceed 1700 V to ground peak A CAUTION Improper connection to the output connector could hamper operation of the Pinnacle Plus unit If you are unsure how to connect your output cable between the Pinnacle Plus unit and your chamber please contact AE Customer Support OUTPUT POWER CABLE RECOMMENDATIONS Choosing the appropriate output power cable for your Pinnacle P
30. Response Bytes Bytes 160 Requests the status of the logic board The 0 6 information in the returning packet is used by request AE Customer Service status i The returning packet contains 6 data bytes 1st and 2nd bytes SW_OPTS1 16 bit value e 0 Single Inverter Unit read only e 5 500ns Gate Drive Unit read only e 7 100 ms ramp bit clear 10 ms ramp e 8 Joule recipe definition bit clear normal 3rd and 4th bytes SW OPTS2 16 bit value e 2 Redefined as READY signal bit clear End of Target Life indicator EOTL e 3 High Speed Baud Rate 19200 38400 57600 115200 bit clear normal 9 No explicit fault clearing requires power cycle to clear bit clear off and reset command clears fault 5th and 6th bytes Always 0 5702285 B O Communication and Control 4 81 Advanced Energy Table 4 17 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 161 request output on status Requests the Control Status Response CSR of most recent output on sequence the returning packet contains 1 data byte 8 bit value 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 e 16 End of target life event e 17 Minimum off time is active e 31 User port reset line active e 32 Contactor is
31. Table 4 17 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 4 68 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Co
32. 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 e the current is above the current threshold of pulsing e the unit detects a hard arc E092 No Master Detected No master system is detected At least one unit must be set as the master unit Verify a unit is set as the master unit or that the link to the master unit has not been broken E093 Invalid Frequency An invalid frequency has been set to properly operate the unit Reset the frequency for the unit E095 Reverse Time Limit Exceeded In a stand alone dual unit most likely you have set a higher voltage limit for the receiver side than for the transmitter side The maximum reverse time is inversely proportioniate to the voltage limit Reduce the reverse time set for the transmitter side or lower the voltage limit in the receiver side 7 18 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW Table 7 4 Error Code Troubleshooting Table Continued Error Code Message Problem Indicated Suggested Action E182 Master Slave Fault A fault has occurred in the master slave system Check your master slave cabling See the I O Communications and Control chapter for more information E183 No Master Detected No master system is detected At
33. and displays error code E086 see Error Code Troubleshooting Table on page 7 13 or passive front panel help code H026 see Help Code Troubleshooting Table on page 7 6 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 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 OVER I Use this menu to view the density of unit over current responses per run To view the over current density 5702285 B O Communication and Control 4 33 Advanced Energy 1 Press PROCESS MONITOR 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 18 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 reset both the counter and the period timing at the start of a parameter change Record the counter at the end
34. and self run frequencies 3 7 Figure 3 2 Pulse reversal time as a function of voltage limit V Limit 3 11 Figure 3 3 Operating range KK kK KK KK KK KK KK KK KK KK KK KK KK KK 3 15 Figure 3 4 Impedance range kk kk kk kk KK kK KK KK ee 3 15 Figure 4 1 37 pin subminiature D female connector SK RR RR RR RR KK 4 1 Figure 4 2 Remote active panel connector ees 4 13 Figure 4 3 Control panel sss mas paga BARBER NEE Vedas KEN KK KK KK KG KEEN PEE 4 16 Figure 4 4 Two line output display screen ee 4 18 Figure 4 5 Control panel main menu functions 00 eee eee ee 4 20 Figure 4 6 Service menu map kk kk kk kk KK KK KK KK K KK ees 4 21 Figure 4 7 Supply menu map kk kk KK KK KK KI KK KK eee 4 22 Figure 4 8 Process menu map kk kk kk kk kK KK KK KK KK KI K KK KIR KI KK mn 4 23 Figure 4 9 Standard Serial port kk KK KK KK KK KK KK KK KK KK KK KK KK 4 44 Figure 4 10 AE Bus port connector M K kK KK KK KK KK KK KK KK mnn 4 46 Figure 4 11 Rocker DIP switch kk kk kk kK KK KK KK KK KK KK KK ERO KK eae aes 4 48 Figure 4 12 Slide DIP switch s kk kk kk kK kK KK KK KK KI KK KK KI K K ERE ES SER 4 48 Figure 4 13 Orientation of the AE Bus port and external DIP switch on the back panel 4 49 Figure 4 14 Graphic representation of an AE Bus message packet 4 53 Figure 4 15 AE Bus communications transaction RR RR RR KK
35. chapter for more from information previous page Target Life Out You have attempted to set Retry setting the target life of Range target life to a value outside using an acceptable value the allowable range See the command 12 in the I O Communication and Control chapter for more information Invalid Recipe You have attempted to enter Retry setting the recipe step Step a recipe step that is invalid using an acceptable value See the I O Communication and Control chapter for more information Ramp Start You have attempted to seta Re adjust the ramp start Continued Point Out of ramp start point to a value point by setting a smaller on next Range outside the allowable range percentage See the Setting page the Ramp section in the T O Communication and Control chapter for a description of the ramp option 7 8 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW Table 7 3 Help Code Troubleshooting Table Continued Help Help Code Problem Indicated Suggested Action Code Message Number H004 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 See the I O Communication Continued tou and Control chapter for previous more information page Run Time Outof You have attempted to set Retry setting the run time Range run time
36. each side 1345 Figure 5 2 Clearances for Pinnacle Plus units stacked in a cabinet 5702285 B Installation 5 3 Advanced Energy MAKING REAR PANEL CONNECTIONS A WARNING RISK OF DEATH OR BODILY INJURY Disconnect all sources of input power before working on this unit or anything connected to it CAUTION Do not apply RF power directly to the output of the Pinnacle Plus unit Damage to the Pinnacle Plus unit could result If you are using both an RF power supply and a Pinnacle Plus supply in the same system include an RF filter in the system Grounding For your convenience the rear panel of the Pinnacle Plus kW supply features three equi potential ground studs two M5 studs and a 10 32 stud These are indicated on the rear panel by a ground symbol Note You must ground the power supply as specified by the conditions of use See Conditions of Use on page 1 6 for more information A CAUTION Before making any other connection connect one of the equi potential ground studs to earth ground Note For optimal performance ground an equi potential ground stud to the system ground Connecting a Pinnacle Remote Active Panel Connections for an Advanced Energy Pinnacle Remote Active Panel are made through a 9 pin male subminiature D connector labeled REMOTE on the rear panel See the I O Communication and Control chapter Note To reduce EMI interference we recommend using shielded cable
37. 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 45 Located on the rear panel the Standard Serial port is a shielded modular jack illustrated on page 4 44 See also the rear panel illustration at the end of the Installation chapter A Viv Figure 4 9 Standard Serial port STANDARD SERIAL PORT PIN DESCRIPTIONS The pin descriptions for this port are as follows 4 44 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 11 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 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 Baud rate of 19 2 kbps Pinnacle Plus unit address of 1 e Odd pa
38. freight costs and ensuring that the units are returned to an authorized AE service center AE will return the repaired unit freight prepaid to you by second day air shipment or ground carrier for local returns repair parts and labor will be provided free of charge Whoever ships the unit either you or AE is responsible for properly packaging and adequately insuring the unit Authorized Returns Before returning any product for repair and or adjustment call AE Global Customer Support and discuss the problem with them 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 Customer Support to determine if the unit must actually be returned for the problem to be corrected Such technical consultation is always available at no charge Units that are returned without authorization from AE Global Customer Support and that are found to be functional will not be covered under the warranty see warranty statement below That is you will have to pay a retest and calibration fee and all shipping charges 5702285 B Troubleshooting and Global Customer Support 7 21 Advanced Energy Warranty Statement The seller makes no express or implied warranty that the goods are merchantable or fit for any particular purpose except as specifically stated in printed AE specifications The sole responsibility of the Seller shall be that it wil
39. 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 See Chapter 6 Operation for more information 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 4 72 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 59 Send 2 data bytes 16 bit value Valid input 2 CSR only joule recipe for the joule recipe repetitions are 1 through repetition 65535 Note This command is only valid when you set the continuous joule recipe type Readback this value with command 233 61 Enables or disables micro arc handling feature 1 CSR codes
40. 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 65534 and never counts down 5702285 B O Communication and Control 4 89 Advanced Energy Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 180 Requests the number of recipe steps the 0 1 returning packet contains 1 data byte 8 bit request value indicating the number of steps recipe steps Note Recall that a value of 0 sent with command 19 disables the ramping recipe feature This value is set with command 19 181 Requests the amount of ramping time you have 1 2 set for a specific ramping recipe step May return request TK CSR code 4 recipe 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 Requ
41. 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 5702285 B O Communication and Control 4 35 Advanced Energy 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 5 MONITOR gt TARGET 5 LIFE To set the target life in 0 01 kWh increments 1 Press PROCESS MONITOR TARGET LIFE 2 Rotate the MODIFY knob to select a target life between 0 and 15000 00 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 x1000 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 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 co
42. least one unit must be set as the master Verify a unit is set as the master unit or that the link to the master unit has not unit been broken AE GLOBAL CUSTOMER SUPPORT Please contact one of the following offices if you have questions Table 7 5 Global Customer Support Locations Office AE World Headquarters 1625 Sharp Point Drive Fort Collins CO 80525 USA Note For returns and repairs please call Global Customer Support to get the correct shipping Contact Phone 24 hrs day 7 days week 800 446 9167 or 970 221 0108 Fax M F 7 00 am 5 30 pm MST 970 407 5981 Email technical support aei com We will respond to email by the next business day address Note For customers outside the US please contact your local AE office AE GmbH Phone 49 711 77927 0 Raiffeisenstrasse 32 Fax 49 711 7778700 70794 Filderstadt Bonlanden Germany AE Japan KK Phone 81 3 32351511 TOWA Edogawabashi Bldg 347 Yamabuki cho Shinjuku ku Tokyo 162 0801 Japan Fax 81 3 32353580 5702285 B Troubleshooting and Global Customer Support 7 19 Advanced Energy Table 7 5 Global Customer Support Locations Continued Office Contact AE Korea Ltd Phone 82 342 705 2100 Gongduk Building 4th floor Fax 82 342 705 2766 272 6 Seohyun Dong Bundang Gu Seongnam Si Kyunggi 463 050 Korea AE United Kingdom Phone 44 1869 320022 Unit 5 Minton Pla
43. method of control Host serial port User port or local panel control 5 Select a regulation mode power current or voltage Note Output power must be off that is output must be de energized to switch between regulation modes 6 Enter a set point value 7 If necessary enter a pulse frequency and reverse time 8 If necessary enable joule mode and select a set point in joules 5702285 B Operation 6 1 Advanced Energy 10 11 12 13 14 15 If necessary enable target life counters and select a target life for each applicable target If necessary enable arc handling and enter appropriate arc handling parameters If necessary create a ramping recipe available through the standard serial port Profibus or Pinnacle Remote Active Panel If necessary set the out of set point timer to a value other than 0 If necessary set limits for output power output voltage output current and or process voltage 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 If you are using a passive front panel verify that the OUTPUT and SETPOINT LEDs light If these LEDs do not light see the Troubleshooting chapter for more information If you are using an active front panel or the Pinnacle Remote Active Panel verify that the ON LED lights Also verify t
44. of a micro arc and 200 us in case of a hard arc To set the arc trip level 1 Press PROCESS ARC LEVEL 2 Rotate the MODIFY knob to select an arc trip level 3 Press ENTER to accept and exit SETTING THE ARC COUNT LIMIT PROCESS 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 ARC 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 O If you set the limit to 0 the ARC LED lights for a predetermined time each time a hard arc is seen by the unit 3 Press ENTER to accept and exit VIEWING THE ARC DENSITY PROCESS ARC 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 5 ARC 5 DENSITY p SECOND and RUN options appear 2 To see arcs per second press SECOND 3 To see arcs per run press RUN
45. of the timed period and repeat To reset the over current density counter 1 Press PROCESS MONITOR OVER I RESET SETTING THE OVER CURRENT TIMER PROCESS MONITOR 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 Table on page 7 13 or passive front panel help code H027 see Error Code Troubleshooting Table on page 7 13 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 OVER I 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 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 39 4 34 O Communication and Control 5702285 B Pinnacle Plus 10 kW Out of Set Point Tolerance Range Set point 0 4 of full scale or 2 of set point whichev
46. 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 56 for more information on CSR codes 0 1 4 82 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 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 process 1st status byte status e 0 Unassigned e Ramp active e 2 Run active e 3 Output power 0 off 1 on e 4 Illegal regulation mode e 5 Cable interlock 6 End of target life event e 7 Set point status 0 within tolerance 1 out of tolerance 2nd status byte 0 Over voltage condition exists e Over current condition exists 2 Unassigned 3 Control circuit fault e 4 Heat sink over temperature event e 5 User interlock open 6 User port reset active e 7 Main contactor interlock open 3rd status byte e 0 Momentary power failure e 1 Unassigned 2 Near end joule value setting has been reached e 3 Unassigned e 4 Side A inverter low 5 Side B inverter low 6 Unassigned interrupt event 7 PROFIBUS error Continued on next page 5702285 B O Communication and Control 4 83 Advanced Energy T
47. point Additionally all units must have the same duty cycle and reverse time Note If different duty cycles and reverse times are desired for your process operate the Pinnacle Plus units as independent units To Rack Ground and Chamber Ground 2092 Figure 5 10 Simple Sync Pulse system SYNC PULSE MASTER SLAVE SYSTEM You can place a series of master slave Pinnacle Plus systems together in a sync pulse system allowing for extraordinary control over hard arcs across a large network of power supplies 5 18 Installation 5702285 B Pinnacle Plus 10 kW Master Master Master To Rack Ground and Chamber Ground Slave 1 9 E Slave 2 Slave 2 y Slave 2 DH HI 00 e 2093 Figure 5 11 Sync Pulse master slave configuration MONITORING YOUR SYNC PULSE SYSTEM There are thr
48. the Out of Set point Timer 00 c eee ee eee 4 34 Changing the Target Functions 00 00 KK KK KK eee 4 35 Setting Process Limits 243 eatem eod ees Meese eee eee ERI ERN E gee 4 36 Setting a Maximum Limit for Output Voltage 4 36 Setting the Maximum Limit for Output Current 4 37 Setting the Maximum Limit for Output Power 4 37 Setting Arc Handling 52e p ah i anes KK KK KK KK Y K K KK KK PS EET gee 4 37 Setting the Voltage Arc Trip Level eee eee eee 4 37 Setting the Arc Count Limit 2 428 ssi0eehebe db KK KK KK taeda yeas 4 38 Viewing the Arc Density kk kk kk KK KK KK KK K KI K K ee 4 38 Setting the Arc Shutdown Time 2 KK KK KAK KK 4 39 Enabling Arc Handling 323 wg uo kk kK KK KK KK KK KK KI K K KK KK KIKIK IK 4 39 Setting Control Parameters kK KK KK KK KK eee 4 39 Setting Recipes as race kk kk kk kK kK KK KK ERR EN KK KK KK KK KK KK KK KK kk 4 40 Setting Joule Mode is iss hb kk kk KK KK KK KK KK KK KK KK KK KK KK KK RE 4 41 Setting the Joule Set point KK KK KK RR KK KK KK 4 42 Setting the Joule Threshold a 4 42 Setting the Ramp sese nee ves NAL SAAD Ges poh KK KK KK KK KK KK IK KK ee 4 43 Standard Serial Flash Port 2002 kk kk kK KK KK KK KK KK KK KK KK KK KK KK 4 44 Standard Serial Port Description 0 0 00 KK KK KK KK 4 44 Standard Serial Port Pin Descriptions
