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APS -3000 Series Operation Manual

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Operations Manual
OM-001-03000-00-04.1
APS - 3000 Series
Power Converters
Entire Contents Copyright
2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.
TM
ADAPTIVE Power Systems
Worldwide Supplier of Power Conversion Equipment

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  • Page 1 Operations Manual OM-001-03000-00-04.1 APS - 3000 Series Power Converters ADAPTIVE Power Systems Worldwide Supplier of Power Conversion Equipment  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.

  • Page 2: Table Of Contents

    Storage and Transportation .............. 1-8 Chapter 2 Specifications Overview ....................2-1 Introduction ..................2-2 APS-3000P Specifications ............... 2-2 Input Electrical Specifications ............2-3 Output Electrical Specifications ............. 2-3 Power versus Output Frequency Rating Chart ....... 2-4 Displays and Controls ..............2-5 Mechanical Specifications ...............

  • Page 3: Contents

    Overview ....................5-1 PLC External Interface ..............5-2 Manual Switcher (Three-Program Control) ........5-3  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series OM-001-03000-00-04.1...
  • Page 4 Overview ....................7-1 Introduction ..................7-1 System Design .................. 7-2 APS-3000 Series System Block Diagram ........7-4  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.

  • Page 5: Contact Information

    17711 Mitchell North • Irvine, CA 92614 USA Telephone: (949) 752-8400 FAX: (949) 756-0838 E-mail: sales@adaptivepower.com Web: http://www.adaptivepower.com  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series OM-001-03000-00-04.1...

  • Page 6: Warranty Information

    APS-3000 Series Service and Spare Parts Limited Warranty APS warrants repair work to be free from defects in material and workmanship for the period of ninety (90) days from the invoice date. This Service and Spare Parts Limited Warranty applies to replacement parts or to subassemblies only.

  • Page 7: Chapter 1 Introduction

    Chapter 1 - Introduction Chapter 1 contains important information you should read BEFORE attempting to install and power-up your APS-3000 Series Power Converter. The information in this chapter is provided for use by experienced operators. Experienced operators understand the necessity of becoming familiar with, and then observing, life-critical safety and installation issues.

  • Page 8: Safety Notices

    CHAPTER 1 INTRODUCTION The APS-3000 Series of Power Converters have been designed to provide frequency and voltage conversion in a controlled test environment. All APS-3000 Series Power Converters provide 3-phase output power. Different APS models cover the power range from 3 kVA to 180 kVA. All units provide user-controlled 3-phase output power within the frequency range of 45 –...
  • Page 9 IF THIS EQUIPMENT IS NOT USED IN A MANNER SPECIFIED BY THE MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 1 - 3 OM-001-03000-00-04.1...
  • Page 10  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 1 - 4 OM-001-03000-00-04.1...

  • Page 11: Preparation For Installation

    If the product has been damaged, please alert the freight company and contact APS or the distributor. Please keep the original box and packing to assist in determining how the damage occurred.

  • Page 12: Installation Instructions

    TheAC input requirement for the APS Power Converter depends on the configured AC input voltage and total power level of the specific APS 3000 model. For three phase AC input models, the current shown in the table below is for each phase.
  • Page 13 Please check the unit data plate to verify the voltage is correct. Operating Environment APS-3000 Series Power Converters are designed to operate reliably over a wide range of environmental conditions. Please operate within the following limits:  Temperature: 0 °C – 40 °C (32 °F – 104 °F) ...

  • Page 14: Example Wiring Diagram

    CHAPTER 1 INTRODUCTION Example Wiring Diagram INPUT / OUTPUT Power Panel at Rear of APS Unit (typical) N C B OUTPUT CONNECTIONS INPUT CONNECTIONS NOTE: Terminal Phases R, S, T are North American (U.S.) A, B, C NOTE: Other terminal configurations are possible. For example, there is no neutral terminal for delta-winding inputs.

  • Page 15: Storage And Transportation

    Please retain all the original packing materials. If the equipment must be sent back for repair, use the original packing materials for packing. Please contact the APS repair center or factory before returning equipment. Be sure to send all accessories and indicate the symptoms and cause of failure if known.

  • Page 16: Chapter 2 Specifications

    Introduction APS-3000 Power Converters are rugged versatile workhorses. The intended location for APS-3000 units is the test floor, not a laboratory workbench. The smallest unit, the APS-3003, weights 305 lbs. The largest unit, the APS3180, weighs around 4000 lbs. Users can select from several modes of operation: ...

