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Advanced Energy Pinnacle Plus+ User Manual

Advanced Energy Pinnacle Plus+ User Manual

Master/slave ae bus, devicenet, mdxl user, nuhf output
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Pinnacle™ Plus+ 10 kW (325–650 Vdc)
Master/Slave AE Bus,
DeviceNet™, MDXL User,
UHF Output
March 2005 5702269-C
User Manual
Samsung Electronics Co., Ltd. v. Demaray LLC
Samsung Electronic's Exhibit 1024
Exhibit 1024, Page 1

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  • Page 1 Pinnacle™ Plus+ 10 kW (325–650 Vdc) Master/Slave AE Bus, DeviceNet™, MDXL User, UHF Output March 2005 5702269-C User Manual Samsung Electronics Co., Ltd. v. Demaray LLC Samsung Electronic's Exhibit 1024 Exhibit 1024, Page 1...
  • Page 2 Ex. 1024 Page 2 Page 2 of 204...
  • Page 3 User Manual Pinnacle™ Plus+ 10 kW 5702269-C Ex. 1024 Page 3 Page 3 of 204...
  • Page 4 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.
  • Page 5 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: •...
  • Page 6 ® Advanced Energy 5702269-C Ex. 1024 Page 6 Page 6 of 204...

  • Page 7: Table Of Contents

    Pinnacle™ Plus+ 10 kW Table of Contents Chapter 1. Safety and Product Compliance Guidelines Important Safety Information ......... 1-1 Interpreting the Manual .
  • Page 8 ® Advanced Energy Maximum Allowable Reverse Time For a Given Frequency ....3-6 Reverse Time As A Function of Voltage Limit ..... . . 3-10 Operating and Impedance Range Illustrations .
  • Page 9 Pinnacle™ Plus+ 10 kW Checking Service-type Faults ........4-25 Checking Service-type Statistics .
  • Page 10 ® Advanced Energy Setting Recipes ..........4-41 Setting Joule Mode .
  • Page 11 Pinnacle™ Plus+ 10 kW UHF Connection with Interlock ....... 5-11 Host Port Card (Master/Slave Operation) .
  • Page 12 ® Advanced Energy Clearing the Error Code ........7-12 Error Code Troubleshooting Table .
  • Page 13 Pinnacle™ Plus+ 10 kW List of Figures Figure 2-1. Pinnacle™ Plus+ functional block diagram......2-2 Figure 3-1. Pulse reversal times and self-run frequencies ..... . 3-7 Figure 3-2.
  • Page 14 ® Advanced Energy Figure 5-12. Sync Pulse cable ......... . 5-20 Figure 5-13.
  • Page 15 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.
  • Page 16 ® Advanced Energy 5702269-C Ex. 1024 Page 16 Page 16 of 204...

  • Page 17: Chapter 1. Safety And Product Compliance Guidelines

    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”...

  • Page 18: Danger, Warning, And Caution Boxes

    Danger, Warning, and Caution Boxes This symbol represents important notes concerning potential harm to people, this unit, ® or associated equipment. Advanced Energy includes this symbol in Danger, Warning, and Caution boxes to identify specific levels of hazard seriousness. DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

  • Page 19: Interpreting Product Labels

    Pinnacle™ Plus+ 10 kW • Always be careful around this equipment. Interpreting Product Labels The following labels may appear on your unit: The product warranty is void if you remove the power supply box cover. Contact AE Global Customer Support for more information (see “AE Global Customer Support”...

  • Page 20: Product Compliance

    ® Advanced Energy Nonionizing radiation NRTL Protective Earth ground Refer to manual for more information 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.

  • Page 21: Safety And Compliance Directives And Standards

    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.

  • Page 22: Safety Directives And Standards

    ® 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.
  • Page 23 • Non-standard connectors for input and/or output power must be inaccessible 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).
  • Page 24 ® Advanced Energy Safety and Product Compliance Guidelines 5702269-C Ex. 1024 Page 24 Page 24 of 204...

  • Page 25: Chapter 2. Theory

    Pinnacle™ Plus+ 10 kW Chapter Chapter 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) •...

  • Page 26: Microprocessor Advantages

    ® 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.

  • Page 27: Input

    Pinnacle™ Plus+ 10 kW Input In the input section, AC line voltage is applied through the circuit breaker to a three- phase contactor. The contactor, when closed, delivers the line voltage to a rectifier bridge, where it is converted to DC. This bus provides DC voltage to the inverter section.

  • Page 28: Remote Interfaces

    ® Advanced Energy Remote Interfaces The Pinnacle Plus+ unit supports four types of interfaces: a User port (Analog/ Digital), a serial (Host) port (RS-232/422/485), an active front panel, and a Pinnacle Remote Panel interface. All four interfaces communicate operator-supplied inputs to the logic control section and provide the operator with status information.

  • Page 29: Chapter 3. Specifications

    Pinnacle™ Plus+ 10 kW Chapter Chapter Specifications FUNCTIONAL SPECIFICATIONS Table 3-1. Functional Specifications Serial communications (Host) port, User port Modes of Control (analog/digital interface), active front panel, and/ or Pinnacle Remote Active Panel Your unit also may feature either a passive front Passive Panel Options panel, remote active panel, blank panel, or an active front panel.
  • Page 30 ® Advanced Energy Table 3-1. Functional Specifications (Continued) You can monitor process values for the following: Process Monitoring target life timer, out-of-set point timer; over- voltage timer, and over-current timer. You can control the synchronization of multiple Sync Pulse independent units with the Pinnacle Plus+ Sync Functionality Pulse source controls.

