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Pinnacle 20 kW
Advanced Energy Pinnacle 20 kW User Manual
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U
S
ER
MANUAL
Fort Collins,
CO 80525 USA
970.221.4670
technical.support@aei.com
1625 Sharp Point Drive
Advanced Energy Industries,
Inc
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EXHIBIT 1062
2
Table of Contents
default chapter
5
Table of Contents
5
Chapter 1. Introduction
15
Read this Section
15
Interpreting the Manual
15
Type Conventions
15
Icons (Symbols)
15
Safety
17
Product Safety/Compliance
18
Directives
18
Standards
18
Table 1-1. Electromagnetic Compatibility (EMC)
18
Table 1-2. Safety Directives
18
Installation Requirements
19
Conditions of Use
19
Chapter 2. Theory
21
General Description
21
Output Impedance Range
21
Output Regulation
21
Interfaces
21
Microprocessor Advantages
22
Displays
22
Arc-Suppression Feature
22
Theory of Operation
22
Input
23
Housekeeping Supply
23
Inverter
23
Output
23
Figure 2-1. Pinnacle Functional Block Diagram
23
Output Measurement
24
Logic Control
24
Remote Interfaces
24
Chapter 3. Specifications
25
Functional Specifications
25
Table 3-1. Functional Specifications
25
Physical Specifications
27
Table 3-2. Physical Specifications
27
Electrical Specifications
28
Table 3-3. Electrical Specifications
29
Figure 3-1. Operating Range
31
Environmental Specifications
32
Figure 3-2. Impedance Range
32
Table 3-4. Climatic Specifications
32
Coolant Specifications
33
Table 3-5. Coolant Specifications
33
Chapter 4. I/O Communication and Control
35
User Port
35
Installation
35
Signals
35
Figure 4-1. 15-Pin User Port
35
Pin-Description Table
36
Table 4-1. User Port Pin Descriptions
36
Devicenet ™ Port
38
Installation
39
Pin Descriptions
39
Rotary Switches: Baud Rate and Addressing
39
Table 4-2. Devicenet ™ Pin Descriptions
39
Operation
40
Figure 4-3. Devicenet Rotary Switches and Leds
40
Poll Command Message
41
Table 4-3. Structure of the Poll Command Message
41
Response Message
42
Table 4-4. Structure of the Poll Command Message
42
Explicit Messaging
43
Rear Panel Leds
43
Module Status LED
44
Table 4-5. MOD Status LED
44
Network Status LED
45
Table 4-6. Network Status LED
45
Passive Display Panel
46
Display
46
Table 4-7. Passive Display Panel Codes
46
Leds
47
Active Front Panel/ Pinnacle Remote Panel
47
Table 4-8. Display Panel Leds
47
Connecting to the Remote Active Panel
48
Figure 4-4. Remote Active Panel Connector
48
Table 4-9. Remote Panel Pin Descriptions
48
Understanding the Panel
49
Control Key
49
Output Display Screen
49
Soft Keys
49
Modify Knob
50
Regulation Switch
50
On/Off Switches & Leds
50
Arc LED
50
Control Panel Interface
50
Output Power Switches
51
Control Switches
51
Figure 4-5. Control Panel
51
Regulation Switches
52
Two-Line Output Display Screen
52
Soft Keys
53
Modify Knob
53
Control Panel Controls
53
Understanding the Menu Options
54
Figure 4-6. Control Panel Main Menu Functions
54
Figure 4-7. Service Menu Map
55
Figure 4-8. Supply Menu Map
55
Using the Service Functions
56
Figure 4-9. Process Menu Map
56
Checking Service-Type Faults
57
Checking Service-Type Statistics
57
Checking the Total Energy Output
57
Checking the Amount of Idle Time
57
Checking the Number of Faults
57
Checking the Number of Cycles
58
Debugging Your Unit
58
Checking Your Master/Slave System
58
Checking Your Hardware Configuration
59
Checking Your Communications Card
59
Checking Your Software Logic
59
Checking Your ROM
59
Checking Your Software Versions
59
Using the Supply Functions
60
Setting the AE Bus Timeout
60
Setting the Supply Parameters
60
Setting the Panel Mode
61
Selecting Remote or Local Mode
61
Selecting a Lock Code
61
Selecting the Number of Clicks
61
Setting the Program Source
62
Using Process Functions
62
Monitoring Your Process
62
Establishing a Minimum Process Voltage
63
Setting an Out-Of-Setpoint Timer
63
Changing the Target Functions
64
Setting Process Limits
65
Setting a Strike Voltage Limit
65
Setting a Maximum Limit for Output Voltage
66
Setting the Maximum Limit for Output Current
66
Setting the Maximum Limit for Output Power
66
Table 4-10. Strike Voltage Limit
66
Setting Arc Handling
67
Setting the Voltage Arc Trip Level
67
Setting the Arc Count Limit
67
Viewing the Arc Density
68
Setting the Length of the Arc Average Window
68
Setting the ARC Times
69
Predefined Arc Handling
69
Table 4-11. Arc Detect, Arc Shutdown, and TCC Times for Pre-Defined Targets
69
Enabling Arc Handling
70
Setting Control Parameters
70
Setting Recipes
71
Setting Ripple Level
72
Using the Target Conditioning Cycle (TCC)
72
Enabling Target Conditioning Cycle (TCC)
72
Setting the Target Conditioning Cycle (TCC) TIMER