49. the joule energy calculation will begin To set the joule threshold level 1 Press PROCESS CONTROL JOULES THRESHOLD LEVEL 4 42 O Communication and Control 5702285 B Pinnacle Plus 10 kW Setting 2 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 3 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 4 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 5 Press ENTER to accept and exit 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 Note 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 Press PROCESS CONTROL RAMP gt ENABLE 2 Rotate the MODIFY knob to select Yes or No to enable or disable ramp mode 3 Press ENTER to accept and e
50. to a value outside using an acceptable value the allowable range See the I O Communication and Control chapter for more information 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 See the I O Communication and Control chapter for more information Joule Threshold You have attempted to set Retry setting the joule Out of Range the joule threshold to a threshold using an value outside the allowable acceptable value See the I range O Communication and Control chapter for more information 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 See the current or voltage I O Communication and Control chapter for more Note Output power must be a off that is 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 See the I O value outside its allowable Communication and range Control chapter for more information 5702285 B Troubleshooting and Global Customer Support 7 9 Advanced Energy
51. you remove one Host card and replace it with another you must restore all system defaults Restoring defaults will reset User limits and ensure the Pinnacle Plus unit recognizes the new Host card Note To reduce EMI interference we recommend using shielded cable to connect to the Host port 5702285 B Installation 5 5 Advanced Energy Contactor Interlock A WARNING The Contactor interlock is nota safety interlock The CONTACTOR INTLK port located on the rear panel is a 9 pin male subminiature D connector see Figure 5 3 on page 5 6 Before turning on output ensure that the interlock loop is closed Note Avoid injection of RF or noise from any power cables To enable the Pinnacle Plus supply s main contactor short together pins 3 and 4 on the CONTACTOR INTLK port through a cheater plug external switch or relay Pin 4 supplies the interlock system string with 18 V and it can source 60 mA Pin 3 can sink 60 mA and the voltage on pin 3 and pin 4 should not exceed 20 V Pins 1 and 2 on this port are feedback connections from a set of normally closed auxiliary connectors on the main contactor Pin 1 Pin 5 vava Pin 6 Pin 9 1370 Figure 5 3 Contactor interlock connector Note The mating connector connector shell and post screws are included in the hardware kit that accompanied your Pinnacle Plus unit Connecting Input Power All power supplies leave the factory with their input voltages id
52. 1 Cooling Requirements kk kk kk kK KK KK KK KK KI KK KK KK KK KK KK KK KK KK KK k 5 2 Cabinet Design Kasa kk kk kk kK kK PE E TEE KK KK ee EU EE ERREUR 5 2 Making Rear Panel Connections 00 00 KK KK KK KK KK KK KK KK 5 4 GOUGING ARA AA E E MD TTMMM O9Y Y 5 4 Connecting a Pinnacle Remote Active Panel 5 4 Connecting a Remote Passive Panel cece eee eee 5 5 Connection for User Port Control KK KK KK ee ee 5 5 Connecting to the Standard Serial Port KK KK KK RR KAK KS 5 5 Connection for Serial Host Port Control 0 0000 e eee eee 5 5 Contactor Interlock isis RR kK KK KK KK KK KK KK KI KK KK KK KK KK IK KAL 5 6 Connecting Input Power kk kk kK Rak KK KK KA KK KK KK KK KK KK KK KK 5 6 Connecting Output Power kk kk kK KK KK KK KK KK KK KK KK KK KK KK KK Ik 5 7 Output Power Cable Recommendations a 5 8 Host Port Card Master Slave Operation 00 KRA 5 9 Master Slave Pulse Port KK KK KK KK KK KK eee 5 10 Master Slave Pulse Port Connector 000 eee RR KA 5 10 Master Slave Pulse Port Pin Descriptions 5 10 Master Slave Pulse Port cable a 5 11 Configuring Your Master Unit 0 00 00 eee eee 5 11 Configuring Your Slave Units e KK KK KK KK KK KK KK 5 12 Master Slave Configuration Examples aaa 5 13 Monitoring Your Master Slave System
53. 21 impedance range output 3 15 input power connecting 5 6 installation 5 1 air cooling requirements 5 2 cabinet design 5 2 contactor interlock 5 6 cooling requirements 5 2 dimensional drawing 5 1 grounding 5 4 input power 5 6 making rear panel connections 5 4 5702285 B Pinnacle Plus 10 kW remote panel 5 4 remote passive panel 5 5 safety requirements 1 6 safety warning 5 4 5 7 serial port 5 5 spacing requirements 5 1 unpacking 5 1 User port 4 1 5 5 installing master slave 5 9 safety warning 1 6 interfaces control panel 4 16 general description 2 1 types 2 4 internal microprocessor 2 2 isolated AE bus 4 46 J joule mode setting 4 41 jumpers AE bus Host 4 50 L label warranty void if seal broken 1 3 LEDs ARC 4 16 passive display panel 4 12 troubleshooting 7 4 local control setting 4 31 LOCAL LED LEDs LOCAL 4 20 LOCAL switch 4 17 low power operation 6 4 M manual see user manual marking CE 1 4 master unit configuring 5 11 master slave card 5 9 clearing faults 5 14 configuring the master 5 11 configuring the slaves 5 12 connecting 5 9 drawing of interface 5 9 monitoring 5 14 on off combinations 5 15 menu control panel options 4 20 control panel selections 4 20 functions selecting control panel functions 4 19 menu map 4 23 message packet AE bus 4 53 microprocessor 2 2 MODIFY knob 4 15 4 19 monitoring master slave system 5 14 monitoring your process 4 32 N network address
54. 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 7 295 294 118 1 3 11 76 38 2 300 298 507 1 3 11 94 38 8 305 303 03 1 3 12 12 39 4 5702285 B 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 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 f
55. 4 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW Table 7 4 Error Code Troubleshooting Table Continued Error Code Message Problem Indicated Suggested Action E011 Unit A s power inverter Using all applicable safety cannot produce power precautions inspect your Side A Inverter AC input power source to Fault Occurred ensure that it is properly connected and that the specified voltage is being applied to the Pinnacle Plus unit Check the input power line voltage on all phases to ensure that it meets specifications see the Specifications chapter Run the power supply to a dummy load to determine if it will indeed produce voltage or current E012 Unit B s power inverter Using all applicable safety cannot produce power precautions inspect your Side B Inverter AC input power source to Fault Occurred ensure that it is properly connected and that the specified voltage is being applied to the Pinnacle Plus unit Check the input power line voltage on all phases to ensure that it meets specifications see the Specifications chapter Run the power supply to a dummy load to determine if it will indeed produce voltage or current E020 The system interlock on Power off the Pinnacle the unit s analog User Plus unit Ensure that the Interlock Open port has not been interlock pin on the User User satisfied port connector has been properly connected see the
56. 4 46 Table 4 13 AE Bus Address Settings c KK KK KK KK eee 4 51 Table 4 14 Setting Switch B ius uoo iue pcm kaa wb KI KK KK haa hk KK KK EE 4 52 Table 4 15 Baud Rate Settings KK KK KK K KK KK KK KK KK KK KK KK 4 52 Table 4 16 Command Status Response CSR Codes 4 57 Table 4 17 AE Bus Commands 0000 KK KK KK KK KK eae 4 59 Table 7 1 Passive Front Panel Help Codes 00 0 KK KK eee eee 7 3 Table 7 2 Troubleshooting LEDs kk kK kK ce KK KK KK ees 7 4 Table 7 3 Help Code Troubleshooting Table 02 00 KK KAK KK 7 6 Table 7 4 Error Code Troubleshooting Table RR KK eee 7 13 Table 7 5 Global Customer Support Locations a 7 19 5702285 B XV Advanced Energy xvi 5702285 B Pinnacle Plus 10 kW Chapter 1 Safety and Product Compliance Guidelines This manual documents how to install operate maintain and troubleshoot the Advanced Energy Apex generator power supply Retain this manual for future reference IMPORTANT SAFETY INFORMATION To ensure safe installation and operation of the Advanced Energy Apex generator read and understand this manual before attempting to install and operate this unit At a minimum read and follow the safety instructions and practices documented under Safety Guidelines on page 1 2 INTERPRETING THE MANUAL The following sections explain the document type c
57. 5 4 3 us 760 4 2 us 765 4 2 us TIO 4 2 us 7715 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 14 Specifications 5702285 B Pinnacle Plus 10 kW Pinnacle Plus 10 kW 325 800 V Output Power Range 1000 800 Voltage Limit Power Limit 325 Operating Range Current Limit Voltage Vdc Measured at the dc inverter output see figure 2 1 30 8 12 5 Current Adc 2148 Figure 3 3 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 4 Impedance range 5702285 B Specifications 3 15 Advanced Energy ENVIRONMENTAL SPECIFICATIONS Table 3 6 Climatic Specifications Temperature Relative Humidity Air Pressure Operating Class 3K3 Class 3K3 Class 3K3 or more Note 1 severe 5 C to 40 C 5 to 85 3 3 80 kPa to 106 kPa 41 F to 104 F 1 g m to 25 g m 800 mbar to 1060 mbar approximately 2000 m above sea level Storage Class 1K4 Class 3K3 Class 3K3 or more severe 25 C to 55 C 5 to 85 3 3 80 kPa to 106 kPa 13 F to 131 F 1 g m to 25 g m 800 mbar to 1060 mb
58. 5 B O Communication and Control 4 3 Advanced Energy Table 4 1 User Port Pin Descriptions Signal Return Pin Name Signal Description Pin Pin Type 1 37 CSI 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 2 on page 4 11 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 4 36 TARGETO D digital This signal is used with input TARGETI D pin 35 and TARGET2 D pin 34 to select the active target life counter See Table 4 3 on page 4 11 for more information 5 36 IREG D digital This signal is used with input PREG D pin 6 to set the regulation mode See Table 4 4 on page 4 11 for more information 6 36 PREG D digital This signal is used with input IREG 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 digital If OFF D pin 14 is low a input momentary low on this pin will turn output power on 4 4 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 1 User Port Pin Descriptions Continued Signal Return Pin
59. 702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 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 kWh and two decimal places for a master slave unit 2000 20 00 kWh 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 instant 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 actual current are implied For example a value of 1500 indicates 15 00 A 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 j voltage First second byte Power level current Third fourth byte Voltage level Fifth sixth byte 2 Current level See commands 165 166 and 167 for the format of the report
60. 85 B Pinnacle Plus 10 kW Table of Contents Chapter 1 Safety and Product Compliance Guidelines Important Safety Information sod E dex ek KK KK KK KK K KK Ren RU LAGA 1 1 Interpreting the Manual paaa secu detec RE NEE eee Pees MERU Oe Ueee ads i 1 1 Type Conventions lt 1 cicsechaanetiveeeeies DARE new dbeeebeerew ens 1 1 Danger Warning and Caution Boxes kk kk KK a 1 2 Safety Guidelines 60 265 a BAET AKA CER KK RR KK KK KK ES KK KK KK KK REESE 1 2 Rules for Safe Installation and Operation 0000 RR KK 1 2 Interpreting Product Labels 2 0000 c KK KK K KK eee 1 3 Product CONMmpIANCe s 4 5 tex dcbet i a d AA 1 4 Product Certification aic ahis Ia kk kK KK KK KK KG KK KK KK KK KK KK KK KK IK 1 4 Safety and Compliance Directives and Standards 1 5 Electromagnetic Compatibility EMC Directives and Standards 1 5 Safety Directives and standards 0 1 6 Installation Requirements kk KK KK KK KK eee 1 6 Conditions of Use issu ts kK KK KK KK KK KK KK KK KK KK KK KK KK KK kk e 1 6 Chapter 2 Theory General Description kk kk kk KK kK KK KK KK KK KK KK KK owen KK KI KK KK ees 2 1 Output Impedance Range XX kk kk kK kK KK KK KK KK KK KK KK KK KK KK 2 1 Output Regulation sisse xus add kis KAYA BANDANG edid Meee ENYE ead 2 1 Interfaces xs k aa al kk A kal ak n k d EEL a kew an ee kan di ERN AR 2 1 Micro
61. A 19 n a 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 4 6 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 1 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 during the last run the pulse will occur when the output is turned off 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 5702285 B O Communication and Control 4 7 Advanced Energy Table 4 1 User Port Pin Descriptions Continued Signal Return Pin Name Si
62. AE bus 4 50 O ON OFF buttons 4 15 4 16 on off sequences master slave systems 5 15 operating overview list 6 1 operation 6 1 out of set point timer setting 4 34 output connecting 5 7 control panel power switches 4 16 impedance range 2 1 3 15 range 3 15 regulation 2 1 setting current limits 4 37 setting power limits 4 37 setting voltage limits setting output limits 4 36 output display screen 4 18 over current timer setting 4 34 over voltage timer setting 4 33 p parameters setting for the supply 4 28 passive display panel 4 12 help codes 7 3 5702285 B Advanced Energy LEDs 4 12 physical specifications 3 3 pin descriptions AE Bus port 4 46 remote panel 4 14 standard serial port 4 45 User port 4 3 Pinnacle Plus remote panel See control panel POWER switch 4 18 process menu map 4 23 process menu functions using 4 32 protocol standard serial port 4 53 pulse reversal times 3 7 R ramp setting 4 43 rear view illustration 5 21 RECIPE menu 4 40 recipes setting 4 40 REGULATION key 4 15 regulation mode User port 4 11 regulation switches 4 17 remote control setting 4 31 remote panel connecting 4 13 5 4 pin descriptions 4 14 remote passive panel connecting 5 5 repair returning units for 7 20 reverse time 6 3 reverse time settings 6 3 reverse time setting 4 19 reverse voltage 3 6 ROM checking 4 27 RS 232 422 485 4 47 S safety conditions of use 1 6 directives 1 5 installa
63. AULT LED is lit error code E002 should be displayed on the panel If the OVERTEMP LED is displayed E004 should be displayed Consult the error codes table in the following section for a suggested response to any of 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 8 Working with the Pinnacle Remote Active Panel verify that the output display screen information is displayed see the Output Display Screen section of the Installation chapter for details If the display screen shows an error message see Error Code Troubleshooting Table in this chapter If the display remains blank cycle the Pinnacle Plus unit s power on and off If the problem re occurs call AE Global Customer Support 9 Determine whether the cooling fans are functioning and ensure your cabinet allows for adequate ventilation for all the units in the cabinet To determine the correct volumes see the Installation chapter If the fans are not functioning properly call AE Global Customer Support 10 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 11 Issuing command 0 through the serial communication Host port will turn the unit off 12 If the pulsing switch is defective the unit will deliver current but not voltage Passive Fr
64. Ace AA San Pinnacle M Plus 10 kW 325 800 Vdc AE Bus 15 V User Master Slave Sync Pulse March 2005 5702285 B User Manual User Manual Pinnacle Plus 10 kW 5702285 B Advanced Energy COPYRIGHT This manual and the information contained herein is the proprietary property of Advanced Energy Industries Inc No part of this manual may be reproduced or copied without the express written permission of Advanced Energy Industries Inc Any unauthorized use of this manual or its contents is strictly prohibited Copyright 2004 Advanced Energy Industries Inc All Rights Reserved DISCLAIMER AND LIMITATION OF LIABILITY The information contained in this manual is subject to change by Advanced Energy Industries Inc without prior notice Advanced Energy Industries Inc makes no warranty of any kind whatsoever either expressed or implied with respect to the information contained herein Advanced Energy Industries Inc shall not be liable in damages of whatever kind as a result of the reliance on or use of the information contained herein PRODUCT USAGE STATEMENT A 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 property damage If the equipment is used in a manner not specif
65. Control 5702285 B Pinnacle Plus 10 kW Table 4 5 Display Panel LEDs Continued 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 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 the 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 ACTIVE FRONT PANEL PINNACLE REMOTE PANEL The Pinnacle Plus supply presents a broad array of features 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
66. Hard arc handling is always enabled 0 1 enable disable micro Send 1 data byte 8 bit value arc handling e 0 Disable e 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 with command 163 65 Enables pulsing at the current threshold 1 CSR codes default setting or always 0 1 2 4 9 pulsing DE 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 Pulsing enabled always Read back this setting with command 163 5702285 B O Communication and Control 4 73 Advanced Energy Table 4 17 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 Q Ty broadcast gutes 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 indication Send 2 data bytes 16 bit value Read back this setting with command 232 73
67. High Power Operation 000 kk KK KK KK KK KK KK KK KK KK KK KK KK 6 5 Cable Recommendations kK KK KK KK KK KK KK KK KK KK KK KK KK KK KK 6 6 Chapter 7 Troubleshooting and Global Customer Support Before Calling AE Global Customer Support 00 KK RR KK KK 7 1 uiam d Pp 7 1 Checks with the Unit Powered Off KK KK KK KK KK eee 7 2 Checks with the Unit Powered On KK KK KK KK ee eee 7 2 Passive Front Panel Help Codes 00 KK KK KK KK eee 7 3 Troubleshooting Table 5 rider RR E KK KK KK KK ee WAG PAA EEA ES 7 4 Checks if the Output Does Not Turn On kk kk kk RR RR RR RR eee 7 5 Help Code Troubleshooting Table 0 000 c cee ee 7 6 Clearing the Error Code issec isa pd EP EESRPRPSERY KK KK KK KK EETEKE 7 12 Error Code Troubleshooting Table 0 00 e eee KK KK 7 13 AE Global Customer Support n ka sex KK KK KK KK Re orR EE TREREERRRRES 7 19 Returning Units for Repair kk kk kk kk kK KK KK KK eee 7 20 Warranty i 2424504 ned CRX ORI REPRE EG RE k Cd R RR A RE ede da 7 21 Authorized Returns 4x ka Aa kk eee RE ER Rd RAS EE EN ERG A wie 7 21 Warranty Statement nus pi RT kk Wehen LR uber pa KIR Vice ee 7 22 5702285 B xi Advanced Energy xii 5702285 B Pinnacle Plus 10 kW List of Figures Figure 2 1 Pinnacle Plus functional block diagram 0000 ee eee 2 2 Figure 3 1 Pulse reversal times