  • Page 31: Physical Specifications

    Pinnacle™ Plus+ 10 kW Table 3-1. Functional Specifications (Continued) Air-cooled Cooling Several fault conditions will either cause the Fault Conditions 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.

  • Page 32: Electrical Specifications

    ® Advanced Energy ELECTRICAL SPECIFICATIONS Table 3-3. Electrical Specifications 180 to 229 VAC, 3-phase, 4-wire, 50 to 60 Hz, no 208 VAC Input Voltage neutral required. Leakage current less than (wye or delta 3.5 mA. connection) Maximum phase to phase voltage: 208 V + 10%...
  • Page 33 Pinnacle™ Plus+ 10 kW Table 3-3. Electrical Specifications (Continued) Accuracy of actual output value to set point at Output Accuracy 25ºC 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 ±1% for 4:1 load change within V-I limits of tap...

  • Page 34: Maximum Allowable Reverse Time For A Given Frequency

    ® Advanced Energy Table 3-3. Electrical Specifications (Continued) Voltage clamped to 1700 V at 50 mA maximum Ignition Capability Ignition cycle runs at 1400 V for 100 ms, then at the user-selected maximum output voltage limit for 900 ms. Depending on the choice and configuration of...

  • Page 35: Figure 3-1. Pulse Reversal Times And Self-Run Frequencies

    Pinnacle™ Plus+ 10 kW s elf-run frequency (kHz) Figure 3-1. Pulse reversal times and self-run frequencies Table 3-4. Reverse Time Given a Self-Run Frequency Requested Actual Pulse Duty Cycle Duty Cycle Frequency Frequency Reversal Time (min%) (max%) (kHz) (kHz) Maximum (µs) Reverse/ Reverse/ Period...
  • Page 36 ® 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 (µs) Reverse/ Reverse/ Period Period 2.00 45.0 54.945 2.20 44.5 60.06 2.40 44.4...
  • Page 37 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 (µs) Reverse/ Reverse/ Period Period 180.18 7.21 43.2 183.486 7.41 190.476 7.62 43.8 194.175...

  • Page 38: Reverse Time As A Function Of Voltage Limit

    ® 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 (µs) Reverse/ Reverse/ Period Period 307.692 12.31 312.5 12.50 37.5 317.46 12.70 38.1...

  • Page 39: Figure 3-2. Pulse Reversal Time As A Function Of Voltage Limit (V-Limit)

    Pinnacle™ Plus+ 10 kW 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 µs 9.8 µs 9.7 µs...
  • Page 40 ® Advanced Energy Table 3-5. Reverse Time as a Function of Voltage Limit (V-Limit) V-Limit Corresponding Reverse Time (in Volts) 8.3 µs 8.2 µs 8.1 µs 8 µs 7.9 µs 7.8 µs 7.7 µs 7.6 µs 7.5 µs 7.4 µs 7.3 µs...

  • Page 41: Operating And Impedance Range Illustrations

    Pinnacle™ Plus+ 10 kW Table 3-5. Reverse Time as a Function of Voltage Limit (V-Limit) V-Limit Corresponding Reverse Time (in Volts) 5.8 µs 5.8 µs 5.7 µs 5.7 µs 5.6 µs 5.6 µs 5.5 µs 5.5 µs 5.4 µs 5.4 µs 5.3 µs 5.3 µs 5.2 µs...

  • Page 42: Figure 3-3. Operating Range

    ® Advanced Energy Figure 3-3. Operating range Figure 3-4. Impedance range 3-14 Specifications 5702269-C Ex. 1024 Page 42 Page 42 of 204...

  • Page 43: Environmental Specifications

    Pinnacle™ Plus+ 10 kW ENVIRONMENTAL SPECIFICATIONS Table 3-6. Climatic Specifications Temperature Relative Humidity Air Pressure Class 3K3 Class 3K3 Class 3K3 (or more Operating severe) (Note 1) C to +40 5% to 85% ° ° 80 kPa to 106 kPa F to +104 +1 g/m to +25 g/m...

  • Page 44: Coolant Specifications

    ® Advanced Energy COOLANT SPECIFICATIONS Table 3-7. Coolant Specifications Air (gas) minimum 0 C, maximum 40 ° ° Coolant Temperature Note: (See “Cooling Requirements” on page 5-3 for more information.) CE Marked devices: install and operate this device in Pollution Degree...

  • Page 45: Chapter 4. I/O Communication And Control

    Pinnacle™ Plus+ 10 kW Chapter Chapter I/O Communication and Control USER PORT The User port allows you to control the Pinnacle unit through a remote controller. The connector is a 15-pin, subminiature-D, female connector (see the following illustration). Figure 4-1. 15-pin User port You may operate the Pinnacle unit solely through the 15-pin User port.

  • Page 46: Installation

    ® Advanced Energy Installation Disconnect all sources of input power before working on this unit or anything connected to it. Note: Signals at the User port can be sensitive to environmental noise. We recommend that you take standard preventative measures against electro- magnetic interference (EMI), including using shielded cabling on the User port Note: Grounding the User port at the power supply reduces noise interference.

  • Page 47: Pin-Description Table

    Pinnacle™ Plus+ 10 kW 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.