  • Page 17: Aps-3000P Specifications

    CHAPTER 2 TECHNICAL SPECIFICATIONS In keeping with their workhorse nature, all APS-3000 units feature a 200% start-up surge-current capability. The ability to source initial surge currents prevents the programmed over-current protection from disabling a test. APS-3000 Specifications The following five tables and surge current graph provide detailed information about the entire family of APS-3000 Series of power converters.

  • Page 18: Input Electrical Specifications

    ± 0.5% Protection Over-Current, Short-Circuit, Over-Temperature Efficiency ≥ 85% (at full load)  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 2 - 3 OM-001-03000-00-04.1...

  • Page 19: Power Versus Output Frequency Rating Chart

    15 minutes then instrument output will shut down because output transformer is too hot.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 2 - 4 OM-001-03000-00-04.1...

  • Page 20: Displays And Controls

    Front Panel Calibration PLC (external) PLC interface controls execution of programmed steps in Memories 1, 2, or 3. Interface The PLC interface is a standard feature of all APS Power Converters. Auto-Voltage Adjust Provides improved voltage regulation Mechanical Specifications Model...

  • Page 21: Output Surge-Current Capability

    The exact time depends upon the temperature and line conditions.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 2 - 6 OM-001-03000-00-04.1...

  • Page 22: Chapter 3 Unit Description

    You need to know the vocabulary of the APS-3000 Series to take full advantage of the information in this manual. Information in this chapter is in three sections: ...
  • Page 23 CHAPTER 3 UNIT DESCRIPTION  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 3 - 2 OM-001-03000-00-04.1...
  • Page 24 CHAPTER 3 UNIT DESCRIPTION Front Panel of APS-3000 Series Power Converter M U L T I M E T E R F R E Q U E N C Y TEST PASS FAIL P - S PROTECT LOCK /LOCAL TEST...
  • Page 25 SYSTEM / PROGRAM set-up, and error messages under output error. TEST indicator When ON, the system is in normal power output operation. PASS indicator Not used for the APS-3000 Series FAIL indicator When ON, the system has encountered an output error. PROTECT indicator When ON, an output error has tripped the system protection circuit.
  • Page 26 UNIT DESCRIPTION V O L T A G E Σ 0-150 PHASE 0-300 APS-3000 Voltage Display Voltage Selection VOLTAGE display Displays the output voltage / defined voltage value and parameters during the SYSTEM / PROGRAM set-up. R indicator When ON, the display indicates the R-phase output (A-phase in US).
  • Page 27 When ON, the panel is in a locked state; the buttons are deactivated. REMOTE indicator When ON, the system is controlled by rear panel external switching. AUTO indicator Not used for the APS-3000 Series MANUAL indicator When ON, the system is in manual mode. PROGRAM indicator When ON, the PROGRAM parameter setting mode is active.
  • Page 28 M U L T I M E T E R P - S LOCK /LOCAL TEST RESET METER APS-3000 Multimeter Display Multimeter Selection MULTIMETER display Displays Power, Power Factor, Testing Time, or Program-Step. P indicator When ON, MULTIMETER displays output Power (kW). PF indicator When ON, MULTIMETER displays Power Factor.

  • Page 29: Cabinet Controls And Connections

    See the following page for illustrations. The Cabinet Controls Table on page 3-9 provides additional information about each of these items. Chassis Details The APS-3000 is built on a rugged chassis for use in demanding test environments. Important elements of the design include:  Handles ...
  • Page 30 Input Power Circuit Breaker Circuit Breaker Input Power Output Power Terminals Terminals (see page 1-7) (see page 1-7) APS-3000 Series Unit (typical) Note: Different models have minor configuration differences Rear Wheels Fixed Position Rear View  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.

  • Page 31: Cabinet Features

    Adequate cooling airflow is essential in maintaining proper operation.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 3 - 10 OM-001-03000-00-04.1...

  • Page 32: Chapter 4 Operating Instructions

    Operating Instructions Chapter 4 – Operating Instructions Use the instructions in Chapter 4 to set up your APS-3000 Power Converter so you can conduct tests. However, before attempting to set up your APS unit for testing, you should be familiar with the information provided in Chapters 1, 2, and 3.