68. NANA Sawa kek BAe 4 1 Installation rrr 4 1 cp HOW Hed BANI See ihe ee akewhe te ete 4 2 Analog signals s a ak salx n ERE ha LR N A ka kl a dl WI al SCR HANGA 4 2 Digital SiQnalS umaasa a nG AGARAN NG hln d Ay i K 0al 4 ber eps 4 3 Pin description Table Ak kk kk kK KK KK KK KK KI KI KK KI EAUX E A ERR ERES 4 3 Passive Display Panel i 2e eo e kk Re KK KK KK KK KK KK KK KE KK KK KK KK KK 4 12 DISplay ACRI rrt 4 12 Bl emaa tona a e rrr A E 4 12 Active Front Panel Pinnacle Remote Panel RR KK 4 13 Connecting to the Remote Active Panel KK RR KK 4 13 Understanding the Panel 000 KK KK KK KK ees 4 14 Control Key s a sa A erriei akaa REN RE RRUEG AR S nk REC RR RR Ro 4 14 Output Display Screen ups manna Ha KK KK KK KK KK KK KK KK KK o gr 4 14 SON KEYS ana asa rece RR RE kaka Skee SOS nm bes OEE ERA dia d E PEE 4 15 Modify KIOD pax we yan aka Wak n eeu MAA WA ELE oh be A k ER HR 4 15 Regulation Key 2 es say ka wl KO RR HANGGA Gn eee aoe Wl kal AE NG 4 15 On Off Buttons amp LEDS 2a a haa kk KK KK KK KK KK KK KK KK KK KK KK 4 15 BIELED Sacs egeat acie haad a eee UNS AANO 4 16 Control Panel Interface eee 4 16 Output Power Key iusso x xc ecu dh KK KK KK KK KK KK o aad basen me 4 16 Control Key 5Z sa sana x n E diz yan Wan h v y k b a ah 4 17 Regulation Key asshole ava KK KK kK kk a kk kk kk kk kk kk 4 17 T
69. Name Signal Description Pin Pin Type 8 n a unassigned n a n a 9 n a 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 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 When this signal is high it input overrides all commands and forces a shut off of output power It also resets the Pinnacle Plus unit after all fault conditions except interlock over temperature and A D conversion faults But it will 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 5702285 B O Communication and Control 4 5 Advanced Energy Table 4 1 User Port Pin Descriptions Continued Signal Return Pin Name Signal Description Pin Pin Type 18 n a 15V output This protected 15 V dc supply output provides a maximum of 100 m
70. Note This display is not zeroed until you turn the output on again or reset the display 4 38 O Communication and Control 5702285 B Pinnacle Plus 10 kW 4 Press EXIT to exit Note You may press RESET at any time at this menu level to clear the arc counters SETTING THE ARC SHUTDOWN TIME PROCESS ARC gt TIME To set the arc shutdown time 1 Press PROCESS ARC TIME 2 Press the soft key under A B to select side A or B An arrow displays next to the letter of the side that is currently selected 3 Rotate the MODIFY knob to select the arc shutdown value in microseconds 4 Press ENTER to save your selection and exit ENABLING ARC HANDLING PROCESS ARC ENABLE This function enables or disables the arc handling functions of the Pinnacle Plus supply 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 hard arc handling To disable the arc handling 1 Press PROCESS ARC ENABLE 2 Select Yes or No for MICRO arc handling 3 Press ENTER to accept and exit Note As an inherent safety feature cycling power to the unit resets arc handling to enabled Note Hard arc handling is always enabled Setting Control Parameters PROCESS CONTROL 5702285 B O Communication and Control 4 39 Ad
71. Pin 1 Pin 5 Of O Pin 6 Pin 9 1370 Figure 4 2 Remote active panel connector The pin descriptions for this connector appear in the following table installation instructions follow the pin description table 5702285 B O Communication and Control 4 13 Advanced Energy Table 4 6 Remote Panel Pin Descriptions Pin Description Do not connect Do not connect Do not connect Do not connect Ground TR N Oo Oc A WO N 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 the 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 16 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 T
72. 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 feature 1 CSR only enable which waits for command 73 before beginning disable joule the joule countdown countdown Send 1 data byte e 0 Disable Non zero Enable Read back this setting with command 163 84 Redefines the PROFIBUS status bits 1 CSR only redefin Bi B Send 1 data byte status bits e 0 Normal format Non zero Joule recipe definition 4 74 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued 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 e 0 Clear bit Non zero Set bit 2nd data byte Configuration option bit number valid entries 2 0 31 e 7 RAMP RESOLUTION 8 JOULE RECIPE STATUS 18 USER PORT EOTL DEFINED AS READY SIGNAL 19 HIGH SPEED AEBUS e 25 EXPLICIT FAULT CLEARING 92 Sets pulse frequency from 0 to 350 kHz in 1 CSR codes 5 kHz increments 0 1 4 9 pulse Wo frequency Note Frequency is limited to 150 KHz when index the pulse mode is set to be enabled always e 0 Pulsing disabled e 1 5 kHz 2 10kHz e 3 15 kHz e 4 to 69 follow the established pattern e 70 350 kHz
73. SS CONTROL JOULES gt 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 x1000 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 SETTING THE JOULE THRESHOLD PROCESS CONTROL 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 CONTROL JOULES THRESHOLD TYPE 2 Rotate the MODIFY knob to select POWER CURRENT or VOLTAGE 3 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 threshold 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
74. TER SLAVE PULSE PORT CABLE PIN 9 PIN 1 PIN 15 PIN 8 A 15 lead ENE PIN 15 PIN 9 Ej 5 lead PIN 9 PIN 15 Figure 5 6 Master Slave Pulse port cable Configuring Your Master Unit Note See Figure 5 7 on page 5 13 for an illustration To configure the master unit 1 Remove all input power from the master and slave units 5702285 B Installation 5 11 Advanced Energy If the Pinnacle Plus supply includes a User card ensure that the interlock inputs are satisfied Refer to the I O Communication and Control chapter for specific User port pin descriptions and required voltage levels 3 Set the MSTR SLV switch see Figure 5 4 in the up MSTR position Connect the included 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 Note The master unit will not have an interface cable connected to port P2 Connect the included master slave pulse interface cable with the 15 pin subminiature D plug ends between the port labeled Master Slave Pulse on the master unit and the port labeled Master Slave Pulse on all associated slave units Use a grounding strap to connect an equi potential ground stud
75. able 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 162 4th status byte 0 4 request e 0 Hard bus fault process e 1 Unassigned status 2 Joules reached continued e 3 Unassigned e 4 Out of set point timer expired e 5 Ground fault detected if your Pinnacle Plus supports this feature 6 Unassigned 7 Unassigned 4 84 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 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 Unassigned 4 Unassigned e 5 Unassigned e 6 Program source 0 internal 1 external e 7 Target life status 0 inactive 1 active 2nd status byte e 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 O open 1 closed 4 Unassigned e 5 Ramp mode 0 disabled 1 enabled 6 Unassigned e 7 Pulsing en
76. abled 0 disabled 1 enabled Continued on next page 5702285 B O Communication and Control 4 85 Advanced Energy Table 4 17 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 163 request config status continued from previous page 3rd status byte 0 e 0 Synch pulse setting 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 e 5 Pulsing enabled 0 at current threshold 1 always e 6 and 7 Threshold type 00 power 01 voltage 10 current 4th status byte 0 Hard arc broadcast 0 disabled 1 enabled Joule countdown hold 0 disabled 1 enabled e 2 through 7 Unassigned 4 164 request set point regulation mode Requests the set point level by whichever 0 method of output regulation has been selected the returning packet contains 3 data bytes First second byte Set point level 16 bit value Third data byte Regulation mode 8 bit value gt 6 Power gt 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 4 86 O Communication and Control 5
77. ar approximately 2000 m above sea level Transportation Class 2K3 Class 2K3 Class 2K3 or more severe 25 C to 70 C 95 Note 2 3 Note 3 66 kPa to 106 kPa 13 F to 158 F 60 g m Yr 660 mbar to 1060 mbar approximately 3265 m above sea level Nara Non condensing Note 2 Maximum relative humidity when the unit temperature slowly increases or when the unit temperature directly increases from 25 C to 30 C Note 3 Maximum absolute humidity when the unit temperature directly decreases from 70 C to 15 C 3 16 Specifications 5702285 B Pinnacle Plus 10 kW COOLANT SPECIFICATIONS Table 3 7 Coolant Specifications Coolant Temperature Air gas minimum 0 C maximum 40 C Note See Cooling Requirements on page 5 2 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 the Safety Compliance section of the Introduction chapter and the declaring letter for specific standards Acoustic Noise Noise generated by this unit is 71 5 dB A ata 1 m distance 5702285 B Sp
78. 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 the Troubleshooting chapter for more information If you are using an active front panel or a Pinnacle Remote Active Panel verify that the display screen displays Advanced Energy Fort Collins Colorado 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 EXXX code appears scrolling on the front panel or on the Pinnacle Remote Active Panel refer to the Error Code Troubleshooting Table in the Troubleshooting chapter Chapter 7 for an explanation and troubleshooting suggestions 3 If you are using the passive panel verify that the BUS FAULT and OVERTEMP LEDs are not lighted If either or both is lighted power down the Pinnacle Plus unit clear the fault and return to Step 1 Refer to the Troubleshooting chapter for error code explanations and troubleshooting suggestions If you are using an active front panel or the Pinnacle Remote Active Panel verify that the two line display information shows on the display screen see the I O Communication and Control chapter for details If the display screen shows an error code and message note the error code number and refer to the Troubleshooting chapter 4 Select a
79. aster Slave Operation The master slave card is located near the top left side of the unit s rear panel when facing the rear panel The master slave Host card includes three ports a 9 pin female subminiature D serial communications port for external serial control and two modular ports P1 and P2 for connecting master and slave units with the master slave cable see Figure 5 4 on page 5 9 Note See Host Port Connector in Chapter 4 for pin and signal descriptions for the 9 pin Host port connector The P1 and P2 molded plug ports are used to connect daisy chain a master unit to a slave unit and a slave unit to another slave unit Note The Master Slave Pulse port must also be connected between master and slave units The Host card also includes a master slave MSTR SLV switch This switch is used to indicate whether the supply is functioning as a master stand alone or slave unit P1 P2 MSTR MSTR SLV AE BUS PORTS 00000 E O SLV 1350 Figure 5 4 Pinnacle Plus master slave interface Host card 5702285 B Installation 5 9 Advanced Energy Master Slave Pulse Port The Pinnacle Plus unit is configured with two female subminiature D ports beneath the master slave Host card on the rear panel of the unit The 15 pin subminiature D port labeled Master Slave Pulse is used for master slave operations The 9 pin subminiature D port labeled Sync Pulse is used
80. ate the product Rules for Safe Installation and Operation Please note the following rules Do not attempt to install or operate this equipment without proper training Ensure that this unit is properly grounded see also Grounding on page 5 4 Ensure that all cables are properly connected see Installation on page 5 1 e Verify that input line voltage and current capacity are within specifications before turning on the power supplies see Electrical Specifications on page 3 4 Use proper electrostatic discharge ESD precautions 1 2 Safety and Product Compliance Guidelines 5702285 B Pinnacle Plus 10 kW Always be careful around this equipment Interpreting Product Labels The following labels may appear on your unit AE WARRANTY VOID IF SEAL IS BROKEN The product warranty is void if you remove the power supply box cover Contact AE Global Customer Support for more information see AE su Global Customer Support on page 7 19 CE label Earth ground 1069 Hazardous voltage HAZARDOUS VOLTAGE Risk of death or bodily injury Disconnect all sources of input power before working on this unit or anything connecte 1332 High voltage Hot surface 5702285 B Safety and Product Compliance Guidelines 1 3 Advanced Energy bo Nonionizing radiation 1030 GP NRTL NRTL C LR 106911 xx 1154 e Protective Earth ground 1029 Re
81. ated 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 Remove power from the Already On on the output but output power supply restart and try power is already on again 7 6 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW Table 7 3 Help Code Troubleshooting Table Continued 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 See the limit to a value outside the Specifications chapter for allowable range more information Timer Out of You have attempted to seta Retry setting the timer using Range timer to a value outside the an acceptable value See the allowable range I O Communication and Control chapter for more information Arc Count Limit You have attempted to set Retry setting the limit using Out of Range the arc count limit to a value an acceptable value See the outside the allowabl
82. ation wye connection only 480 VAC Input Current Not available for this configuration 3 4 Specifications 5702285 B Pinnacle Plus 10 kW Table 3 3 Electrical Specifications Continued 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 within V I limits of tap 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 0 015 C lt 150 ppm C variation in the regulated output parameter over 20 C to 40 C ambient temperature range Output Ripple Voltage 360 Hz 300 Hz The component of output voltage ripple as related to input line frequency is less than 2 rms Accuracy of All Analog Signals 1 of the actual value V kW or A or 0 2 of the full scale value whichever is greater Power Factor gt 0 95 for 10 kW Standard Output Range full power 10 kW over the 325 to 800 Vdc range in DC mode with a maximum current of 30 8 A Note Output is measured at the DC inverter output see Figure 2 1 on page 2 2 Note Do not use an output cable
83. b to change values and move 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 SETPT menu 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 remote panel turn on and off the output power The relevant LED lights to indicate output is on or off 5702285 B O Communication and Control 4 15 Advanced Energy ARC LED 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 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 arc handling through a control panel or with Command 61 of the Standard Serial port 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 Ha
84. 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 The DIP switch see Figure 4 11 on page 4 48 and Figure 4 12 on page 4 48 is used to set the AE Bus address 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 5702285 B O Communication and Control 4 47 Advanced Energy There are two types of DIP switches on AE Bus interfaces rocker DIPs and slide DIPs see Figure 4 11 on page 4 48 and Figure 4 12 on page 4 48 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 de
85. ber 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 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 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 4 70 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 43 Sets the un
86. bility EMC Directives Directive Description 89 336 EEC EC Council directive on the approximation of the laws of the Member States relating to electromagnetic compatibility EMC Directive Table 1 2 Electromagnetic Compatibility EMC Standards Standards Description 47 CFR Part 18 Code of Federal Regulations 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 and medical ISM radio frequency equipment Class A Group 2 CISPR 11 EN 61000 6 2 Electromagnetic Compatibility generic immunity sstandard industrial 5702285 B Safety and Product Compliance Guidelines 1 5 Advanced Energy SAFETY DIRECTIVES AND STANDARDS Table 1 3 Safety Directives Directive Description 73 23 EEC EC Council directive on the harmonization of the laws of the Member States relating to electrical equipment designed for use within certain voltage limits LVD Low Voltage Directive Table 1 4 Safety Standards Standards Description EN 50178 Electronic equipment for use in electrical power installations Installation Requirements Install this unit according to the following requirements A WARNING Operating and maintenance personnel must receive proper training before
87. bled always Short reverse times will increase the 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 will raise the plasma voltage during the sputter cycle Plasma voltage can be as much as double the DC voltage 5702285 B Operation 6 3 Advanced Energy 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 supply to respond to a false arc or overcurrent event in excess To avoid this problem use a scope to make sure that the voltage does not ring back 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 If you cannot reach a certain output power increased reverse time will increase the output power at a given maximum DC output voltage shown at the front panel LOW POWER OPERATION VERSUS HIGH POWER OPERATION The Advanced Capability Pinnacle Plus unit features two modes of operation which allow it to operate effectively in many processes and over a large range of power settings To better manage these varied process requirements the Pinnacle Plus unit features two different modes of operation l