  • Page 48: Table 4-1. User Port Pin Descriptions

    ® Advanced Energy Table 4-1. User Port Pin Descriptions (Continued) Signal Return Pin Name Signal Description Type COM.A This signal is used as a remote ground. VOUT.A (pin 2), POUT.A (pin 3), and XPROG.A (pin 5) should be referenced to this pin.

  • Page 49: Devicenet™ Port

    Pinnacle™ Plus+ 10 kW DEVICENET™ PORT The rear panel of your Pinnacle Plus+ unit features DeviceNet port for interfacing with a DeviceNet network. The DeviceNet port is a round, five-pin, male micro connector, which is electrically isolated from the power supply (see Figure 4-2). Note: Dual Pinnacle Plus+ units (units containing two, seperate inverters) share the common DeviceNet network micro connector, but each side is controlled and operated independently through this port.

  • Page 50: Pin Descriptions

    ® Advanced Energy PIN DESCRIPTIONS This table lists the pin numbers and DeviceNet pin names. See the DeviceNet Specification (revision 2.0) for definitions of these pin names. ™ Table 4-2. DeviceNet Pin Descriptions Pin Number Pin Name Drain CAN_H CAN_L...

  • Page 51: Operation

    Pinnacle™ Plus+ 10 kW Use the NODE ADDRESS rotary switches, MSD and LSD, to select the unit’s address (MAC ID). MAC IDs 0 through 63 are valid. Use the MSD switch to select the MAC ID’s most significant digit; use the LSD switch to select the MAC ID’s least significant digit.

  • Page 52: Table 4-3. Structure Of The Poll Command Message

    ® Advanced Energy information about this message, refer to section 7-6 of the DeviceNet specification (revision 2.0 or later). The following table represents the structure of the poll command message. Table 4-3. Structure of the poll command message Byte Bit 7...

  • Page 53: Response Message

    Pinnacle™ Plus+ 10 kW Ramping The Pinnacle Plus+ unit examines the ramping-to-set point rate only if the output power set point has been set to a new value. Ramping will begin again at 0 after an off-on sequence has occurred. RESPONSE MESSAGE The following table represents the structure of the response message.

  • Page 54: Explicit Messaging

    ® Advanced Energy The scaling for power output is 0 to 10 V, where 10 V = the full rated output power capability of the Pinnacle Plus+ power system (master and slave units). The read back is limited to 10 V (0FFF ), even in those cases where output may temporarily exceed the maximum output capability of the power system.

  • Page 55: Module Status Led

    Pinnacle™ Plus+ 10 kW MODULE STATUS LED The MOD bi-color (amber/green) LED provides device status. It indicates whether the device has power and is operating properly. The following table shows the LED’s various states and their meanings. Table 4-5. MOD Status LED If the LED is the state indicated is which means that...

  • Page 56: Network Status Led

    ® Advanced Energy NETWORK STATUS LED The NET bi-color (amber/green) LED indicates the status of the communication link. The following table shows the LED’s various states and their meanings. Table 4-6. Network Status LED If the LED is the state indicated is...

  • Page 57: Passive Display Panel

    Pinnacle™ Plus+ 10 kW Table 4-6. Network Status LED (Continued) If the LED is the state indicated is which means that Connection Time-out, one or more I/O Flashing Amber Critical Link Failure connections are in the timed-out state. Critical Link Failure communication has failed;...

  • Page 58: Leds

    ® Advanced Energy 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 µs). 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 µs).

  • Page 59: Active Front Panel/ Pinnacle Remote Panel

    Pinnacle™ Plus+ 10 kW 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;...

  • Page 60: Understanding The Panel

    ® Advanced Energy Table 4-8. Remote Panel Pin Descriptions (Continued) Description 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.

  • Page 61: Soft Keys

    Pinnacle™ Plus+ 10 kW 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.

  • Page 62: Control Panel Interface

    ® Advanced Energy CONTROL PANEL INTERFACE Your Pinnacle Plus+ unit may have either an active front panel, which is an integrated part of the unit, or an active remote panel, which is connected to the DISPLAY port on the rear panel of the unit. This manual uses the term “control panel” to refer to either of these panels since they function identically.

  • Page 63: Regulation Key

    Pinnacle™ Plus+ 10 kW To control the Pinnacle Plus+ supply from a serial interface or the DeviceNet port, press the CONTROL key until the HOST LED lights. To control the Pinnacle Plus+ supply from the User port, press the CONTROL key until the USER LED lights. When the Pinnacle Plus+ unit is in host or user control mode, you can view all the menu items, but you cannot modify parameters or lock the display.

  • Page 64: Figure 4-6. Two-Line Output Display Screen

    ® Advanced Energy Figure 4-6. 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) • Power readback (in watts) • Clock ID: what the supply is doing...

  • Page 65: Setting The Reverse Time, Frequency, And Set Point

    Pinnacle™ Plus+ 10 kW • 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.

  • Page 66: Understanding The Menu Options

    ® Advanced Energy SERVICE SUPPLY PROCESS Figure 4-7. 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.

  • Page 67: Figure 4-8. Service Menu Map

    Pinnacle™ Plus+ 10 kW Figure 4-8. Service menu map Figure 4-9. Supply menu map 5702269-C I/O Communication and Control 4-23 Ex. 1024 Page 67 Page 67 of 204...