  • Page 33: Basic Operation

    300V range is one-half that in the 150V range.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 2 OM-001-03000-00-04.1...
  • Page 34 For example, if you specify a 200V lower voltage limit, the system will not allow you to switch to the low voltage (150V max) range.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 3 OM-001-03000-00-04.1...
  • Page 35 OCP being displayed. For a listing and discussion of all displayed error conditions, see the Error Messages section of this chapter.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 4 OM-001-03000-00-04.1...
  • Page 36 Note: If your unit shuts down due to a detected Over-Current condition, the FREQUENCY display shows OCP.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 5 OM-001-03000-00-04.1...
  • Page 37 Press the TEST button to start the output. The TEST LED (on the FREQUENCY display) will light, indicating normal voltage output.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 6 OM-001-03000-00-04.1...
  • Page 38 This procedure is used to avoid accidental adjustments to the system.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 7 OM-001-03000-00-04.1...
  • Page 39 PROGRAM button (again) to exit the Program Mode. See Page xx for program parameters and instructions.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 8 OM-001-03000-00-04.1...

  • Page 40: System Parameter Settings

    OPERATING INSTRUCTIONS System Parameter Settings APS-3000 front panel displays are used to present status, test data, and system parameters. This is the normal mode of display during operation. A special operator- selected mode (described below) is entered when using the front panel displays for setting system parameters.
  • Page 41 CHAPTER 4 OPERATING INSTRUCTIONS  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 10 OM-001-03000-00-04.1...

  • Page 42: Setting System Parameters (Programming)

    The FrEq HI value must be higher than the FrEq LO value.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 11 OM-001-03000-00-04.1...
  • Page 43 Note: The parameter settings for current and power are described in the following section, Program Parameter Settings.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 12 OM-001-03000-00-04.1...

  • Page 44: Program Parameter Settings

    PROGRAM (on the CURRENT Display), to leave the Program Parameter Setting mode.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 13 OM-001-03000-00-04.1...

  • Page 45: Setting Program Parameters (Programming)

    RESET (Standby) status, pressing the CURRENT ︿ or ﹀ buttons will adjust the current high limit.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 14 OM-001-03000-00-04.1...

  • Page 46: Error Messages

    OPERATING INSTRUCTIONS Error Messages Why are there Errors? Setup mistakes happen. Overloads occur. Systems under test fail. When the APS-3000 unit encounters a fault condition, an error has occurred. The result is:  The front panel display presents a message.
  • Page 47  LVP Output voltage was low  OPP Output power was high  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 16 OM-001-03000-00-04.1...
  • Page 48 CHAPTER 4 OPERATING INSTRUCTIONS  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 17 OM-001-03000-00-04.1...

  • Page 49: Interpreting Error Messages

    DC voltage). This means the INVERTER supply voltage is less than the normal working range for the APS-3000. An alarm will sound; the FAIL LED will flash; the PROTECT LED will light; and the VOLTAGE and CURRENT displays will show their corresponding values.
  • Page 50 PROTECT LED will light; and the VOLTAGE and CURRENT displays will show the corresponding values at the time of over-voltage.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 19 OM-001-03000-00-04.1...
  • Page 51 VOLTAGE and CURRENT displays will show the corresponding values at the time of over- power.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 4 - 20 OM-001-03000-00-04.1...

  • Page 52: Chapter 5 External Interfaces

    External Interface Chapter 5 – External Interface This chapter provides information about the three types of APS-3000 external interfaces. Use the information in Chapter 5 to take advantage of the remote control and / or data acquisition capabilities of your unit. You will probably find that test operations controlled from the front panel are relatively intuitive.

  • Page 53: Plc External Interface

    If the system encounters an error, the front panel RESET button or the ON/OFF control at the PLC remote can be enabled to perform a system reset. A sketch of the APS PLC DE-9 pinouts and simple switch configuration is shown on the following page.

  • Page 54: Manual Switcher (Three-Program Control)

    Diodes (+ side) 1N4148 or 1N914, etc. PLC DE-9 Connector and Control  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 5 - 3 OM-001-03000-00-04.1...

  • Page 55: Chapter 6 System Calibration

    Whether you perform calibration prior to a critical test or as a scheduled annual maintenance task, the procedures for calibration are identical. Note, the values of some calibration parameters are different for different sizes of APS models. This chapter includes tables of all calibration parameters for all models. Please use the calibration values that are for your particular model.

  • Page 56: Calibration Setup

    ± 0.2%, (See Calibration Settings Table for your APS model)  Restive Load Bank, Calculated for your APS model (See following Example) How to Calculate the Size of the Test Load (Example) For an example, suppose your system is an APS3030.
  • Page 57 CLEANING SHOULD BE REFERRED TO PERSONNEL AUTHORIZED BY THE FACTORY TO SERVICE THIS EQUIPMENT.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 6 - 3 OM-001-03000-00-04.1...