88. byte recipe type pe typ e Timed e 2 Joule continuous e 3 Joule discrete 197 Requests the version 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 5702285 B O Communication and Control 4 93 Advanced Energy Table 4 17 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 If a 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 4 94 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number Response Bytes of 220 req
89. ce Fax 44 1869 325004 Market Court Victoria Road Bicester Oxon OX26 6QB UK AE Taiwan Ltd Phone 886 2 82215599 10F 6 No 110 Chung Shan Rd Fax 886 2 82215050 Sec 3 Chungho City Taipei Hsien Taiwan 235 AE China Phone 86 755 83867986 Rm 910 Anhui Building Fax 86 755 83867984 No 6007 Shennan Road Shenzhen China 518040 RETURNING UNITS FOR REPAIR Before returning any product for repair and or adjustment first follow all troubleshooting procedures If after following these procedures you still have a problem or if the procedure instructs you to call AE Global Customer Support and discuss the problem with a representative Be prepared to give the model number and serial number of the unit as well as the reason for the proposed return This consultation call allows Global Customer Support to determine whether the problem can be corrected in the field or if the unit needs to be returned Such technical consultation is always available at no charge If you return a unit without first getting authorization from Global Customer Support and that unit is found to be functional you will be charged a re test and calibration fee plus shipping charges To ensure years of dependable service Advanced Energy products are thoroughly tested and designed to be among the most reliable and highest quality systems available worldwide 7 20 Troubleshooting and Global Customer Support 5702285 B Pinna
90. cle Plus 10 kW WARRANTY Advanced Energy AE products are warranted to be free from failures due to defects in material and workmanship for 12 months after they are shipped from the factory please see Warranty Statement below for details Note 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 Customer Support for more information see AE Global Customer Support on page 7 19 In order to claim shipping or handling damage you must inspect the delivered goods and report such damage to AE within 30 days of your receipt of the goods Please note that failing to report any damage within this period is the same as acknowledging that the goods were received undamaged For a warranty claim to be valid it must Be made within the applicable warranty period Include the product serial number and a full description of the circumstances giving rise to the claim Have been assigned a return material authorization number see below by AE Global Customer Support All warranty work will be performed at an authorized AE service center see list of contacts at the beginning of this chapter You are responsible for obtaining authorization see details below to return any defective units prepaying the
91. 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 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 e ARC set arc parameters 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 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 minimize over voltage conditions When the unit detects a
92. d 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 50 50 9 0 2 00 45 0 55 54 945 8 1 2 20 44 5 60 60 06 74 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 00 09 4 9 3 60 44 1 95 94 787 47 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 8 165 165 289 2 7 6 61 44 6 170 169 492 2 6 6 78 44 1 175 175 439 2 5 7 02 43 9 3 8 Specifications 5702285 B Pinnacle Plus 10 kW 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 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 71 44 7 200 200 2 2 8 44 205 204 082 2 2 8 16 44 9
93. dance 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 communications Host port The serial communications port the active front panel 5702285 B Theory 2 1 Advanced Energy 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 a
94. down down down down SETTING BAUD RATES AND COMMUNICATION MODE Also use the DIP switch see Figure 4 11 on page 4 48 and Figure 4 12 on page 4 48 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 BRI set the baud rates Table 4 14 Setting Switch 8 Switch Position Communication Mode Up RS 232 Down RS 485 422 Table 4 15 Baud Rate Settings Baud Rate Baud Rate BRO BR1 RS 232 RS 485 422 1200 9600 up up 4800 19 200 up down 9600 38 400 down up 19 200 57 600 down down AE BUS COMMUNICATIONS The following sections describe communications between a host and the Pinnacle Plus supply 4 52 O Communication and Control 5702285 B Pinnacle Plus 10 kW 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 message 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 14 Header address and length of data field Command see the command list later in this chapter Optional length byte Data e Checksum e
95. e 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 knob 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 4 26 O Communication and Control 5702285 B Pinnacle Plus 10 kW HIGH SPEED AEBUS Changes the baud rates requires a power cycle on the unit before the change takes effect The following are the baud rates when HIGH SPEED AEBUS is disabled or enabled Table 4 10 Baud Rates When HIGH SPEED AEBUS is Disabled Enabled Disabled Enabled Same for RS232 422 485 1200 19200 4800 38400 9600 57600 19200 115200 EXPLICIT FAULT CLEARING Changes the fault clearing method changes immediately When method is set to DISABLED power must be cycled on the unit to clear the fault When method is
96. e 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 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 A DANGER Power down the Pinnacle Plus unit and take proper ESD precautions before removing the unit s top cover to position jumpers Failing to power down the unit in this case could result in death or severe personal injury Failing to take proper ESD precautions in this case could result in damage to the unit To provide for a 0 to 5V scaling Place the P1 jumper level in signal across pins 2 and 3 Place the P5 jumper voltage current and power read backs across pins 1 and 2 Place the P4 jumper level out signal across pins 1 and 2 4 2 I O Communication and Control 5702285 B Pinnacle Plus 10 kW e Place the P3 jumper REF A across pins 2 and 3 To provide for a 0 to 10V scaling Place the P1 jumper level in signal across pins 1 a
97. e 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 energized that System Input Power is does not have input power Fault Note For more information about error codes please refer to the Troubleshooting chapter 5 20 Installation 5702285 B Pinnacle Plus 10 kW REAR PANEL ILLUSTRATION 186k pms puno19 SW N pnis J0 99UU02 luo sno jndino punoo Z 0L p409 aun Ndu pnis punoJo S OQ ene L oso o ao o e2 2202 CO CO ajew uld gz sjewa4 uid G ajew uid 7 HOG xyoopeju jew y uld 7 10 9B U07 uen Log Jesn Od jenas pJepuejg Hog Jeueg eAnoy gjowsy yog Jes puooes 104 uonisog jeuondo Joje sue1 1090 01q JSOH snqyoJd sng dv Hog jeues Sod jeuondo umoys pieg jsoH 81e s J8 sen Figure 5 12 Hear view illustration 5 21 Installation 5702285 B Advanced Energy 5 22 Installation 5702285 B Pinnacle Plus 10 kW Chapter 6 Operation OPERATING OVERVIEW The following list represents a general description of how to operate a Pinnacle Plus unit You will want to adapt this list to your Pinnacle Plus configuration and your application environment and requirements 1 Power on the Pinnacle Plus unit 2 If you
98. e eee eee KK KK 4 27 Using the Supply Functions 5 cccissecc kk kK kK KK KK KK KK KK KK KK KK KK KK KK 4 28 Setting the AE Bus Timeout lt ciccecveeneernepsed ieee becedu KK KK 4 28 Setting the Supply Parameters kk kk KK KK KK KK KK KK RR KK KK 4 28 Setting Pulse Parameters KK KK KK KK KK KK KK ee 4 28 Enabling Pulsing at Current Threshold or Always 4 29 Setting Sync Pulse Hard Arc Detection Broadcast 4 29 Setting The Unit as a Sync Pulse Transmitter or Receiver 4 30 Selecting Constant Duty Cycle kk KK KK KK KK KK KERR eee 4 30 Setting the Program Source 0 00 e eee KK KK K 4 30 Setting the Panel Mode KK KK eect eee 4 31 Selecting Remote or Local Mode eee eee KK 4 31 Selecting a Lock Code kk 2 kK KK KK KK tes 4 31 Selecting the Number of Clicks 00 KK KK cece eee 4 31 Using Process Functions kk kk kK KK KK KI KK KK KK KK KK KK kk kk kk kk ka 4 32 Monitoring Your Process aqux BA WG KK KK KK KK KK KK KK KK KK KK KK KK e 4 32 Viewing the Over Voltage Density KK KK KK KK KK eee 4 32 Resetting the over Voltage Density 00 KK KI KIRI 4 33 Setting the Over Voltage Timer 0 000 c KK KK KAK KAK KK 4 33 Viewing the Over Current Density aa 4 33 Resetting the Over Current Density lille 4 34 Setting the Over Current Timer 000000 4 34 Setting
99. e input air temperature is correct that the Pinnacle Plus unit s fans are functioning properly and that your cabinet allows for adequate ventilation for all the units in the cabinet For more information see the Installation chapter 5702285 B Troubleshooting and Global Customer Support 7 13 Advanced Energy Table 7 4 Error Code Troubleshooting Table Continued Error Code Message Problem Indicated Suggested Action E005 The AC input power line Using all applicable safety dipped below required precautions inspect your Momentary Power operating conditions AC input power source to Fluctuation This condition may be ensure that it is properly due to an AC power connected and that the black out or brown out specified voltage is being applied to the Pinnacle Plus unit See the Specifications chapter for AC input power specifications E006 The DSP has failed Call AE Global Customer Support DSP Watch Dog Failure E007 There has been an 1 Remove all input Initialization Fault initialization fault power from the power supply and then restart the unit 2 Reset all defaults and then try step 1 above again 3 If this fault persist call AE Global Customer Support E009 Output Ground Fault Detected Output positive terminal is not PE grounded Connect output positive terminal to PE ground available only on certain options 7 1
100. e range I O Communication and Control chapter for more information Arc Timer Out You have attempted to set Retry setting the timer using of Range the arc timer to a value an acceptable value See the outside its allowable range I O Communication and Control chapter for more information 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 See the I O Communication and Control chapter for more information 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 See the I O Communication and Control chapter for more information ag Reverse Time You have attempted to set Retry setting the reverse time page Out of Range reverse time to a value using an acceptable value outside the allowable range See the I O Communication and Control chapter for more information 5702285 B Troubleshooting and Global Customer Support 7 7 Advanced Energy Table 7 3 Help Code Troubleshooting Table Continued 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 See the available I O Communication and Continued Control
101. eaker 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 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 5702285 B Theory 2 3 Advanced Energy Remote Interfaces The Pinnacle Plus unit supports four types of interfaces a User port Analog
102. ecifications 3 17 Advanced Energy 3 18 Specifications 5702285 B Pinnacle Plus 10 kW Chapter 4 O Communication and Control 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 Pin 1 OOOOOOOOOOOOOOOOOO O00000000000000000 O O 1153 Figure 4 1 37 pin subminiature D female connector Installation AN DANGER Disconnect all sources of input power before working on this unit or anything connected to it 5702285 B O Communication and Control 4 1 Advanced Energy 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 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 th
103. ed Energy Table 4 17 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 e First byte Recipe step must be a value between 0 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 e First byte Recipe step must be a value greater than 0 but no greater than 8 e 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 4 66 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response
104. ed as a regarding this procedure see slave Master Slave Operation in chapter 5 of this manual H026 Can t Change You have attempted to Disable the master slave in Master Slave initiate a unit function that is system and retry initiating System not allowed while the power the unit function For more supply is configured in a information on this master slave system procedure see Master Slave Operation in chapter 5 of this manual 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 See the I O Communication and Control chapter for more information 5702285 B Troubleshooting and Global Customer Support 7 11 Advanced Energy Table 7 3 Help Code Troubleshooting Table Continued Help Help Code Problem Indicated Suggested Action Code Message Number H031 User Port Reset The User port reset is De assert the User port reset is Active asserted function See the I O Communication and Control chapter for more information H099 Command Not The Pinnacle Plus unit Review the list of Implemented does not support the commands For a list of command most recently sent commands see the I O by the computer host Communication and Control chapter If by following the information in these checklists and this table you fail to identify the problem please call AE Global C
105. ed 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 5702285 B l O Communication and Control 4 87 Advanced Energy Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 170 Requests the arc shutdown time The returning 0 2 request arc packet contains 2 data bytes shutdown Byte 1 Unused 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 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 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 point This value is set with command 4 174 Requests the ove
106. ee options for monitoring your Pinnacle Plus units while in a sync pulse configuration depending on your unit s features These options are as follows If you have a passive front panel or remote passive panel attached to any unit in the system you can view the out for that unit For more information see the I O Communication and Control chapter If you have an active front panel or Pinnacle Plus Remote Active Panel attached to any unit in the system you can monitor the output power current or voltage of the unit and its set points For more information see the I O Communication and Control chapter e If you have a host computer connected to a serial port on any unit in the system you can monitor the output power current or voltage of the unit and its set points 5702285 B Installation 5 19 Advanced Energy Clearing Faults in a Sync Pulse System The following table describes some of the errors you might encounter with a Pinnacle Plus master slave system Table 5 4 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 Sync Pulse e All units in the system ar
107. el The first five min switches A4 to A0 are used to specify the address of a Pinnacle Plus unit see Table 4 13 on page 4 51 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 13 on page 4 51 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 Note You must remove the power supply cover to change between RS 422 and RS 485 5702285 B O Communication and Control 4 49 Advanced Energy DANGER Disconnect all sources of input power before working on this unit or anything connected to it In addition take proper ESD precautions before removing the unit s top cover to position jumpers The mode of differential communication that is RS 485 or RS 422 is selected via the jumper labeled as such You must first remove the unit cover then place the jumper across pins 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 If have selected RS 422 or if your Pinnacle Plus unit is the last device on an RS 485 multi drop chain place the jumpers across pins 1 and 2
108. entified on the rear panel and on an enclosed test checklist The Apex generator power supply provides the following input voltages depending on your unit configuration 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 5 6 Installation 5702285 B Pinnacle Plus 10 kW The AC line input connection is provided by means of a five terminal DIN terminal block on the rear panel 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 Note No neutral connection is required However if neutral is present connect it to the N terminal AN DANGER This device must be operated in an overvoltage Il category installation only To connect your system to the power supply you need stranded wire of a gauge consistent with your application and applicable requirements and the power input specification To connect to the power supply s input power connector 1 2 I A t RK Strip approximately 60 to 70 mm of the insulation from the end of the power cord Separate the five wires and strip approximately 10 mm of the insulation from each wire Ensure that the ground wire the yellow and green wire is approximately 7 mm longer than the other wires Crimp on each lead a ferule of appropriate size
109. enu options press TYPE 2 A screen displays that allows you to set the type as TIMED JOULE CONTINOUS or JOULE DISCRETE Use the Modify knob to make your selection Press ENTER to save your selection 3 If you set the recipe type to be JOULE CONTINOUS a REPEAT menu option displays Select REPEAT to enter the number of recipe repetitions Use the Modify knob to enter an amount between 1 and 65535 Note The recipe repetitions feature is only available with the JOULE CONTINUOUS option 4 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 If a timed recipe is active the timed recipe overrides the joule feature To enable joule mode 1 Press PROCESS CONTROL JOULES ENABLE 5702285 B O Communication and Control 4 41 Advanced Energy 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 PROCE