  • Page 68: Using The Service Functions

    ® Advanced Energy Figure 4-10. Process menu map USING THE SERVICE FUNCTIONS Use this option to view diagnostics and software versions of your supply. The menu options are: 4-24 I/O Communication and Control 5702269-C Ex. 1024 Page 68 Page 68 of 204...

  • Page 69: Checking Service-Type Faults

    Pinnacle™ Plus+ 10 kW • 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 →...

  • Page 70: Checking The Number Of Cycles

    ® Advanced Energy 4 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: 4 POWER displays the number of line power faults.

  • Page 71: Checking Your Hardware Configuration

    Pinnacle™ Plus+ 10 kW CHECKING YOUR HARDWARE CONFIGURATION SERVICE → DEBUG → HW CONFIG To find out whether or not a card is installed in slot 1 or 2: 1. Press SERVICE → DEBUG → HW CONFIG. 4 A report of the personality cards installed in the supply in slot 1 and slot 2 appears.

  • Page 72: Checking Your Rom

    ® Advanced Energy 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 4-12. Baud Rates When HIGH SPEED AEBUS is Disabled/Enabled...

  • Page 73: Using The Supply Functions

    Pinnacle™ Plus+ 10 kW 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: •...

  • Page 74: Enabling Pulsing At Current Threshold Or Always

    ® Advanced Energy 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.

  • Page 75: Setting The Unit As A Sync Pulse Transmitter Or Receiver

    Pinnacle™ Plus+ 10 kW SETTING THE UNIT AS A SYNC PULSE TRANSMITTER OR RECEIVER SUPPLY → PULSE → 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: •...

  • Page 76: Setting The Panel Mode

    ® Advanced Energy 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 →...

  • Page 77: Using Process Functions

    Pinnacle™ Plus+ 10 kW The clicks feature specifies the number of high speed counts per click for the MODIFY knob. The value you enter is a multiplier for each click of the knob when you turn the knob quickly. When you turn the knob slowly, the multiplier does not take effect.

  • Page 78: Resetting The Over-Voltage Density

    ® Advanced Energy 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”...

  • Page 79: Resetting The Over-Current Density

    Pinnacle™ Plus+ 10 kW 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”...

  • Page 80: Changing The Target Functions

    ® Advanced Energy Out-of-Set Point Tolerance Range = Set point ±0.4% of full scale or 2% of set point, whichever is greater. When an out-of-set point condition occurs, the unit shuts off output and displays error code E001. (See the “Error Codes” section of the “Troubleshooting” chapter for more information about error codes).

  • Page 81: Setting Process Limits

    Pinnacle™ Plus+ 10 kW has priority. If a change to the target is attempted on the front panel, “User Port Has PRIORITY” displays, and you must depress the MODIFY knob to exit (ENTER is no longer displayed). PROCESS → MONITOR→ TARGET → LIFE To set the target life in 0.01 kWh increments: 1.

  • Page 82: Setting The Maximum Limit For Output Current

    ® Advanced Energy 2. Rotate the MODIFY knob to select a value between 0 and the maximum rated output voltage for the supply. 3. Press ENTER to accept and exit. SETTING THE MAXIMUM LIMIT FOR OUTPUT CURRENT PROCESS → LIMITS → CURRENT This function lets you set a maximum limit for output current.

  • Page 83: Setting The Arc Count Limit

    Pinnacle™ Plus+ 10 kW 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 µs in the case of a micro arc, and 200 µs in case of a hard arc.

  • Page 84: Setting The Arc Shutdown Time

    ® Advanced Energy 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 → TIME To set the arc shutdown time: 1.

  • Page 85: Setting Recipes

    Pinnacle™ Plus+ 10 kW 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.

  • Page 86: Setting Joule Mode

    ® Advanced Energy 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.

  • Page 87: Setting The Joule Set Point

    Pinnacle™ Plus+ 10 kW 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.

  • Page 88: Setting The Ramp

    ® Advanced Energy 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.

  • Page 89: Standard Serial (Flash) Port

    Pinnacle™ Plus+ 10 kW 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.

  • Page 90: Transmission Parameters

    ® Advanced Energy Table 4-13. Serial Port Pin Descriptions Description Do not connect Power supply transmit Power supply receive 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.

  • Page 91: Ae Bus (Host) Port

    Pinnacle™ Plus+ 10 kW 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.

  • Page 92: Transmission Parameters

    ® Advanced Energy Table 4-14. AE Bus Host Port Pin Descriptions (Continued) Pin Name Description TR+ / + RS-485 (+) transmit/receive data; RS-422 (+) received data RS-422 (-) transmit data RS-422 (+) transmit data Transmission Parameters The communications capability of the serial AE Bus port is limited to the following parameters: •...

  • Page 93: Figure 4-13. Rocker Dip Switch

    Pinnacle™ Plus+ 10 kW There are two types of DIP switches on AE Bus interfaces: “rocker” DIPs and “slide” DIPs (see Figure 4-13 on page 4-49 and Figure 4-14 on page 4-49). Your supply will have one of these types. While the switches on these DIPs are slightly different, they serve the same function.

  • Page 94: Figure 4-15. Orientation Of The Ae Bus Port And External Dip Switch On The Back Panel

    ® Advanced Energy 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. Figure 4-15. Orientation of the AE Bus port and external DIP switch on the...

  • Page 95: Setting The Pinnacle Plus+ Unit's Ae Bus Address

    Pinnacle™ Plus+ 10 kW 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.