  • Page 58: Calibration Instructions

     At the MULTIMETER Display, pressing the RESET button aborts the calibration process.  Your APS unit identifies power phase R, S, and T. These three phases are equivalent to the North American Phases A, B, and C.  The system must be restarted after all calibration operations have been completed.
  • Page 59 Resistive loads are not sensitive to frequency.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI. APS-3000 Series 6 - 5 OM-001-03000-00-04.1...

  • Page 60: Low-Voltage Mode (V-Lo) Calibration

    5. At the Multimeter Display, press the LOCK button to finish low-voltage calibration. 6. Proceed to the next calibration function, unless this completes system calibration. 7. Note, to exit the Calibration Mode, your APS system must be restarted after you have completed ALL calibration operations.
  • Page 61 5. At the Multimeter Display, press the LOCK button to finish high-voltage calibration. 6. Proceed to the next calibration function, unless this completes system calibration. 7. Note, to exit the Calibration Mode, your APS system must be restarted after you have completed ALL calibration operations.

  • Page 62: Low-Current Mode (A-Lo) Calibration

    36.00 45.00 54.00 5. At the MULTIMETER Display, press the TEST button. The APS unit will automatically perform a low-current output reading and will output approximately 120 VAC. 6. The external RMS ammeter will display the actual current output. The CURRENT Display shows the calibration value (see Calibration Table, above).
  • Page 63 9. At the Multimeter Display, press the LOCK button to complete low-current calibration. 10. Proceed to the next calibration function, unless this completes system calibration. 11. Note, to exit the Calibration Mode, your APS system must be restarted after you have completed ALL calibration operations. ...
  • Page 64 27.00 36.00 45.00 54.00 5. At the MULTIMETER Display, press the TEST button. The APS unit will automatically perform a high-current output reading and will output approximately 120VAC. 6. The external RMS ammeter will display the actual current output. The CURRENT Display shows the calibration value (see Calibration Table, above).
  • Page 65 9. At the Multimeter Display, press the LOCK button to complete high-current calibration. 10. Proceed to the next calibration function, unless this completes system calibration. 11. Note, to exit the Calibration Mode, your APS system must be restarted after you have completed ALL calibration operations. ...

  • Page 66: Low-Power Mode (P-Lo) Calibration

    = A). After you calibrate Phase R, you will repeat this step for Phases S and T. 3. The size of the load should be calculated based on the low-current parameter for your particular APS unit, as shown in the following Calibration Table. Use 120 VAC for the voltage.
  • Page 67 9. At the Multimeter Display, press the LOCK button to complete low-power calibration. 10. Proceed to the next calibration function, unless this completes system calibration. 11. Note, to exit the Calibration Mode, your APS system must be restarted after you have completed ALL calibration operations. ...
  • Page 68 36.00 45.00 54.00 5. At the MULTIMETER Display, press the TEST button. The APS unit will automatically perform a high-power output reading and will output approximately 120 VAC. 6. The external RMS power meter will display the actual power output. The CURRENT Display shows the calibration value (see Calibration Table, above).
  • Page 69 CHAPTER 6 INSTRUMENTATION CALIBRATION 10. Proceed to the next calibration function, unless this completes system calibration. 11. Note, to exit the Calibration Mode, your APS system must be restarted after you have completed ALL calibration operations.  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc.

  • Page 70: Chapter 7 System Maintenance

    Introduction No internal parts require user maintenance. If the equipment appears to have a malfunction, please contact APS or the distributor for service (see page "v"). The wiring and block diagram are for reference only. Scheduled Maintenance The APS-3000 Series Frequency Converters should be inspected and calibrated once per year to ensure safety and accuracy of the equipment.

  • Page 71: System Design

    Do not modify this equipment. Any modifications void the warranty automatically, and violate the tested safety standards of the unit. APS does not take responsibility for such equipment. Parts or accessories not certified by APS will not be covered under the warranty.
  • Page 72 SERVICABLE INTERNAL PARTS. System Block Diagram If you are interested in how the APS-3000 works, you can learn more by reviewing the System Block Diagram on the following page. Please note, the block diagram is supplied for information purposes only. There are no serviceable components available to the user.

  • Page 73: Aps-3000 Series System Block Diagram

    Inverter DC Bus Hi / Lo Test Blown Fuse Test Overheat Test APS-3000 Series System Block Diagram  Entire Contents Copyright 2004 by Adaptive Power Systems, Inc. (APSI) • All Rights Reserved • No reproduction without written authorization from APSI.

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