110. er User port 4 11 theory of operation 2 2 functional diagram 2 2 timeout setting 4 28 setting for AE bus 4 47 transmission parameters AE bus 4 47 standard serial port 4 45 troubleshooting checking software revision 4 27 checking your ROM 4 27 checks if output does not turn on 7 5 checks with the unit on 7 2 clearing master slave faults 5 14 debugging 4 25 help codes 7 6 LEDs 7 4 passive front panel help codes 7 3 two line display 4 18 U unit specifications 3 1 unpacking the unit 5 1 user manual symbols used 1 3 type conventions 1 1 User port 4 1 cathode switch 4 11 connecting 5 5 installation 4 1 pin description table 4 3 regulation mode 4 11 signals 4 2 target life counter 4 11 V viewing arc density 4 38 5702285 B Index v Advanced Energy voltage arc trip level 6 2 voltage arc trip level setting 4 37 VOLTAGE switch 4 18 W warranty authorized returns 7 21 conditions of use 1 6 filing a claim 7 21 returning units 7 21 statement 7 22 warranty void if seal broken label 1 3 7 21 Index vi 5702285 B
111. er 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 ENABLE To enable or disable the target life counter for the selected target 1 Press PROCESS MONITOR 5 TARGET ENABLE 2 Rotate the Modify knob to select YES or NO 3 Press ENTER to accept and exit PROCESS 5 MONITOR 5 TARGET gt SELECT To change the active target life counter 1 Press PROCESS MONITOR TARGET gt SELECT 2 Rotate the MODIFY knob to select the active target number 3 Press ENTER to accept and exit Note The User port has priority in selecting targets Thus
112. erial 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 Process Control You can control the process with the following features joule mode ramping and recipes 5702285 B Specifications 3 1 Advanced Energy Table 3 1 Functional Specifications Continued 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 multiple 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 s
113. erial 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 You can change arc trip level voltage You can enable or disable micro arc handling but hard arc handling is always enabled e 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 3 2 Specifications 5702285 B Pinnacle Plus 10 kW Table 3 1 Functional Specifications Continued Cooling Air cooled Fault Conditions Several fault conditions will 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 PHYSICAL SPECIFICATIONS Table 3 2 Physical Specifications 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 Output Power Cable For optimal performance it is recommended that you use an output power cable 3 05 m 10 in length or shorter No
114. essible to the operator 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 RK5 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 through 100 A rated breaker Note See Electrical Specifications on page 3 4 for more information about the electrical specifications of your power supply If your unit does not have a circuit breaker install and operate it with an AE approved circuit breaker on the AC input to provide the required over current protection In addition you must provide the primary circuit protection such as the branch circuit backup fuse 5702285 B Safety and Product Compliance Guidelines 1 7 Advanced Energy 1 8 Safety and Product Compliance Guidelines 5702285 B Pinnacle Plus 10 kW Chapter 2 Theory GENERAL DESCRIPTION The Advanced Energy Pinnacle Plus series of DC power supplies provide the ultimate advantages in DC power They Are light and compact 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 Deliver full power over a 4 1 impe
115. ests the set point level you have set for a 1 3 specific ramping recipe step May return request P 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 mode e First and second bytes Value of set point in the mode indicated Third byte Regulation mode gt 6 Power gt 7 Voltage gt 8 Current This value is set with command 22 4 90 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 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 run time Send 1 data byte 8 bit value indicating the or recipe step e prang 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 23 184 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
116. et the V arc trip level use the ARC menu on an active front panel or the Pinnacle Remote Active Panel or AE Bus or PROFIBUS Command 10 see the I O Communication and Control chapter For sputter applications the V arc trip level should be set above 60 V for bias applications the V arc trip level can be set below 40 V A trip level between 40 V to 60 V can cause the unit to become unstable at start up FREQUENCY AND REVERSE TIME SETTINGS Frequency and reverse time settings affect the arc and process behavior of the Pinnacle Plus supply AE defines reverse time as the time that the pulsing switch is closed that is when no power is transferred to the plasma By action of the pulsing switch and output inductor output voltage is reversed See Table 3 4 on page 3 7 for reverse time specifications Reverse time is only relevant during pulsing operation 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 will need a good oscilloscope and a high voltage probe 2000 V rated that has been calibrated for the scope you are using Note AE recommends using a TEK 320 380 3054 3012 3032 or better with a 1 100 P5100 voltage probe Frequency and reverse time settings can affect arc and process behavior in the following ways Higher frequencies will reduce the tendency to arc Note Frequency is limited to 150 kHz when the pulse mode is set to be ena
117. etween a host computer and a Pinnacle Plus unit Host Pinnacle Plus it Transmits message packet 77 7 Receives packet Waits SendsACK tl N NS Assembles N CSR byte SS or N data byte s IN Then transmits t Receives ACK SS N N N Waits wp Receives packet 2 t Sends ACK Waits Z Y Z Y ps Receives ACK t time END OF TRANSACTION 1139 Figure 4 15 AE Bus communications transaction First the host computer sends a message packet to the Pinnacle Plus unit The packet contains one of the following 5702285 B O Communication and Control 4 55 Advanced Energy Acommand 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 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
118. fer to manual for more information 8 S N Short circuit protected PRODUCT COMPLIANCE The following sections include information about unit compliance and certification including the conditions of use required to be in compliance with the standards and directives Product Certification Certain options of this product are certified by CE marking self addressed by AE Compliance Engineering EMC measurements verified by an independent third party EMC testing laboratory 1 4 Safety and Product Compliance Guidelines 5702285 B Pinnacle Plus 10 kW For more information refer to the letter of conformance US or declaration of conformity EU accompanying the product Safety and Compliance Directives and Standards Certain options of this unit have been tested for and comply with the following safety and electromagnetic compatibility EMC directives and standards and semiconductor industry guidelines Note This device must be installed and used only in compliance with the directives and standards listed in addition to VDE 0113 EN 60204 IEC 60204 and applicable requirements Note Any unauthorized expansion repair modification or misuse of this product violates any compliance or certification associated with the product In this situation you are responsible to guarantee the compliance of the product ELECTROMAGNETIC COMPATIBILITY EMC DIRECTIVES AND STANDARDS Table 1 1 Electromagnetic Compati
119. fications chapter for more information 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 Check the LEDs on all units to determine that the proper ones are lit Note any error code that is any Exxx number displayed on the front panel or Pinnacle Remote Active Panel See Error Code Troubleshooting Table later in this chapter for additional information Working with the passive front panel ensure that the front panel LEDs POWER ON INTERLOCK OUTPUT and SETPOINT LEDs are lit see Troubleshooting Table in this chapter Note which if any of these 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 Table in this chapter for a suggested response to any of these errors Verify that LEDs light to show the control and regulation settings Then verify that the OFF LED is lit 7 2 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW 6 If you suspect an LED is malfunctioning cycle the Pinnacle Plus unit s power on and off If the problem reoccurs call AE Global Customer Support 7 Working with the passive front panel note whether the BUS FAULT or OVERTEMP LEDs on the front panel are illuminated see Error Code Troubleshooting Table in this chapter If the BUS F
120. for synchronized pulsing operations and is discussed later in this chapter See Sync Pulse Operation on page 5 15 Note See the rear panel illustration of the Pinnacle Plus power supply at the end of this chapter for the location of these ports MASTER SLAVE PULSE PORT CONNECTOR Pin 8 Pin 15 Pin 1 60000006 pananaga Pin 9 1061 Figure 5 5 Master Slave Pulse port connector MASTER SLAVE PULSE PORT PIN DESCRIPTIONS The following table provides pin and signal descriptions for the Master Slave Pulse port Table 5 1 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 5 10 Installation 5702285 B Pinnacle Plus 10 kW Table 5 1 Master Slave Pulse Port Pin and Signal Descriptions Pin Associated Pin Name Description Pin 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 MAS
121. gnal Description Pin Pin Type 22 37 EOTL D digital Normally this pin is output configured to signal the end Or 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 high when the active target life counter reaches zero thus indicating that target life has ended READY D If your unit is configured for use with an Advanced Energy Varian Interface unit a digital low on this pin indicates faults are active ready bit is de asserted and the unit is not ready to output power A digital high 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 Full scale represents the rating of the supply see the Specifications chapter of this manual for more information 4 8 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 1 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 re
122. gns of damage to the unit itself cables and connectors If damage has occurred power off the unit and call AE Global Customer Support If there are no obvious signs of damage proceed with the checks on the following lists 5702285 B Troubleshooting and Global Customer Support 7 1 Advanced Energy Checks with the Unit Powered Off Perform the following checks with the unit powered off 10 Ensure the power to the unit is off Check for visible damage to the unit cables and connectors 1 2 3 4 Ensure all unit connectors are installed correctly and are fastened tightly Check to determine whether any system related circuit breakers have been tripped Ensure all phases of the main input power are applied to the appropriate power supply terminals Ensure there is input power to both the unit and the remote and ensure the input power meets specifications Ensure ground connections are adequate and secure and comply with local safety codes 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 I O Communication and Control chapter Ensure that the interlock loop is closed both at the Contactor Interlock and at the User port See the description of the Contactor Interlock in the Installation chapter for more information Ensure that input power meets specifications See the Speci
123. h command 10 All arc counters are updated every 100 ms or 10 times per second 190 request hard arc density Requests how many hard arcs occurred in the previous run returning packet contains 4 data bytes 32 bit value indicating the number of hard arcs in the previous 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 4 92 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 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 card First byte Identity of card in slot 1 gt 0 Card not present 01 or 17 Dual User port gt 03 or 26 PROFIBUS 05 or 21 Single User port 18 or 28 AE Bus p 23 or 30 DeviceNet e Second byte Identity of card in slot 2 gt O Card not present gt 03 or 26 PROFIBUS 04 Host Protocol Translator 05 or 21 Single User port gt 18 or 28 AE Bus 22 or 29 Master slave card with AE Bus 196 Requests the recipe type set with command 33 0 1 request Returns 1 data
124. hat the display screen shows values for output information If the display screen shows an error code and message see the Troubleshooting chapter for error code explanations and troubleshooting suggestions UNDERSTANDING PINNACLE PLUS ARC HANDLING Your Pinnacle Plus unit will power up every time with micro arc handling enabled You can safely disable micro arc handling if your process allows it Hard arc handling cannot be disabled The following paragraphs describe what the arc handling settings are and how they might interact with each other with your system and with your process Voltage Arc Trip Level By setting the voltage arc V arc trip level you are indicating the voltage threshold as measured at the DC inverter output see Figure 2 1 on page 2 2 at which the Pinnacle Plus 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 6 2 Operation 5702285 B Pinnacle Plus 10 kW 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 however that some target types experience hard arcs at 100 V so do not assume that 50 V is right for all processes Note The recommeded V arc trip level for low impedance metal targets is the default value of 70 V To s
125. he 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 18 for more information 4 14 O Communication and Control 5702285 B Pinnacle Plus 10 kW 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 39 Activate the set point value then turn the MODIFY knob until the set point you want is displayed then deactivate the set point value 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 3 on page 4 16 and Figure 4 5 on page 4 20 MODIFY KNOB Use the MODIFY kno
126. ication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 17 Tells the Pinnacle Plus supply whether the 3 CSR codes source of information for regulation mode and 0 1 2 9 program set points is internal or external the source can source 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 Non zero value Program source is external that is an analog value from the User port Note A User card must be installed for this feature to be available Read back these values with command 163 19 Specifies the number of recipe steps in your 1 CSR codes recipe 0 1 2 4 9 recipe steps Send 1 data byte 8 bit value the value must be at least O 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 5702285 B O Communication and Control 4 65 Advanc
127. ied by the manufacturer the protection provided by the equipment may be impaired All personnel who work with or who are exposed to this equipment must take precautions to protect themselves against serious or possibly fatal bodily injury Advanced Energy Industries Inc AE provides information on its products and associated hazards but it assumes no responsibility for the after sale operation of the equipment or the safety practices of the owner or user This equipment produces or uses potentially lethal high voltage high current radio frequency RF energy NEVER DEFEAT INTERLOCKS OR GROUNDS TRADEMARKS Ac ADVANCED isa registered trademark of Advanced Energy Industries IC ENERGY Inc Advanced Energy is a registered trademark of Advanced Energy Industries Inc AE is a registered trademark of Advanced Energy Industries Inc iv 5702285 B Pinnacle Plus 10 kW Pinnacle is a trademark of Advanced Energy Industries Inc CUSTOMER FEEDBACK Advanced Energy s technical writing staff has carefully developed this manual using research based document design principles However improvement is ongoing and the writing staff welcomes and appreciates customer feedback Please send any comments on the content organization or format of this user manual to e tech writing aei com To order a manual please contact Technical Support e technical support aei com 5702285 B Advanced Energy vi 57022
128. ies 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 that fans or blowers be mounted so that the hot air is removed from the cabinet as quickly as possible Each Pinnacle Plus kW supply dissipates up to 10 of its maximum power at full rated output The minimum air flow required by the Pinnacle Plus kW supply is CFM cubic feet per minute 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 For example if three Pinnacle Plus kW units were to be mounted in a cabinet see Figure 5 2 on page 5 3 the minimum CFM requirement would be CFM of cabinet air volume CFM This would result in a total power dissipation within the cabinet of W W The difference in temperature between coolant air and exhaust air would be approximately 20 C 5 2 Installation 5702285 B Pinnacle Plus 10 kW Input Air Through Front Panel A 4 102 mm minimum clearance between rear of rack and rear of enclosure i Exhaust Air 1 25 mm minimum clearance between unit and top of rack 0 0 mm minimum clearance between units 3 76 mm minimum clearance from enclosure to rack
129. ime 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 DEFAULTS 2 Rotate the MODIFY knob to display YES or NO 3 Press ENTER to accept and exit Setting Pulse Parameters SUPPLY PULSE 4 28 O Communication and Control 5702285 B Pinnacle Plus 10 kW Use this menu entry to alter pulsing type parameters ENABLING PULSING AT CURRENT THRESHOLD OR ALWAYS SUPPLY PULSE ENABLE Use this menu function to enable pulsing at the current threshold default setting or to enable pulsing always If the unit is set to pulse at the current threshold pulsing is disabled until the Pinnacle Plus unit detects current flow above the current threshold At this point the unit will begin to pulse For more information see High Power Operation on page 6 5 If the unit is set to pulse always the unit will pulse from the moment it is energized For more information see Low Power Operation on page 6 4 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 6 5 for information about high power operation To enable pulsing at the current threshold or always