  • Page 96: Table 4-15. Ae Bus Address Settings

    ® Advanced Energy Table 4-15. AE Bus Address Settings Address 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.

  • Page 97: Setting Baud Rates And Communication Mode

    Pinnacle™ Plus+ 10 kW Table 4-15. AE Bus Address Settings (Continued) Address down down down down down down down down down down down down down SETTING BAUD RATES AND COMMUNICATION MODE Also use the DIP switch (see Figure 4-13 on page 4-49 and Figure 4-14 on page 4-49) to set the baud rate for the AE Bus port.

  • Page 98: Ae Bus Protocol

    ® Advanced Energy 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.

  • Page 99: Command

    Pinnacle™ Plus+ 10 kW 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 that the unit can determine when the entire message has been received.

  • Page 100: Checksum

    ® Advanced Energy 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.

  • Page 101: Understanding Command Status Response (Csr) Codes

    Pinnacle™ Plus+ 10 kW • A command that requests data or status information • A command and data that change a parameter setting • An executable command Once the Pinnacle Plus+ unit receives the message packet, the Pinnacle Plus+ unit verifies that the message is intended for it and not for another unit in the network.

  • Page 102: Table 4-18. Command Status Response (Csr) Codes

    ® Advanced Energy Table 4-18. Command Status Response (CSR) Codes Code Meaning 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.

  • Page 103: Ae Bus Commands

    Pinnacle™ Plus+ 10 kW Table 4-18. Command Status Response (CSR) Codes (Continued) User set point out of range Command not accepted (there is no such command) Figure 4-18. 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).

  • Page 104: Table 4-19. Ae Bus Commands

    ® Advanced Energy Table 4-19. AE Bus Commands Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Null command. CSR Codes: null off Sets DC output off; this request is always CSR Codes: honored, regardless of which interface has...
  • Page 105 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Specifies the output set point level for CSR Codes: whichever method of regulation mode has been 0,1,4,6,9 set point selected.
  • Page 106 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Send 2 data bytes to set the arc shutdown time. CSR only arc shutdown • Byte 1 = Unused time •...
  • Page 107 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Specifies the voltage level at which the unit CSR codes: indicates an arc is occurring. Sixteen discrete 0,1,4,9 voltage arc levels are available.
  • Page 108 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Specifies which target will be active. 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.
  • Page 109 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Chooses the mode of control for the Pinnacle CSR codes: Plus+ supply. 0,2,5,9,12 control mode Send 1 data byte: •...
  • Page 110 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Tells the Pinnacle Plus+ supply whether the CSR codes: source of information for regulation mode and 0,1,2,9 program set points is internal or external (the source can...
  • Page 111 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Specifies the length of ramping time for a CSR codes: recipe step (that is, how long the unit will take 0,1,2,4,9 recipe ramp to reach the set point you have defined for the...
  • Page 112 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Specifies the length of time the unit will run at CSR only set point for a recipe step. If you enable joule...
  • Page 113 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Tells the Pinnacle Plus+ supply to calculate its CSR codes: logic CRC. 0,2,9 calculate Note: During the approximately 2 seconds it logic CRC takes to calculate the CRC, the Pinnacle Plus+ unit will not respond to any other...
  • Page 114 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Enables or disables an out-of-set point timer CSR codes: and specifies how long you want the power 0,1,4,9 out-of-set...
  • Page 115 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Enables or disables an over-current timer and CSR codes: specifies how long you want the power supply 0,1,4,9 over-current to tolerate an over-current condition before timer...
  • Page 116 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Sets the unit’s synch pulse feature as a CSR codes: transmitter or a receiver. 0,1,2,9 sets synch Send 1 data byte:...
  • Page 117 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Sets a maximum limit for output power. CSR codes: 0,1,4,9 Send 2 data bytes (16-bit value); value must be user power between 0 and the maximum rated output limit...
  • Page 118 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Send 2 data bytes (16-bit value). Valid input CSR only for the joule recipe repetitions are 1 through joule recipe repetition 65535.
  • Page 119 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Enable or disable the hard-arc broadcast CSR codes: feature. 0,1,2,9 enable or Send 1 data byte: disable hard-arc •...
  • Page 120 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Changes the configuration option bit. Requires CSR only 2 data bytes. change configuration 1st data byte - Bit setting: option bit •...
  • Page 121 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Sets pulse reverse time from 0.4 µsto 5.0 µs (in CSR codes: 0.1 µs increments): 0,1,4,9,33 pulse reverse •...
  • Page 122 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the output capacity of the power supply; the returning packet contains 6 request characters indicating capacity in kilowatts.
  • Page 123 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the output power limit. Accuracy is +0.3% of the full rated output voltage for the request user supply.
  • Page 124 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests pulse reverse time (read in 0.1 µs increments); the returning packet contains 1 request pulse byte: reverse time •...
  • Page 125 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests control mode; the returning packet contains 1 data byte (8-bit value): request • 2 = Serial (Host) port control mode •...
  • Page 126 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the status of the logic board. The information in the returning packet is used by request AE Customer Service.
  • Page 127 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the Control Status Response (CSR) of most recent output on sequence; the returning request packet contains 1 data byte (8-bit value): output on •...
  • Page 128 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests a report on process status; the returning packet contains 4 data bytes: request 1st status byte: process status •...
  • Page 129 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes 4th status byte: • 0 = Hard bus fault request • 1 = Unassigned process status • 2 = Joules reached (continued) •...
  • Page 130 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the system configuration status; the returning packet contains 4 data bytes. request 1st status byte: config status • 0 = Host program source (0 = internal, 1 = external) •...
  • Page 131 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes 3rd status byte: • 0 = Synch pulse setting request (0 = receiver, 1 = transmitter) config status •...
  • Page 132 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests a snapshot of the output power level at that instant; the returning packet contains 2 request data bytes (16-bit value) indicating power actual power level.
  • Page 133 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the arc shutdown time. The returning packet contains 2 data bytes. request arc shutdown • Byte 1 = Unused •...
  • Page 134 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the hard arc count limit; the returning packet contains 4 data bytes (a 32-bit value) request hard indicating the limit.
  • Page 135 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the number of recipe steps; the 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...
  • Page 136 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the run time you set for a specific 2 or 4 recipe step or, if joule recipe is enabled, this...
  • Page 137 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the arc density that occurred in the previous second; returning packet contains 4 arc density data bytes. per second •...
  • Page 138 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the identity of the unit's personality cards. The returning packet contains 2 data request bytes: personality • First byte = Identity of card in slot 1:...
  • Page 139 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Returns a list of fault codes representing active Variable faults affecting the unit. request fault list Send 1 data byte. •...
  • Page 140 ® Advanced Energy Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests unit statistics; returning packet contains 4 data bytes (32-bit value). (May return request CSR code 5) Send 1 data byte (8-bit value):...
  • Page 141 Pinnacle™ Plus+ 10 kW Table 4-19. AE Bus Commands (Continued) Command Description Number Codes or Transmit Number of Data Response Bytes Bytes Requests the crc of the logic, front panel or DSP. (May return request logic, CSR code 5) The returning packet contains 2 data bytes (16- panel, or DSP bit value).