73
Setting Joule Mode
73
Setting the Joule Setpoint
73
Setting the Joule Threshold
74
Setting the Ramp
74
Standard Serial (Flash) Port
75
Standard Serial Port Description
75
Figure 4-10. Standard Serial Port
75
Transmission Parameters
76
AE Bus Serial Communications (Host) Port
76
Table 4-12. Serial Port Pin Descriptions
76
Pin Descriptions
77
Figure 4-11. Host Port Connector
77
Table 4-13. AE Bus (Host) Port Pin Descriptions
77
Transmission Parameters
78
Using Dips to Set the Pinnacle Unit's Network Address
78
Switch Settings
78
External Dips
79
Figure 4-12. Rocker DIP Switch (Internally Located on a Master/Slave Interface Card)
79
Figure 4-13. Slide DIP Switch (Externally Located on Units Without a Master/Slave Card)
79
Internal Dips
80
Figure 4-14. Orientation of the Host Port and DIP Switch on the Back Panel (Units Without a Master/Slave Interface Card Installed)
80
Min-Switches
81
Figure 4-15. Location of the Internal DIP Switch on the Master/Slave Interface Card
81
Setting the Pinnacle Unit's Network Address
82
Table 4-14. Address Settings
82
Setting Baud Rates and Communication Mode
83
Host/Pinnacle Communications
83
Table 4-16. Baud Rate Settings
83
Communications Protocol
84
Header
84
Figure 4-16. Graphic Representation of a Message Packet
84
Command
85
Optional Length Byte
85
Data (Data Bytes)
85
Checksum
85
Creating an Ideal Communications Transaction
86
Figure 4-17. AE Bus Communications Transaction
86
Understanding Command Status Response (CSR) Codes
87
Table 4-17. Command Status Response (CSR) Codes
88
Host/Pinnacle Software Commands
89
Figure 4-18. Communications Transaction Example
89
Table 4-18. Host Port Commands
89
Figure 4-2. Devicenet
119
Host Port Command Sequence Examples
121
Example 1: Setting the Timeout Value
121
Example 2: Setting Target Life
122
Unit Illustrations
124
Figure 4-19. Passive Front Panel (Front View)
124
Figure 4-20. Active Front Panel (Front View)
125
Figure 4-21. Remote Panel (Front View)
126
Figure 4-22. Remote Panel (Rear View)
127
Figure 4-23. Remote Panel (Dimensions)
128
Chapter 5. Installation
129
Unpacking
129
Meeting Spacing Requirements
129
Figure 5-1. Dimensional Drawing
130
Cooling Requirements
131
Cabinet Design
131
Figure 5-2. Top, Side, and Inter-Unit Clearance for Pinnacle Units Stacked in a Cabinet
133
Making Rear Panel Connections
134
Grounding
134
Connecting a Pinnacle Remote Active Panel
134
Connecting a Remote Passive Panel
135
Connecting for User Port Control
135
Connecting to the Standard Serial Port
135
Connecting for Serial (Host) Port Control
135
Contactor Interlock
135
Connecting for Devicenet Control
136
Connecting Input Power
136
Figure 5-3. Contactor Interlock Connector
136
Connecting Output Power
138
Terminal Block Output Connector
138
Figure 5-4. Rear View of Terminal Block Housing Without Strain Relief Attached
139
Connecting for Master/Slave
140
Configuring Your Master Unit
141
Configuring Your Slave Units
141
Figure 5-5. Pinnacle Master/Slave Interface
141
Figure 5-6. Configuration for Pinnacle Master/Slave System
142
Monitoring Your Master / Slave System
143
Clearing Faults in a Master/Slave System
143
Understanding Master/Slave Input On/Off Combinations
144
Table 5-3. Input Sequences for Master and Slave Units
144
Back Panel Illustration
147
Figure 5-7. Passive and Active Front Panel (Rear View)
147
Chapter 6. Operation
149
Operating Overview
149
Understanding Pinnacle Arc Handling
150
Voltage Arc Trip Level
151
TCC Algorithm Enable
151
Target Type: Metal
152
Target Type: Non-Metal
152
Target Type: Custom
152
Arc Detect Delay Time
152
Arc Shutdown Time
153
Arc Recovery Test
153
Arc Recovery Time
153
Chapter 7. Troubleshooting and Customer Support
155
Before Calling AE Global Support
155
First Check
155
Checks with the Power off
155
Checks with the Power on
156
Checks if the Output Does Not Turn on
157
Help Code Troubleshooting Table
157
Table 7-1. Help Codes
157
Passive Display Panel Codes
159
Table 7-2. Passive Display Panel Codes
159
LED Troubleshooting Table
160
Table 7-3. Troubleshooting Leds
160
Clearing the Error Code
161
Error Code Troubleshooting Table
162
Table 7-4. Error Codes
168
Error E081 Fault Vector
170
Slave Status Low Byte
170
Slave Status High Byte
171
Personality Card Status
171
AE Global Support
172
Table 7-5. AE Global Support Locations
172
Returning Units for Repair
173
Warranty
173
Authorized Returns
174
Warranty Statement
174
4
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Advanced Energy Pinnacle 20 kW Specifications
General
Brand
Advanced Energy
Model
Pinnacle 20 kW
Category
Power Supply
Language
English
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