130. 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 DANGER RISK OF DEATH OR BODILY INJURY Disconnect all sources of input power before working on this unit or anything connected to it 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 supplemental Protective Earth ground terminal to an earth ground terminal with a copper wire that is sized according to the applicable requirements 1 6 Safety and Product Compliance Guidelines 5702285 B Pinnacle Plus 10 kW For delta connected mains primary and supplemental Protective Earth ground wires must be connected Install and operate this device in an overvoltage category II installation only Use only a shielded power cable on the output power connector CE marked power supplies install and operate this device only in a pollution degree 2 or better environment which means an indoor location such as a computer room office or factory floor where only non conductive pollution occurs during operation Occasionally condensation causes temporary conductivity when the device is not operating Non standard connectors for input and or output power must be inacc
131. 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 of this manual for more information Selecting Constant Duty Cycle SUPPLY PULSE 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 DUTY CYC 2 Select YES to enable function 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 To select the desired source and type 1 Press SUPPLY PGM SRC 4 30 O Communication and Control 5702285 B Pinnacle Plus
132. it s synch pulse feature as a 1 CSR codes transmitter or a receiver 0 1 2 9 sets synch pulse as Send 1 data byte transmitter or 0 Receiver receiver i e Non zero Transmitter 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 5702285 B O Communication and Control 4 71 Advanced Energy Table 4 17 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 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
133. it Continue connecting together subsequent slave unit chassis in this manner We recommend you connect the ground stud on the master unit to system ground 5 12 Installation 5702285 B Pinnacle Plus 10 kW MASTER SLAVE CONFIGURATION EXAMPLES The following block diagram provides a high level view of possible configurations for a Pinnacle Plus master slave system Note See Sync Pulse Configuration Examples on page 5 17 for further possible configurations for master slave operations Master Slave Pulse System The following configuration allows you to configure up to 6 Pinnacle Plus power supplies in a master slave configuration In this configuration the errors are shared among the network units C Master O To Rack Ground and Chamber Ground o O Slave 1 eo O C e Slave 2 C 2094 Figure 5 7 Master Slave Pulse system diagram 5702285 B Installation 5 13 Advanced Energy Monitoring Your Master Slave System There are three options for monitoring your Pinnacle Plus units while in a master slave configuration depending on your unit s features These options are as follows e If you have a passive front panel or remote passive panel attached to your master unit you can view the combined output of your master slave syste
134. l manufacture the goods in accordance with its published specifications and that the goods will be free from defects in material and workmanship The seller s liability for breach of an expressed warranty shall exist only if the goods are installed started in operation and tested in conformity with the seller s published instructions The seller expressly excludes any warranty whatsoever concerning goods that have been subject to misuse negligence or accident or that have been altered or repaired by anyone other than the seller or the seller s duly authorized agent This warranty is expressly made in lieu of any and all other warranties express or implied unless otherwise agreed to in writing The warranty period is 12 months after the date the goods are shipped from AE In all cases the seller has sole responsibility for determining the cause and nature of the failure and the seller s determination with regard thereto shall be final The AE Warranty Statement may be superseded by a service agreement entered into between AE and the buyer 7 22 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW A active front panel See control panel addressing AE bus 4 47 AE Application Note 5600031 5 4 AE bus checksum 4 55 communication mode 4 52 communications transaction example 4 58 connector 4 46 data bytes 4 54 DIP switch 4 47 isolated cards 4 46 jumpers RS 485 422 4 50 message packet 4 53 setting add
135. labeled Term If you have selected RS 485 and your Pinnacle Plus unit is not the last device on a multi drop chain place the jumpers across pins 2 and 3 for no termination SETTING THE PINNACLE PLUS UNIT S AE BUS ADDRESS Use the DIP switch see Figure 4 11 on page 4 48 and Figure 4 12 on page 4 48 to set the unit s AE Bus address see Table 4 13 on page 4 51 For units with a single output an allowable address is between 1 and 31 For units with a dual output the address switches pertain to Side A Side B is addressed by adding 15 to the address of Side A Allowable addresses for Side A are 1 to 15 Side B addresses will then be 16 to 30 respectively For units with a dual output and two AE Bus cards one AE Bus card in the Serial port and one AE Bus card in the User port you set the AE Bus address as you would for a dual output The address switch on both cards pertains to Side A and Side B is addressed by adding 15 to the address of Side A Note You can set both addresses on each card to be the same address for side A or have two different addresses for side A as shown in the example below For example For the AE Bus card in the Serial port you set the address switch for Side A to 3 If you communicate to this card at address 3 you control Side A of the unit If you communicate to this card at address 8 you control Side B For the AE Bus card in the User port you set the address switch for Side A
136. le associated with this signal 35 36 TARGETI D digital 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 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 Dedicated return for digital outputs Pins 1 2 3 20 21 and 22 should be referenced to this pin 4 10 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 2 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 7 low high 4 or 8 low low Table 4 3 Target Life Counter pin 34 35 and 4 Target Life Counter Pin 34 Pin 35 Pin 4 1 low low low 2 low low high 3 low high low 4 low high high 5 high low low 6 high low high 7 high high low 8 high high high Table 4 4 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 5702285 B O Communication and Control Advanced Energy PASSIVE DISPLAY PANEL The passive front panel and remote passive panel let you monitor power current or voltage receive err
137. le value is the maximum rated output for the supply To set the user current limit 1 Press PROCESS LIMITS CURRENT 2 Rotate the MODIFY knob to select a value between O 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 POWER This function lets you set a maximum limit for output power The maximum allowable value is the maximum rated output for the supply To set the user power limit 1 Press PROCESS LIMITS POWER 2 Rotate the MODIFY knob to select a value between O and the maximum rated output power 3 Press ENTER to accept and exit 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 establish arc handling parameters for normal process runs In addition the PROCESS menu lets you view arc density Statistics SETTING THE VOLTAGE ARC TRIP LEVEL PROCESS ARC LEVEL 5702285 B O Communication and Control 4 37 Advanced Energy This function lets you set the voltage arc trip level that is the output voltage level as measured at the DC inverter output see Figure 2 1 on page 2 2 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 for 5 us in the case
138. longer than 32 8 feet 10 m Usable Output Range See Figure 3 3 on page 3 15 Impedance Range See Figure 3 4 on page 3 15 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 5702285 B Specifications 3 5 Advanced Energy Table 3 3 Electrical Specifications Continued Ignition Capability Voltage clamped to 1700 V at 50 mA maximum Ignition cycle runs at 1400 V 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 will be either O to 5 V or 0 to 10 V full scale If your supply 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 Output Frequency self run 5 kHz to 350 kHz 5 kHz increments Note The PNCL PLUS self run frequency has a granularity of 50 ns Therefore the maximum difference from set point to actual is always l
139. lus supply will produce the best process results For UHF connectors RG393 cable is recommended For two pin pluggable connectors twisted pair cable with an external shield is recommended or RG393 for use with PG 11 style strain relief connectors In general the shortest cable will give you the widest process window and the best results cables should be no longer than 3 05 m 10 Long cables may cause the Pinnacle Plus supply to turn off because of excessive reflected power WARNING Never use an output power cable longer than 9 15 m 30 or damage to your Pinnacle Plus unit may result 5 8 Installation 5702285 B Pinnacle Plus 10 kW Master Slave Operation Note This function is only available on units specially configured for master slave operation at the factory and equipped with a master slave Host card Up to six Pinnacle Plus power supplies may be configured to operate in a master slave system allowing you to increase your total system power up to 60 kW Any Pinnacle Plus unit that features the master slave Host card can function as either a master unit or a slave unit See Figure 5 4 on page 5 9 for an illustration of the master slave Host card Note Pinnacle Plus units without a master slave Host card cannot function as a master or slave Note When running a master slave system in voltage regulation be aware that the Pinnacle Plus units may not share current or power Host Port Card M
140. m power or current The passive front panel of each slave unit displays the individual unit s output For more information see the I O Communication and Control chapter If you have an active front panel or Pinnacle Plus 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 For more information see the I O Communication and Control chapter If you 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 CLEARING FAULTS IN A MASTER SLAVE SYSTEM If a 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 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 The following table describes some of the errors you might encounter with a Pinnacle Plus
141. ments The clearance between either side of the Pinnacle Plus supply and the enclosure must be 76 mm 3 in The clearance between the top of the Pinnacle Plus supply and the top of the enclosure must be 25 mm 1 in No clearance is required between power supplies The clearance between the rear of the Pinnacle Plus supply and the enclosure must be 102 mm 4 in with adequate ventilation Figure 5 1 Dimensional drawing 5702285 B Installation 5 1 Advanced Energy COOLING REQUIREMENTS WARNING For CE marked power supplies Install and operate this device only in a pollution degree 2 or better environment which means an indoor location such as a computer room office or factory floor where only non conductive pollution occurs during operation Occasionally condensation causes temporary conductivity when the device is not operating For the Pinnacle Plus supply to be sufficiently cooled the cabinet must be set up to e Bring in sufficient coolant air of the correct temperature 0 to 40 C maximum e Distribute coolant air to the power supplies e Prevent air exhausted from the cabinet from circulating back and becoming input air Exhaust the hot air from the cabinet with minimal airflow restriction See Figure 5 2 on page 5 3 for a dimensional diagram Cabinet Design The following is a synopsis of the principles to follow when designing a cabinet containing a stack of Pinnacle Plus power suppl
142. mmand Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 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 49 142 Requests the output voltage limit Accuracy is 0 2 0 3 of the full rated output voltage for the request user supply voltage limit 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 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 51 146 Requests pulse frequency index read in 5 kHz 0 1 increments the returning packet contains 1 request pulse byte frequency index e 0 0kHz pulsing disabled e 1 5 kHz e 2 10 kHz e 3 15 kHz 4 to 69 follow the established pattern e 70 350 kHz This value is set with command 92 4 78 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table
143. mmands 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 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 Sets the ramp start point as a percentage of set 1 CSR codes point when output is turned on The range is O 0 1 4 9 ramp start to 95 point percentage Send a 1 byte value of 0 to 95 of set point Read back this value with command 152 33 Set the type of recipe The default is Timed 1 CSR only reGIpe 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 e To disable the timer send a value of 0 Read back with command 174 5702285 B O Communication and Control 4 69 Advanced Energy Table 4 17 AE Bus Commands Continued Command Description Num
144. most soft key will bring up the main menu tree When at the top level you have three menu options e Service e Supply 4 20 O Communication and Control 5702285 B Pinnacle Plus 10 kW 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 menu options SERVICE FAULTS i J STATS ENERGY TIME I IDLE RUN EVENTS HP FAULTS H gt MORE gt OVRTMP BUS H INTRLOCK INVRTR IRQS MONITOR SETPT c DSP LB CYCLES gt OUTPUT UNIT DEBUG SYSTEM aaa FAULTS UNITS HW CONFIG CARD EHH QUEUE LOGIC BUFFER UNIT I MEMORY E ROM I CARD PANEL 1648 Lp swREV i cone TT CARD PANEL DSP LOGIC Figure 4 6 Service menu map 5702285 B O Communication and Control 4 21 Advanced Energy AE BUS DEFAULTS PULSE H ENABLE PULSING ENABLED AT CURRENT THRESHOLD PULSING ENABLED ALWAYS gt B CAST o YES TX RX O DUTY CYCLE gt O YES N TRANSMIT RECEIVE N LOCK PGM_SRC PANEL P SELECT SET CODE LOCK UNIT 1649 Figu
145. n 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 4 32 O Communication and Control 5702285 B Pinnacle Plus 10 kW 1 Press PROCESS MONITOR 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 18 RESETTING THE OVER VOLTAGE DENSITY PROCESS MONITOR OVER V 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 OVER V gt RESET SETTING THE OVER VOLTAGE TIMER PROCESS MONITOR 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 shuts off output When the timer expires the unit shuts off output
146. nd 2 Place the P5 jumper voltage current and power readbacks across pins 2 and 3 Place the P4 jumper level out signal across pins 2 and 3 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 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 are 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 570228
147. ndling on page 4 39 for more information 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 e A two line display five soft keys and a MODIFY knob Two line Display WA Control 5 Qua cs a argae Cl 25 spinnA4cle Penson J O curent oe OF CJ CO CJ Os Five Soft Keys m Figure 4 3 Control panel Output Power Key Use the following keys to turn output power on and off 4 16 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 7 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 To control
148. nnel See AE Global Customer Support on page 7 19 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 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 Table on page 7 13 7 4 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW Table 7 2 Troubleshooting LEDs Continued LED On Off Status INTERLOCK X Normal INTERLOCK X An interlock fault condition exists Note the error code on the display and see Error Code Troubleshooting Table on page 7 13 BUS FAULT X A bus fault condition exists Note the error code on the display and see Error Code Troubleshooting Table on page 7 13 BUS FAULT X Normal OVERTEMP X An over temperature fault condition exists Note the error code on the display and see Error Code Troubleshooting Table on page 7 13 OVERTEMP X Normal 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
149. ntinues 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 maximum output voltage current and power Note 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 Note You cannot set a set point greater than the corresponding limit in that regulation mode SETTING A MAXIMUM LIMIT FOR OUTPUT VOLTAGE 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 4 36 O Communication and Control 5702285 B Pinnacle Plus 10 kW Setting 2 Rotate the MODIFY knob to select a value between O 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 allowab
150. on the master unit to an equi potential ground stud on the first slave unit To configure a master unit as a stand alone unit do the following 1 2 Set the MSTR SLV switch in the up MSTR position Remove all Master Slave interface cables from the master unit Configuring Your Slave Units To configure a slave unit Note See Figure 5 7 on page 5 13 for an illustration 1 2 Remove input power from the master and slave units If the Pinnacle Plus supply includes a User card ensure that the interlock inputs are satisfied Refer to the I O Communication and Control chapter for specific User port pin descriptions and required voltage levels 3 Set the MSTR SLV switch see Figure 5 4 in the down SLV position Connect the included 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 Note The last slave unit on your 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 port labeled Master Slave Pulse on the master unit and the port labeled Master Slave Pulse on all associated slave units Use a grounding strap to connect an equi potential ground stud on the first slave unit to an equi potential ground stud of the next slave un