  • Page 142: Front Panel Illustrations

    ® Advanced Energy FRONT PANEL ILLUSTRATIONS 4-98 I/O Communication and Control 5702269-C Ex. 1024 Page 142 Page 142 of 204...

  • Page 143: Figure 4-19. Passive Front Panel (Front View)

    Pinnacle™ Plus+ 10 kW Figure 4-19. Passive front panel (front view) Figure 4-20. Active front panel (front view) 5702269-C I/O Communication and Control 4-99 Ex. 1024 Page 143 Page 143 of 204...

  • Page 144: Figure 4-21. Remote Panel (Front View)

    ® Advanced Energy Figure 4-21. Remote panel (front view) 4-100 I/O Communication and Control 5702269-C Ex. 1024 Page 144 Page 144 of 204...

  • Page 145: Figure 4-22. Remote Panel (Rear View)

    Pinnacle™ Plus+ 10 kW Figure 4-22. Remote panel (rear view) 5702269-C I/O Communication and Control 4-101 Ex. 1024 Page 145 Page 145 of 204...

  • Page 146: Figure 4-23. Remote Panel (Dimensions)

    ® Advanced Energy Figure 4-23. Remote panel (dimensions) 4-102 I/O Communication and Control 5702269-C Ex. 1024 Page 146 Page 146 of 204...

  • Page 147: Chapter 5. Installation

    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.

  • Page 148: Figure 5-1. Dimensional Drawing

    ® Advanced Energy Figure 5-1. Dimensional drawing Installation 5702269-C Ex. 1024 Page 148 Page 148 of 204...

  • Page 149: Cooling Requirements

    Pinnacle™ Plus+ 10 kW COOLING REQUIREMENTS 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.

  • Page 150: Figure 5-2. Clearances For Pinnacle™ Plus+ Units Stacked In A Cabinet

    ® Advanced Energy dissipation within the cabinet of 3000 W (1000 + 1000 + 1000 = 3000 W). The difference in temperature between coolant air and exhaust air would be approximately 20°C. Figure 5-2. Clearances for Pinnacle™ Plus+ units stacked in a cabinet...

  • Page 151: Making Rear Panel Connections

    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.

  • Page 152: Connecting A Remote Passive Panel

    ® Advanced Energy 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.

  • Page 153: Contactor Interlock

    Pinnacle™ Plus+ 10 kW Contactor Interlock The Contactor interlock is not a 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 5-7). Before turning on output, ensure that the interlock loop is closed. Note: Avoid injection of RF or noise from any power cables.

  • Page 154: Connecting Output Power

    ® Advanced Energy 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.

  • Page 155: Output Power Cable Recommendations

    Pinnacle™ Plus+ 10 kW 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. 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.

  • Page 156: Uhf Output Connector

    ® Advanced Energy UHF OUTPUT CONNECTOR The unit is shipped without a cover on the output power connector. Install the unit so that the output power connector is inaccessible to the user since lethal voltages are potentially present at the output connector once the input connections are complete.

  • Page 157: Military Spec Number

    Pinnacle™ Plus+ 10 kW MILITARY SPEC NUMBER Note that the military specification number for this connector is SO-239. Select cables and tools appropriate for this mil-spec, and assemble connecting materials according to specifications. Also note that the connector housing may provide interlock capability (see the details in the following sections).

  • Page 158: Figure 5-7. Pinnacle Plus+ Master/Slave Interface Host Card

    ® Advanced Energy 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.

  • Page 159: Figure 5-8. Master/Slave Pulse Port Connector

    Pinnacle™ Plus+ 10 kW 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.