151. ont Panel Help Codes When only a Passive Front Panel PFP is available the Pinnacle Plus unit will display 4 character strings on start up to identify personality cards installed in the unit A code will flash once for each card installed The following table describes the strings Table 7 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 5702285 B Troubleshooting and Global Customer Support 7 3 Advanced Energy Table 7 1 Passive Front Panel Help Codes Continued PFP Display String Personality 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 Table Table 7 2 Troubleshooting LEDs LED On Off Status POWER X Normal 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 See the Specifications chapter for AC input power specifications If the unit is damaged the internal main fuses may be opened Note These fuses should only be accessed by AE perso
152. ontinues 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 4 56 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 16 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 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 i
153. onventions and the danger warning and caution boxes that provide information about the specific levels of hazard seriousness Type Conventions Please note the following type conventions e Pin and signal names appear in capitalized italics POWER ON New terms appear in italicized text Unit labels switches indicators and so on appear in boldface text MODIFY Commands 162 and command names set point appear in boldface lowercase text 5702285 B Safety and Product Compliance Guidelines 1 1 Advanced Energy Danger Warning and Caution Boxes 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 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 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 oper
154. or 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 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 ps 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 and other troubleshooting materials see the Troubleshooting chapter LEDs Table 4 5 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 4 12 O Communication and
155. ow power operation is 1000 W or less and high power power is greater than 1000 W To select the mode of operation one must set the user power limit based on the 1000 W dividing line 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 the output is on The specific conditions under which the operation modes differ are Initial output on or ignition e Arc shutdown extinguishing the plasma Open load circuit condition at output Additionally the operational mode voltage limits are altered slightly should you select voltage as the mode of regulation Low Power Operation For low power operation the power limit must be set to 1000 W or less and the following is true 6 4 Operation 5702285 B Pinnacle Plus 10 kW Mode Low Power Operation Ignition No ignition is present in all control modes The Pinnacle Plus unit 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 High Power Operation For high power operation the power limit is set to greater than 1000 W and the following is true Mode High Power Operation Ignition Under high power operation Power or Current regulation pulsing is disabled the voltage jumps to maximum voltage
156. pically contains data or a CSR see Creating an Ideal AE Bus Communications Transaction on page 55 depending on what was requested Since some commands do not require data sometimes the Data field is not present 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 4 54 O Communication and Control 5702285 B Pinnacle Plus 10 kW 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 checksum 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 b
157. presents the rating of the supply see the Specifications chapter of this manual for more information 26 n a 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 n a 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 5702285 B O Communication and Control 4 9 Advanced Energy Table 4 1 User Port Pin Descriptions Continued Signal Pin 32 Return Pin 9 Pin Name Signal Type analog output REF A Description This signal provides an 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 1 and 2 e To reference to 5 V place the jumper across pins 2 and 3 33 n a unassigned n a n a 34 36 TARGET2 D digital input 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 tab
158. pressed On slide DIPs up means that the slide is pushed toward the numbers A o lt x 2 w A2 gt j A1 AO o BRO 4 BR1 LJ Unit Address Baud Rate Communication Mode Dip switch shown 2 1 2 times actual size 1683 Figure 4 11 Rocker DIP switch a Unit Pen Baud Rate Communication Mode Dip switch shown 2 1 2 times actual size 1684 Figure 4 12 Slide DIP switch On units where the DIP switch is located externally on the rear panel it can be difficult to see the numbers 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 4 48 O Communication and Control 5702285 B Pinnacle Plus 10 kW 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 a AE Bus Port L 22220222L OBEO ROER RRO 0060000262020 E E EPIO O 020202000202020 2020201 GNG soono nnana O O QROROROROKOKORORCKOKO HOH HOO Figure 4 13 Orientation of the AE Bus port and external DIP switch on the back pan
159. processor Advantages kk kk kk kk kK KK KK KK KK teen a KI KK ees 2 2 Displays rre PEP a A a 2 2 Arc suppression Feature i kk kd kk KK KK or DRE KK KK KK KK KK 2 2 Theory of Operation iiia danse dash KK KK KK KK KK KK KK KK KI KK KK KK KK KK NR 2 2 APU odere ie OU diripere hi adl dex dpa adus qund deo o eee mae NA 2 3 Housekeeping Supply kk kk KK KK KK KK KK KK eere 2 3 inui rr IULIUS 2 3 er QUT rU 2 3 Output Measurement eh 2 3 DC Chopper Section gt idu ec e Ye REGCERIF etme dees POR SRE NESE Re Sex 2 3 LOGI CONMO ccc 4x ss sa sis s da ane RO RUE d Hi aa k kik hoe Si WA be eee ees 2 3 Remote InteraeBS suceeded es EE PRICE eS RYE EORR ER HORS EE pac 2 4 Chapter 3 Specifications Functional Specifications s s kk kk KK KK KK KK eee 3 1 Physical Specifications aah NEN kK KK KK KK KK KK KK KK KK IK KK KK KK KK KAL 3 3 Electrical Specifications cesa ck kk ce RR KK KK KK KK KK KK KIR KK KK KK KK 3 4 5702285 B vii Advanced Energy Maximum Allowable Reverse Time For a Given Frequency 3 6 Reverse Time As A Function of Voltage Limit a 3 10 Operating and Impedance Range Illustrations 3 14 Environmental Specifications kk kK KK KK KK KK es 3 16 Coolant Specifications 3 sx xn saa 3 RO xa KG AR Ka d Xu l WANA AW KA babes 3 17 Chapter 4 I O Communication and Control gus RI PPP err BA
160. put 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 Readbacks Clock I D Clock L L J L J L J Y b Reverse Time Frequency Setpoint Setpoint Warning Field Menu of Pulsing Source Access 1488 Figure 4 4 Two line output display screen The following information appears in the top line of the display left to right Voltage readback Current readback in amps e Power readback in watts Clock ID what the supply is doing gt RMP output is on and ramping gt RUN output is on and the clock shows the elapsed time p OFF output is off and the clock shows the last run time Clock Note If the last run time is 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 Reverse time 4 18 O Communication and Control 5702285 B Pinnacle Plus 10 kW Frequency of pulsing Set Point Source i internal e external 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 p EOTL end of target life OC over current condition p OV over voltage condition
161. r of Response Bytes 6 set point Specifies the output set point level for whichever method of regulation mode has been selected 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 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 2 CSR Codes 0 1 4 6 9 19 4 60 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 8 Send 2 data bytes to set the arc shutdown time 2 CSR only arc shutdown time Byte 1 Unused e
162. r voltage timer value the 0 2 returning packet contains 2 data bytes 16 bit request over value indicating the value voltage timer 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 First byte Number of hours e Second byte Number of minutes Third byte Number of seconds 4 88 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 17 AE Bus Commands Continued Command Description Number CSR of Codes or Transmit Number of Data Response Bytes Bytes 178 Requests the hard arc count limit the returning 0 4 packet contains 4 data bytes a 32 bit value request hard indicating the limit arc count limit This value is set with command 9 179 Requests the active recipe step number the 0 4 or 6 ramp run status and the ramp run time request remaining the returning packet contains 4 or 6 active recipe data bytes depending on the recipe type step ramp run status First byte Active recipe step number and ramp run e Second byte Ramp run or recipe type time status 1 ramp 2 run 4 continuous remaining recipe 5 discrete recipe 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
163. re 4 7 Supply menu map gt CLICKS 4 22 O Communication and Control 5702285 B Pinnacle Plus 10 kW PROCESS MONITOR TIMER RESET b TIMER RESET TARGET ENABLE SELECT LIMITS VOLTAGE LIFE CURRENT ARC LEVEL COUNT DENSITY SECOND RUN ENABLE CONTROL RECIPE JOULES _ THRESHOLD TYPE ENABLE LEVEL SETPT RAMP ENABLE START PT TIME 1650 Figure 4 8 Process menu map USING THE SERVICE FUNCTIONS Use this option to view diagnostics and software versions of your supply The menu options are 5702285 B O Communication and Control 4 23 Advanced Energy FAULTS customer service information STATS supply statistics DEBUG debug screens MEMORY ROM CRC checksums SW REV software revision numbers Checking Service type Faults SERVICE FAULTS Customer service will use this option Checking Service type Statistics SERVICE STATS Use this option to check the service type statistics CHECKING THE TOTAL ENERGY OUTPUT SERVICE STATS ENERGY To check the total energy output Press SERVICE STATS ENERGY The total energy output for the unit appears CHECKING THE AMOUNT OF IDLE TIME SERVICE STATS TIME To check the amount of time idle and the amount of time r
164. resses 4 47 setting baud rates 4 52 setting network address 4 50 setting timeout 4 28 timeout period 4 47 AE bus commands 4 58 AE bus host 4 46 AE Bus port pin descriptions 4 46 AE bus port transmission parameters 4 47 air cooling requirements 5 2 analog signals 4 2 arc count limit setting 4 38 arc density viewing 4 38 arc handling understanding 6 2 arc handling enabling 4 39 ARC LED 4 16 arc suppression feature description 2 2 B baud rate setting AE bus 4 52 Index C cabinet design 5 2 cathode switch User port 4 11 CE marking 1 4 changing target functions 4 35 checksum AE bus 4 55 command status response codes 4 56 commands AE bus 4 58 communication transaction example AE bus 4 58 communications mode setting 4 52 communications protocol standard serial port 4 53 conditions of use 1 6 connecting master slave 5 9 connections contactor interlock 5 6 input power 5 6 output power 5 7 rear panel 5 4 remote panel 4 13 5 4 serial port 5 5 User port 5 5 connector AE bus 4 46 Host AE bus 4 46 User port 4 1 connecttions remote passive panel 5 5 contactor interlock connecting 5 6 CONTROL key 4 14 control panel 4 13 choosing regulation modes 4 15 CONTROL key 4 14 control mode switches 4 17 controls 4 20 CURRENT switch 4 18 HOST switch 4 17 5702285 B Advanced Energy interface 4 16 LOCAL switch 4 17 menu maps 4 21 options 4 20 selections 4 20 MODIFY knob 4 15 4 19 monitoring your proce
165. rity e 1 start bit 8 data bits one stop bit Low order bytes are transmitted before high order bytes 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 5702285 B O Communication and Control 4 45 Advanced Energy 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 Support 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 Pin 1 Pin 6 1017 Figure 4 10 AE Bus port connector Pin Descriptions Refer to the following table for pin descriptions Table 4 12 AE Bus Host Port Pin Descriptions
166. rror checking Figure 4 14 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 2 2 10765 432107 654321076543210 Header Optional Checksum 5 bit address 3 bit length 1138 Figure 4 14 Graphic representation of an AE Bus message packet 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 host 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 5702285 B O Communication and Control 4 53 Advanced Energy 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 The remaining three bits tell the receiving unit how long the Data field is so tha
167. s 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 5702285 B O Communication and Control 4 57 Advanced Energy Table 4 16 Command Status Response CSR Codes Continued 36 User set point out of range 99 Command not accepted there is no such command HOST PINNACLE PLUS OAh 06h 64h 00h 68h Header Cmd Data Chksum ACK 09h 06h 00h OFh Header Cmd CSR Chksum 06h ACK time 2251 Figure 4 16 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 parameter 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 56 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 of the table Some of these commands may return CSR codes those codes are listed in the same column 4 58 O Communication and Con
168. s 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 intelligent 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 30 menen Point of DC DC AC e gt _ gt Section e MEER Voltage Chopper pc ng In Unit A Measurement Section 1 Housekeeping Bis Logic Remote Supplies Control Interfaces Display pa Figure 2 1 Pinnacle Plus functional block diagram 2 2 Theory 5702285 B Pinnacle Plus 10 kW Input In the input section AC line voltage is applied through the circuit br
169. s to a series of screens through which you enter ramp time set point and run timer for each step To set the ramp time set point and run timer value for each step 1 After you have entered a value from 1 through 8 at the OF STEPS screen see steps 1 and 2 above you should be looking at a screen that requests a RAMP TIMER value 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 Press ENTER the display progresses to a screen requesting a RUN TIMER value 4 40 O Communication and Control 5702285 B Pinnacle Plus 10 kW 5 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 6 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 7 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 recipe type 1 From the RECIPE m
170. set to ENABLED the OFF or RESET command will clear the fault Checking Your ROM SERVICE MEMORY To perform ROM cyclic redundancy check CRC checking Note There is a momentary delay before the CRC will display Note Not all cards support this option 1 Press SERVICE MEMORY gt ROM gt CARD 2 To calculate and display the active panel local or remote CRC press PANEL 3 To calculate and display the DSP CRC press DSP 4 To calculate and display the logic board CRC press LOGIC Checking Your Software Versions SERVICE SW REV To find out the software number and version of your system software components 1 Press SERVICE SW REV 2 To display the software version of the configuration press CONFIG 3 To display the software version of the cards installed in your unit press CARD 4 To display the software version of the active panel software press PANEL 5702285 B O Communication and Control 4 27 Advanced Energy 5 To display the software version of the DSP software press DSP 6 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 DEFAULTS e PULSE PANEL PGM_SRC Setting the AE Bus Timeout SUPPLY AE BUS To set your AE Bus timeout time 1 Press SUPPLY AEBUS 2 Rotate the MODIFY knob to adjust the AE Bus t
171. ss 4 32 ON OFF buttons 4 15 output display screen 4 14 output power switches 4 16 POWER switch 4 18 REGULATION key 4 15 regulation switches 4 17 selecting control mode 4 31 selecting functions 4 19 setting control parameters 4 39 setting panel mode 4 31 soft keys 4 15 4 19 two line display screen 4 18 VOLTAGE switch 4 18 control switches 4 17 coolant specifications 3 17 cooling requirements 5 2 CSR codes 4 56 CURRENT switch 4 18 customer support before calling 7 1 contact information 7 19 D data bytes AE bus 4 54 debugging your unit 4 25 digital signals 4 3 dimensions drawing 5 1 DIP switch AE bus 4 47 communication mode setting 4 52 setting baud rates 4 52 display passive panel 4 12 DISPLAY button 4 12 E electrical specifications 3 4 enabling arc handling 4 39 environmental specifications 3 16 error codes clearing 7 12 clearing master slave faults 5 14 errors checking service menu 4 24 F faults checking service menu 4 24 clearing in a master slave system 5 14 frequency setting 4 19 frequency time settings 6 3 functional specifications 3 1 G general description 2 1 grounding 5 4 H help codes passive front panel 7 3 troubleshooting 7 6 high power operation 6 4 Host AE bus isolated cards 4 46 Host connectors AE bus 4 46 Host port see also AE bus Host HOST switch 4 17 how to operate the unit 6 1 l icons in user manual 1 2 on unit 1 3 illustrations front panel 4 97 rear view 5
172. ster 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 Slow down the AE Bus communication rate or the rate at which commands are sent E070 Internal DeviceNet An internal communications error has occurred on the No suggested action Communications DeviceNet card Slot 0 Error E081 This error occurs at Ordinarily if this fault Initializing Master startup in units that are configured with a master does not clear automatically there is a Slave slave Host interface card hardware problem Check Once the master slave your master slave cabling Host card has been successfully initialized the fault self clears E086 The unit was in an No suggested action Overvoltage overvoltage condition for longer than was set on the overvoltage timer 5702285 B Troubleshooting and Global Customer Support 7 17 Advanced Energy Table 7 4 Error Code Troubleshooting Table Continued Error Code Message Problem Indicated Suggested Action E087 The unit was in an No suggested action overcurrent condition for Overcurrent longer than was set on the overcurrent timer E088 One of the following Cycle AC power to the short circuit conditions unit Short Circuit Condition occurred a shorted chamber shorted cable or