  • Page 160: Figure 5-9. Master/Slave Pulse Port Cable

    ® Advanced Energy Table 5-1. Master/Slave Pulse Port Pin and Signal Descriptions Associated Pin Name Description PON-MSP Return Pulse On signal return Cable shield SYNC_POWER_SENSE Verifies all units have logic control power unassigned unassigned unassigned unassigned OC-MSP Overcurrent signal OC-MSP Return...
  • Page 161 Pinnacle™ Plus+ 10 kW 2. 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 5-7) in the "up" (MSTR) position. 4.

  • Page 162: Figure 5-10. Master/Slave Pulse System Diagram

    ® Advanced Energy 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 5-20 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.
  • Page 163 Pinnacle™ Plus+ 10 kW 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: • 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 system (power or current).
  • Page 164 ® Advanced Energy 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.

  • Page 165: Figure 5-11. Sync Pulse Connector

    Pinnacle™ Plus+ 10 kW To Enable/Disable Broadcast Hard Arc Detection: • Press SUPPLY → PULSE→ B’CAST Sync Pulse Port Connector Figure 5-11. Sync Pulse connector Sync Pulse Port Pin Descriptions The following table provides pin and signal descriptions for the Sync Pulse port. Table 5-3.
  • Page 166 ® Advanced Energy Sync Pulse Port Cable 57" lead 4" lead Figure 5-12. 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.
  • Page 167 Pinnacle™ Plus+ 10 kW In the Sync Pulse system all units pulse at the same frequency but may have their own unique output power set point. Additionally, all units must have the same duty cycle and reverse time. Note: If different duty cycles and reverse times are desired for your process, operate the Pinnacle Plus+ units as independent units.
  • Page 168 ® Advanced Energy Figure 5-14. Sync Pulse master/slave configuration MONITORING YOUR SYNC PULSE SYSTEM There are three options for monitoring your Pinnacle Plus+ units while in a sync pulse configuration, depending on your unit’s features. These options are as follows: •...
  • Page 169 Pinnacle™ Plus+ 10 kW 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: •...
  • Page 170 ® Advanced Energy REAR PANEL ILLUSTRATION Figure 5-15. Rear view illustration 5-24 Installation 5702269-C Ex. 1024 Page 170 Page 170 of 204...
  • Page 171 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.
  • Page 172 ® Advanced Energy 9. If necessary, enable target life counters and select a target life for each applicable target. 10. If necessary, enable arc handling and enter appropriate arc-handling parameters. 11. If necessary, create a ramping recipe (available through the standard serial port, Profibus, or Pinnacle Remote Active Panel).
  • Page 173 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.
  • Page 174 ® 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.
  • Page 175 Pinnacle™ Plus+ 10 kW Mode Low Power Operation No ignition is present in all control modes. The Pinnacle Plus+ Ignition unit begins pulsing immediately. Following the shutdown the unit continues to pulse regardless Hard and of plasma conditions. Micro Arc Shutdown The unit continues to pulse.
  • Page 176 ® 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.
  • Page 177 Pinnacle™ Plus+ 10 kW Chapter Chapter Troubleshooting and Global Customer Support BEFORE CALLING AE GLOBAL CUSTOMER SUPPORT 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: •...
  • Page 178 ® Advanced Energy Checks with the Unit Powered Off Perform the following checks with the unit powered off. 1. Ensure the power to the unit is off 2. Check for visible damage to the unit, cables, and connectors. 3. Ensure all unit connectors are installed correctly and are fastened tightly.

  • Page 179: Table 7-1. Passive Front Panel Help Codes

    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”...

  • Page 180: Table 7-2. Troubleshooting Leds

    ® Advanced Energy Table 7-1. Passive Front Panel Help Codes (Continued) PFP Display String Personality Card Host Protocol Translator Card P-04 Single User Card P-05 or P-21 AE Bus Card P-18 or P-28 Master/Slave Card with AE Bus P-22 or P-29...
  • Page 181 Pinnacle™ Plus+ 10 kW Table 7-2. Troubleshooting LEDs (Continued) Status Normal INTERLOCK An interlock fault condition exists. Note the INTERLOCK error code on the display and see “Error Code Troubleshooting Table” on page 7-13. A bus fault condition exists. Note the error BUS FAULT code on the display and see “Error Code Troubleshooting Table”...

  • Page 182: Table 7-3. Help Code Troubleshooting Table

    ® 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.
  • Page 183 Pinnacle™ Plus+ 10 kW Table 7-3. Help Code Troubleshooting Table (Continued) Help Help Code Problem Indicated Suggested Action Code Message Number You have attempted to set a Retry setting the limit using H004 User Limit power, voltage or current an acceptable value. See the Out of Range limit to a value outside the “Specifications”...
  • Page 184 ® Advanced Energy Table 7-3. Help Code Troubleshooting Table (Continued) Help Help Code Problem Indicated Suggested Action Code Message Number You have attempted to Retry setting the target using H004 Invalid Target select a target that is not an acceptable value. See the Selection available.
  • Page 185 Pinnacle™ Plus+ 10 kW Table 7-3. Help Code Troubleshooting Table (Continued) Help Help Code Problem Indicated Suggested Action Code Message Number You have attempted to set Retry setting the ramp time H004 Ramp Time Out ramp time to a value outside using an acceptable value.
  • Page 186 ® Advanced Energy Table 7-3. Help Code Troubleshooting Table (Continued) Help Help Code Problem Indicated Suggested Action Code Message Number You have attempted to De-assert the analog set H006 Analog Setpoint change the regulation mode, point and retry the function.
  • Page 187 Pinnacle™ Plus+ 10 kW Table 7-3. Help Code Troubleshooting Table (Continued) Help Help Code Problem Indicated Suggested Action Code Message Number You have attempted to Delay initiating the desired H019 Can’t Change initiate a unit function that is function until the recipe is While Recipe is Active not allowed while the power...
  • Page 188 ® Advanced Energy Table 7-3. Help Code Troubleshooting Table (Continued) Help Help Code Problem Indicated Suggested Action Code Message Number The User port reset is De-assert the User port reset H031 User Port Reset asserted. function. See the “I/O is Active Communication and Control”...