173. stopped talking to the communications and senda PROFIBUS Watch Pinnacle Plus supply master reset to clear the Dog Expired after establishing Pinnacle Plus unit s communications display E054 The PROFIBUS interface Cycle the Pinnacle Plus PROFIBUS MAC Reset or Offline has taken itself off line probably in response to another error unit s power off and on and re establish communications between the master and slave If the error code reappears call AE Global Customer Support 7 16 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW Table 7 4 Error Code Troubleshooting Table Continued Error Code Message Problem Indicated Suggested Action E055 A PROFIBUS command Slow down the PROFIBUS arrived before the last communication rate or the PROFIBUS sent command was rate at which commands Command Buffer executed and cleared are sent Make sure data Overflow from memory consistency module consistency is enabled in the PROFIBUS master E059 The PROFIBUS master To recover from the off PROFIBUS Master Released Unit 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 state have a PROFIBUS master establish communication with the Pinnacle Plus unit and send a ma
174. t 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 5 0 us 0 1 us increments up to a 45 reverse duty cycle for a given frequency See Maximum Allowable Reverse Time For a Given Frequency on page 3 6 and Frequency and Reverse Time Settings on page 6 3 for more information Reverse Voltage Approximately 10 of the operating voltage voltage readback shown on the active front panel interface 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 3 6 Specifications 5702285 B Pinnacle Plus 10 kW 12 k e maximum allowable reverse time usec 0 Figure 3 1 Pulse reversal times and self run frequencies Table 3 4 Reverse Time Given a Self Run Frequency SOD GPP PSG FF q9 fF 2 self run frequency kHz Oo LO P oD ah DP a 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 35 35 026 10 1 40 35 0 40 40 10 1 60 40 0 45 45 045 9 9 1 80 44 6 5702285 B Specifications 3 7 Advance
175. t 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 O 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 58 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 the 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 ty
176. te The output power cable must not exceed 10 m 32 87 or you may damage your power supply Input Power Connector Five terminal DIN compression terminal block Maximum wire size 6AWG User Port Connector Please reference the I O Communication and Control chapter Serial Host Port Connector Please reference the I O Communication and Control chapter 5702285 B Specifications 3 3 Advanced Energy ELECTRICAL SPECIFICATIONS Table 3 3 Electrical Specifications 208 VAC Input Voltage 180 to 229 VAC 3 phase 4 wire 50 to 60 Hz no neutral required Leakage current less than wye or delta 3 5 mA connection Maximum phase to phase voltage 208 V 10 Maximum phase to ground chassis voltage 250 V DANGER RISK OF DEATH OR BODILY INJURY For delta connections considerably more leakage current will exist You must connect the primary and supplemental Protective Earth ground wires 208 VAC Input Current 35 A nominal per phase at least 90 EFF 50 A circuit breaker 400 VAC Input Voltage 360 to 440 VAC 3 phase 4 wire 50 to 60 Hz no neutral required Leakage current less than 3 5 wye connection only 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 Not available for this configur
177. 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 8 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 power 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 5702285 B O Communication and Control 4 17 Advanced Energy Table 4 9 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 out
178. the value With command 230 send one data byte e 0 Logic e 2 DSP 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 pe recipe e Bytes 1 and 2 Number of repetitions set repititions Bytes 3 and 4 Current repetition in process reports 0 if output is off 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 4 96 O Communication and Control 5702285 B Pinnacle Plus 10 kW FRONT PANEL ILLUSTRATIONS 1654 OO OO NA ee Xx TO Q XS OOOQOOQ Cn Co Co eo ADVANCED ENERGY Acle Ar pinn Q a 5702285 B O Communication and Control 4 97 Advanced Energy Figure 4 17 Passive front panel front view CI CO 1656 Push to Exit Menu Q Pow Q Current O Voltag ol x UU CC Cre o 9 Ng J IC ENERGY pinnAcle ADVANCED AE Q O Figure 4 18 Active front panel front view 4 98 O Communication and Control 5702285 B Pinnacle Plus 10 kW O Modify Push to return to menu O t
179. tion 1 6 safety warning installation 5 4 selecting local remote operation 4 31 self run frequencies 3 7 serial communications AE bus 4 46 standard flash port 4 44 serial port connecting 5 5 service menu checking faults 4 24 checking statistics 4 24 debugging your unit 4 25 map 4 21 using functions 4 23 set point out of setp oint timer 4 34 setting 4 19 setting arc count limit 4 38 setting control parameters 4 39 setting joule mode 4 41 setting out of set point timer 4 34 setting output current limits 4 37 setting over current timer 4 34 setting over voltage timer 4 33 setting power limits 4 37 setting ramp 4 43 setting supply parameters 4 28 setting voltage arc trip level 4 37 slave units configuring 5 12 soft keys 4 15 4 19 software checking your versions 4 27 Host commands 4 58 spacing requirements 5 1 dimensions 5 1 stacked units 5 3 specifications coolant 3 17 electrical 3 4 environmental 3 16 functional 3 1 physical 3 3 stacked power units spacing requirements 5 3 standard serial port 4 44 communications protocol 4 53 CSR codes 4 56 pin descriptions 4 45 transmission parameters 4 45 statistics service menu 4 24 subminiature D 4 46 supply menu functions 4 28 5702285 B Pinnacle Plus 10 kW map 4 22 switches control panel control mode 4 17 control panel power 4 16 control panel regulation 4 17 symbols in user manual 1 2 on unit 1 3 T target functions changing 4 35 target life count
180. to 1 If you communicate to this card at address you control Side A of the unit If you communicate to this card at address 6 you control Side B 4 50 O Communication and Control 5702285 B Pinnacle Plus 10 kW Table 4 13 AE Bus Address Settings Address A4 A3 A2 Al AO 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 24 down down up up up 25 down down up up down 26 down down up down up 27 down down up down down 28 down down down up up l O Communication and Control 4 51 Advanced Energy Table 4 13 AE Bus Address Settings Continued Address A4 A3 A2 Al AO 29 down down down up down 30 down down down down up 31 down
181. to connect to the Remote Active Panel port 5 4 Installation 5702285 B Pinnacle Plus 10 kW Connecting a Remote Passive Panel Connections for a remote passive front panel are made through the female 15 pin subminiature D connector labeled MONITOR on the rear panel 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 unit Connection for User Port Control Please reference the I O Communication and Control chapter for instructions on connecting your analog digital interface Note To reduce EMI interference we recommend using shielded cable to connect to 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 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 Please reference the I O Communication and Control chapter for details on making this connection Note To reduce EMI interference we recommend using shielded cable to connect to the serial port Connection for Serial Host Port Control Please reference the I O Communication and Control chapter for instructions on connecting your serial communications Host port Note Any time
182. trol 5702285 B Pinnacle Plus 10 kW Table 4 17 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 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 method Send 1 data byte 8 bit value e 6 Power 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 enable e 0 Disable Non zero value Enable Read back this value with command 153 5702285 B O Communication and Control 4 59 Advanced Energy Table 4 17 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Numbe
183. ts cables should be no longer than 10 feet 3 05 m Long cables may cause the Pinnacle Plus supply to turn off because of excessive reflected power A WARNING Never use an output power cable longer than 9 15 m 30 or damage to your Pinnacle Plus unit may result 6 6 Operation 5702285 B Pinnacle Plus 10 kW Chapter 7 Troubleshooting and Global Customer Support BEFORE CALLING AE GLOBAL CUSTOMER SUPPORT AN 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 two types of helpful troubleshooting sections A general checklist of potential problem areas 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 Customer Support representative AN WARNING Operating and maintenance personnel must have the correct training before setting up maintaining or troubleshooting high energy electrical equipment Potentially 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 supply check for obvious si
184. ucing arcing in multiple cathode applications Additionally Sync Pulse features a broadcast mode in which hard arc detection signals are transmitted 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 Sync Pulse feature may be available even if your unit is not configured with a master slave Host card The broadcast hard arc detection feature can be disabled from the Active Front Panel or from a Remote Active Front Panel by using the Process menu 5702285 B Installation 5 15 Advanced Energy To Enable Disable Broadcast Hard Arc Detection e Press SUPPLY PULSE gt B CAST Sync Pulse Port Connector Pin 1 Pin 6 1017 Figure 5 8 Sync Pulse connector Sync Pulse Port Pin Descriptions The following table provides pin and signal descriptions for the Sync Pulse port Table 5 3 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 4 8 PON SP Pulse On 5 9 POFF SP Pulse Off 6 1 and2 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 5 16 Installation 5702285 B Pinnacle Plus 10 kW Sync Pulse Port Cable
185. uest customer service statistics Requests unit statistics returning packet contains 4 data bytes 32 bit value Send 1 data byte 8 bit value 0 Total output in kilowatt hours 1 Total idle time 2 Total run time 3 Total unit on events 4 Total output on events 5 Total over temperature events 6 Total control circuit faults 7 Total out of set point events 8 Total hard bus fault events 9 Total power fluctuation events 10 Unassigned 11 Total Side A inverter low events 12 Total Side B inverter low events 13 Total user interlock open events 14 Total cable interlock open events 15 Total contactor interlock open events 18 Total PROFIBUS fault events 19 Total pre defined interrupt events 20 Total unassigned interrupt events 22 Total dsp watchdog faults 24 10 ms bus fault events 1 4 May return CSR code 5 223 request unit s fault status AE service request 5702285 B O Communication and Control 4 95 Advanced Energy Table 4 17 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 CSR code 5 panel or DSP The returning packet contains 2 data bytes 16 CRC bit value To receive the logic CRC first send command 24 which calculates
186. umber e Second third fourth fifth bytes Target life in kilowatt hours two decimal places are implied that is to get 1 kW send a value of 100 Read back this value with command 157 13 Enables or disables the target life counter 1 CSR codes 0 1 2 9 target enable Send 1 data byte 8 bit value e Oz Inactive Non zero value Target life is active Read back this value with command 163 5702285 B O Communication and Control 4 63 Advanced Energy Table 4 17 AE Bus Commands Continued 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 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 6 Active control panel Read back this value with command 155 15 Enables or disables the ramp feature 1 CSR codes f 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 4 64 O Commun
187. unction 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 2 on page 3 11 is a graph of pulse reversal times as a function of the user voltage limit Table 3 5 on page 3 11 provides a detailed list of reverse times and the corresponding user voltage limit 3 10 Specifications 5702285 B Pinnacle Plus 10 kW 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 2 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 5702285 B Specifications 3 11 Advanced Energy Table 3 5 Reverse Time as a Function of Voltage Limit V Limit
188. unning 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 STATS EVENTS To check the number of faults Press SERVICE STATS EVENTS 4 24 O Communication and Control 5702285 B Pinnacle Plus 10 kW gt 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 OVRTMP displays the number of over temperature faults gt BUS displays the number of bus faults INVRTR displays the number 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 IRQs appears 7 If you press MONITOR you can check the number of set point timer faults and process voltage faults 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 5 EVENTS FAULTS and CYCLES options appear 2 Press the CYCLES soft key p OUTPUT and UNIT options appear 3 To get a report of the number of output on events press the OUTPUT soft key
189. upply model is not information see the I O equipped with a User card Communication and Control chapter H016 Reset Target Target life counter is Reset the target life counter Life enabled and has expired 7 10 Troubleshooting and Global Customer Support 5702285 B Pinnacle Plus 10 kW Table 7 3 Help Code Troubleshooting Table Continued Help Help Code Problem Indicated Suggested Action Code Message Number H019 Can t Change You have attempted to Delay initiating the desired While Recipe is initiate aunit function thatis 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 For more information see the I O Communication and Control chapter H021 Joule Delivery The joules delivered counter Delay initiating the desired Not Complete is enabled and running and function until the joule you have attempted to turn counter expires Or turn off output power before the disable joule mode and then counter expired shut off output power For more information see the I O Communication and Control chapter H025 Configured as a You have attempted to De assert the slave status of Slave Unit initiate a unit function that is the unit and retry the not allowed while the power function For information supply is configur
190. ustomer Support 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 To re set the unit s user selectable parameters to the factory defaults read about the default function in the I O Communication and Control chapter 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
191. 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 contains 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 5702285 B l O Communication and Control 4 91 Advanced Energy Table 4 17 AE Bus Commands Continued Command Description Number of Transmit Data Bytes CSR Codes or Number of Response Bytes 188 arc density per second Requests the arc density that occurred in the previous second returning packet contains 4 data bytes First second byte Micro arcs 16 bit value Third fourth bytes Hard arcs 16 bit value 0 4 189 request micro arc density Requests how many micro arcs occurred in the previous run returning packet contains 4 data bytes 32 bit value indicating the number of 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 wit
192. vanced Energy Use this menu option to set up Pinnacle parameters that directly control the output of your process The menu options are RECIPE JOULES 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 when running recipes the joule feature isn t triggered You must use the joule recipe feature to have this functionality Use the RECIPE menu to implement a ramping recipe This function lets you program the Pinnacle Plus to ramp up in incremental steps 1 to 8 steps are possible For each step you must set a ramp time a set point and a run timer 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 the 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 number of recipe steps 1 Choose the regulation mode Note Use the REGULATION key to toggle between power current and voltage Use the MODIFY knob to select a value between 0 and the full rated output of the supply 2 Press PROCESS CONTROL RECIPE 3 Rotate the MODIFY knob to select a value from 1 through 8 4 Press ENTER the display progresse
193. wo Line Output Display Screen KK KK KK KK KK KK KK KK KK 4 18 Setting the Reverse Time Frequency and Set point 4 19 SON KEYS 25145 a 0 ma dd kl k kulk kh A KAG d ke Gu DEE kik ke NUR R CRREN KG 4 19 Modify ipo a kc ayn GA PAPANO aces edhe al y NG KARGA WADA 4 19 Control Panel Controls Jk kk kK kK KK KK KK KK KK KK KK K KK KK KK KK KK KK 4 20 Understanding the Menu Options kk kK KK KK KK KK KK KK KK KK KK KK 4 20 Using the Service Functions XAK KK KK KK KK KK KK KK KK KK KK KK KK KK 4 23 Checking Service type Faults KK KK KK KK KK KK KK KK KK KK 4 24 Checking Service type Statistics kK KK KK KK ee 4 24 Checking the Total Energy Output 4 24 Checking the Amount of Idle Time eee eee eee 4 24 Checking the Number of Faults KK KK KK KK KK RR KK eee 4 24 Checking the Number of Cycles KK KK KK eee eee eee 4 25 Debugging Your Unit 1 kk ike sce ch pes be ER NEHA KK dee oa ee bun mi 4 25 Checking Your Master Slave System Faults 4 25 Checking Your Hardware Configuration 0 00 00 4 26 viii 5702285 B Pinnacle Plus 10 kW Checking Your Communications Card 0000 eee eae 4 26 Checking Your Software Logic 0 0 0 KK KK KK KK KK KK KK 4 26 Checking Your ROM iustior kk kK kK KK KK KK KK KK KK KK KK KK KK KK KK ke 4 27 Checking Your Software Versions kk kk kk kK cec
194. xit To select the ramp starting point a percentage of the set point to begin ramping 1 Press PROCESS CONTROL RAMP 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 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 5702285 B O Communication and Control 4 43 Advanced Energy 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 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

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