  • Page 189: Table 7-4. Error Code Troubleshooting Table

    Pinnacle™ Plus+ 10 kW Error Code Troubleshooting Table Table 7-4. Error Code Troubleshooting Table Error Code Message Problem Indicated Suggested Action The DSP failed to Power the unit off and then E000 respond to the processor. back on. If the error code DSP Init Control reappears, contact AE Fault...
  • Page 190 ® Advanced Energy Table 7-4. Error Code Troubleshooting Table (Continued) Error Code Message Problem Indicated Suggested Action The AC input power line Using all applicable safety E005 dipped below required precautions, inspect your Momentary Power operating conditions. AC input power source to...
  • Page 191 Pinnacle™ Plus+ 10 kW Table 7-4. Error Code Troubleshooting Table (Continued) Error Code Message Problem Indicated Suggested Action Unit A's power inverter Using all applicable safety E011 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...
  • Page 192 ® Advanced Energy Table 7-4. Error Code Troubleshooting Table (Continued) Error Code Message Problem Indicated Suggested Action The ribbon cable between Call AE Global Customer E021 the logic card and the Support. Interlock Open: inverter board has come Cable loose.
  • Page 193 Pinnacle™ Plus+ 10 kW Table 7-4. Error Code Troubleshooting Table (Continued) Error Code Message Problem Indicated Suggested Action A PROFIBUS command Slow down the PROFIBUS E055 arrived before the last communication rate or the PROFIBUS sent command was rate at which commands Command Buffer executed and cleared are sent.
  • Page 194 ® Advanced Energy Table 7-4. Error Code Troubleshooting Table (Continued) Error Code Message Problem Indicated Suggested Action The unit was in an No suggested action. E087 overcurrent condition for Overcurrent longer than was set on the overcurrent timer. One of the following...

  • Page 195: Table 7-5. Global Customer Support Locations

    Pinnacle™ Plus+ 10 kW Table 7-4. Error Code Troubleshooting Table (Continued) Error Code Message Problem Indicated Suggested Action A fault has occurred in Check your master/slave E182 the master/slave system. cabling. See the “I/O Master/Slave Fault Communications and Control” chapter for more information.
  • Page 196 ® 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.
  • Page 197 Pinnacle™ 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).
  • Page 198 ® 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 will manufacture the goods in accordance with its published specifications and that the goods will be free from defects in material and workmanship.
  • Page 199 Pinnacle™ Plus+ 10 kW Index active front panel. See control panel cabinet design 5-3 addressing CE marking 1-4 AE bus 4-48 changing target functions 4-36 DeviceNet 4-6 checksum AE Application Note AE bus 4-56 #5600031 5-5 command status response AE bus codes 4-57 checksum 4-56 commands...
  • Page 200 ® Advanced Energy LOCAL switch 4-19 AE bus 4-48 menu communication mode, setting 4-53 maps setting baud rates 4-53 4-23 display options 4-22 passive panel 4-13 selections 4-22 DISPLAY button 4-13 MODIFY knob 4-17 4-21 monitoring your process 4-33 ON/OFF buttons 4-17...
  • Page 201 Pinnacle™ Plus+ 10 kW on unit 1-3 LOCAL LED illustrations LEDs front panel 4-98 LOCAL 4-21 rear view 5-24 LOCAL switch 4-19 impedance range, output 3-14 low power operation 6-4 input power connecting 5-7 installation 5-1 manual, see user manual air cooling requirements 5-3 marking, CE 1-4 cabinet design 5-3...
  • Page 202 ® Advanced Energy connecting 5-8 remote panel control panel power switches 4-18 connecting 4-15 impedance range 2-1 3-14 pin descriptions 4-15 range 3-14 remote passive panel regulation 2-1 connecting 5-6 setting current limits 4-38 repair, returning units for 7-20 setting power limits 4-38...
  • Page 203 Pinnacle™ Plus+ 10 kW User port 4-2 slave units, configuring 5-15 soft keys 4-17 4-21 software checking your versions 4-28 Host commands 4-59 spacing requirements 5-1 dimensions 5-2 stacked units 5-4 specifications coolant 3-16 electrical 3-4 environmental 3-15 functional 3-1 physical 3-3 stacked power units spacing requirements 5-4...
  • Page 204 ® Advanced Energy checking your ROM 4-28 checks if output does not turn on 7-5 checks with the unit on 7-2 clearing master/slave faults 5-17 debugging 4-26 help codes 7-6 LEDs 7-4 passive front panel help codes 7-3 two-line display 4-19...

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